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Advanced transmission studies

The NASA Lewis Research Center and the U.S. Army Aviation Systems Command share an interest in advancing the technology for helicopter propulsion systems. In particular, this paper presents highlights from that portion of the program in drive train technology and the related mechanical components. The major goals of the program are to increase the life, reliability, and maintainability; reduce the weight, noise, and vibration; and maintain the relatively high mechanical efficiency of the gear train. The current activity emphasizes noise reduction technology and analytical code development followed by experimental verification. Selected significant advances in technology for transmissions are reviewed, including advanced configurations and new analytical tools. Finally, the plan for future transmission research is presented.

Coy, John J.↗

Advanced transmission studies

The NASA Lewis Research Center and the U.S. Army Aviation Systems Command share an interest in advancing the technology for helicopter propulsion systems. In particular, this paper presents highlights from that portion of the program in drive train technology and the related mechanical components. The major goals of the program are to increase the life, reliability, and maintainability; reduce the weight, noise, and vibration; and maintain the relatively high mechanical efficiency of the gear train. The current activity emphasizes noise reduction technology and analytical code development followed by experimental verification. Selected significant advances in technology for transmissions are reviewed, including advance configurations and new analytical tools. Finally, the plan for future transmission research is presented.

Coy, John J.↗

Updating and Refining BISON TRISO Assessment

Several advanced reactor concepts consider tristructural isotropic (TRISO) fuel in their designs. To support the advanced reactor industry, the Nuclear Energy Advanced Modeling and Simulation (NEAMS) program within the U.S. Department of Energy (DOE) is developing modeling and simulation capabilities within the BISON fuel performance code. Assessment of these capabilities against available experi- mental data, such as the Advanced Gas Reactor (AGR) program, is essential in instilling confidence in the code predictions. Associated uncertainties in model inadequacy, experimental measurements, and manufacturing are also of importance. This report discusses the updating and standardization of the existing assessment suite in BISON for TRISO fuel performance analysis. The cases considered the AGR-1, AGR-2, and AGR-3/4 experimental programs. The report also includes a preliminary investigation into the sources of model inadequacy associated with silver (Ag) release fractions using the AGR-2 Compact 2-1-2 as a case study. The results indicate that uncertainties in the operating temperatures supplied to the model and the form of those temperature conditions (spatially averaged versus spatially resolved) both affect Ag release predictions. This suggests that previously observed model inadequacy can be attributed to both physical models and the operating conditions supplied to them. These findings will be leveraged to guide development of assessment cases for additional experiments and refinement of physical models for behaviors that potentially influence Ag release, such as palladium penetration.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Rotor Performance at High Advance Ratio: Theory versus Test

Five analytical tools have been used to study rotor performance at high advance ratio. One is representative of autogyro rotor theory in 1934 and four are representative of helicopter rotor theory in 2008. The five theories are measured against three sets of well documented, full-scale, isolated rotor performance experiments. The major finding of this study is that the decades spent by many rotorcraft theoreticians to improve prediction of basic rotor aerodynamic performance has paid off. This payoff, illustrated by comparing the CAMRAD II comprehensive code and Wheatley & Bailey theory to H-34 test data, shows that rational rotor lift to drag ratios are now predictable. The 1934 theory predicted L/D ratios as high as 15. CAMRAD II predictions compared well with H-34 test data having L/D ratios more on the order of 7 to 9. However, the detailed examination of the selected codes compared to H-34 test data indicates that not one of the codes can predict to engineering accuracy above an advance ratio of 0.62 the control positions and shaft angle of attack required for a given lift. There is no full-scale rotor performance data available for advance ratios above 1.0 and extrapolation of currently available data to advance ratios on the order of 2.0 is unreasonable despite the needs of future rotorcraft. Therefore, it is recommended that an overly strong full-scale rotor blade set be obtained and tested in a suitable wind tunnel to at least an advance ratio of 2.5. A tail rotor from a Sikorsky CH-53 or other large single rotor helicopter should be adequate for this exploratory experiment.

Harris, Franklin D.↗

A review on the state of thermal hydraulics research on air ingress scenarios in High-Temperature Gas-cooled Reactors following a D-LOFC

With the expectation of near-immediate carbon neutrality, widespread implementation of proven High-Temperature Gas-cooled Reactors (HTGRs) embodies a viable solution pathway given their inherent, passive safety features and high thermal efficiency. This study provides an overview of the current state of research involving the thermal hydraulics associated with air ingress from a depressurized loss of forced cooling (D-LOFC) in HTGRs. Accurately characterizing and predicting the physical phenomena underlying air ingress is of paramount concern, as the integrity of the fuel and core graphite support structures are threatened by the presence of oxygen. Broadly speaking, the air ingress scenario can be delineated into three main stages: (1) Depressurization, (2) Density-Driven Flow, and (3) Natural Convection. In tandem with the underlying fundamental theory, this review collates and synthesizes the existing body of contemporary research concerning the air ingress scenario following a D-LOFC. As evinced by this review, our current understanding and predictive abilities have benefited from extensive research, predominantly concentrated on the rate of air ingestion into the core. Here, additional research is necessary to holistically capture the phenomenology of an air ingress scenario following a D-LOFC by considering an additional variable: the oxygen content of the ingressing air. The latter variable requires investigation into the complex interactions of the fully integrated system. Additionally, while numerical tools are evolving domestically through the Nuclear Energy Advanced Modeling and Simulation program, a sufficiently validated code remains absent.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

Modeling of Prismatic High Temperature Reactors in Pronghorn

Pronghorn is a MOOSE based thermal-hydraulics code developed at Idaho National Laboratory (INL) for advanced nuclear reactor analysis. It has been previously applied to model pebble-bed high temperature reactors (HTRs), liquid-metal cooled reactors, and molten salt reactors, among others. This work leverages the coarse-mesh modeling capabilities in Pronghorn to model the Oregon State University (OSU)'s High Temperature Test Facility (HTTF). The HTTF is a 1:4 height scaled-down facility of General Atomics' Modular High Temperature Gas-cooled Reactor (MHTGR). The facility is primarily built to generate data for code and model validation, and does not precisely replicate MHTGR conditions. Nevertheless, it encompasses the main physics associated with MHTGR transients.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

Thermal hydraulic analysis of the AFIP-7 irradiation test in the Advanced test Reactor – Model correlation and performance evaluation

We report as a system level code, RELAP5 is widely used in the nuclear field for the reactor hydraulic analysis. In the component/experimental level, it is frequently employed as well. This paper demonstrates that the RELAP5 flow simulation of the AFIP-7 irradiation experiment which has a complicated 3D geometry/flow path deviates by ~28% from the flow evaluation through a computational fluid dynamics (CFD) simulation, which has been validated against a flow test performed at Oregon State University. Thermal safety compliance analysis of an experiment planned to be irradiated in the Advanced Test Reactor is usually performed using the finite element analysis code, Abaqus. This research reveals the disadvantages of the Abaqus simulation in the flow instability and departure from nucleate boiling evaluations via a conjugate heat transfer analysis of the AFIP-7 irradiation experiment. As a result, a detailed CFD simulation is suggested for irradiation experiments with complicated flow paths, rather than a simplified RELAP5 simulation or hand calculations. The validated simulation approach will be integrated with the Boehmite correlations to investigate the oxide growth prediction on the fuel cladding in Part II of this research.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

FY26 Progress on Demonstration of a Multiphysics Steady State Capability for Modeling Core Radial Expansion in SFRs

Under the U.S. Department of Energy Office of Nuclear Energy Advanced Modeling and Simulation (NEAMS) Program, an integrated multiphysics approach is being developed to model the core bowing phenomena important to liquid metal-cooled fast reactors. Core bowing is an important passive safety mechanism in liquid metal-cooled fast reactors and involves multiphysics effects including radiation transport, fluid flow, heat transfer, and mechanical response to temperature and flux gradients. This report summarizes recent progress on developing a multiphysics, MOOSE-based workflow to predict core bowing and associated reactivity feedback. Significant new capabilities in the reactor physics code Griffin - sodium backfill and pin power reconstruction for deformed geometries - were applied in this effort. This year’s work included verification, code comparisons, sensitivity studies, and coupled demonstrations that advance the state of MOOSE-based core bowing workflow. Griffin’s sodium backfill capability was verified by demonstrating that its automated treatment of geometry expansion and material-density updates reproduces manual calculations exactly, confirming solid mass conservation and proper coolant backfilling in expanded geometries. Reconstructed pin powers were compared for Griffin’s ductheterogeneous and ring-heterogeneous treatments in single-, seven-, and nineteen-assembly cases, with best agreement observed in lower-leakage configurations and the duct-heterogeneous approach offering substantially lower computational cost. Thermal-hydraulic sensitivity sensitivities showed that MOOSE SCM, SAM, and CFD are expected to produce similar deformation predictions despite variances in their temperature predictions, and that explicit treatment of inter-assembly flow becomes increasingly important as gap flow rate increases. Finally, coupled demonstrations on small multi-assembly configurations using Griffin, MOOSE Solid Mechanics, MOOSE SCM, and Heat Conduction produced physically consistent reactivity feedback from thermal expansion and bowing. The coupled demonstrations simulated grid plate expansion as well as resultant core bowing at full power conditions. Simplifications were made in current workflow, namely the assumption of instantaneous full power conditions following hot zero power, and pre-expanding the Griffin geometry axially due to lack of an axial fuel pin expansion model and temperature feedback to Griffin.

Wozniak, Nicholas↗

Particle-in-cell Simulations of Relativistic Magnetic Reconnection with Advanced Maxwell Solver Algorithms

Abstract Relativistic magnetic reconnection is a nonideal plasma process that is a source of nonthermal particle acceleration in many high-energy astrophysical systems. Particle-in-cell (PIC) methods are commonly used for simulating reconnection from first principles. While much progress has been made in understanding the physics of reconnection, especially in 2D, the adoption of advanced algorithms and numerical techniques for efficiently modeling such systems has been limited. With the GPU-accelerated PIC code WarpX, we explore the accuracy and potential performance benefits of two advanced Maxwell solver algorithms: a nonstandard finite-difference scheme (CKC) and an ultrahigh-order pseudo-spectral method (PSATD). We find that, for the relativistic reconnection problem, CKC and PSATD qualitatively and quantitatively match the standard Yee-grid finite-difference method. CKC and PSATD both admit a time step that is 40% longer than that of Yee, resulting in a ∼40% faster time to solution for CKC, but no performance benefit for PSATD when using a current deposition scheme that satisfies Gauss’s law. Relaxing this constraint maintains accuracy and yields a 30% speedup. Unlike Yee and CKC, PSATD is numerically stable at any time step, allowing for a larger time step than with the finite-difference methods. We found that increasing the time step 2.4–3 times over the standard Yee step still yields accurate results, but it only translates to modest performance improvements over CKC, due to the current deposition scheme used with PSATD. Further optimization of this scheme will likely improve the effective performance of PSATD.

79 ASTRONOMY AND ASTROPHYSICS↗

An evaluation of three two-dimensional computational fluid dynamics codes including low Reynolds numbers and transonic Mach numbers

Full-potential, Euler, and Navier-Stokes computational fluid dynamics (CFD) codes were evaluated for use in analyzing the flow field about airfoils sections operating at Mach numbers from 0.20 to 0.60 and Reynolds numbers from 500,000 to 2,000,000. The potential code (LBAUER) includes weakly coupled integral boundary layer equations for laminar and turbulent flow with simple transition and separation models. The Navier-Stokes code (ARC2D) uses the thin-layer formulation of the Reynolds-averaged equations with an algebraic turbulence model. The Euler code (ISES) includes strongly coupled integral boundary layer equations and advanced transition and separation calculations with the capability to model laminar separation bubbles and limited zones of turbulent separation. The best experiment/CFD correlation was obtained with the Euler code because its boundary layer equations model the physics of the flow better than the other two codes. An unusual reversal of boundary layer separation with increasing angle of attack, following initial shock formation on the upper surface of the airfoil, was found in the experiment data. This phenomenon was not predicted by the CFD codes evaluated.

Hicks, Raymond M.↗

The Galileo Spacecraft: A Communications Legacy for Future Space Flight

The Galileo mission to Jupiter has implemented a wide range of telecommunication improvements in response to the loss of it's high gain antenna. Among the communications enhancements that have been made are the use of advanced compression techniques, packetized telemetry, new error correcting codes and algorithms, more efficient modulation, variable transmission data rates, routine ground antenna arraying (even between continents,) extremely sensitive ground receivers, and non-real-time automated data reconstruction. This telecommunications legacy of Galileo will aid in our abillity to conduct a meaningful exploration of the solar system, and beyond, at a reasonable cost.

Galileo↗

Development and Implementation of a CTF Code Verification Suite.

CTF is a thermal hydraulic subchannel code developed to predict light water reactor (LWR) core behavior. It is a version of Coolant Boiling in Rod Arrays (COBRA) developed by Oak Ridge National Laboratory (ORNL) and North Carolina State University (NCSU) and used in the Consortium for the Advanced Simulation of LWRs (CASL). Here, the existing CTF code verification matrix is expanded, which ensures that the code is a faithful representation of the underlying mathematical model. The suite of code verification tests are mapped to the underlying conservation equations of CTF and significant gaps are addressed. As such, five new problems are incorporated: isokinetic advection, conduction, pressure drop, convection, and pipe boiling. Convergence behavior and numerical errors are quantified for each of the tests and all tests converge at the correct rate to their corresponding analytic solution. A new verification utility that generalizes the code verification process is used to incorporate these problems into the CTF automated test suite.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

Supporting Development for the Stirling Radioisotope Generator and Advanced Stirling Technology Development at NASA Glenn Research Center

A high-efficiency, 110-We (watts electric) Stirling Radioisotope Generator (SRG110) for possible use on future NASA Space Science missions is being developed by the Department of Energy, Lockheed Martin, Stirling Technology Company (STC), and NASA Glenn Research Center (GRC). Potential mission use includes providing spacecraft onboard electric power for deep space missions and power for unmanned Mars rovers. GRC is conducting an in-house supporting technology project to assist in SRG110 development. One-, three-, and six-month heater head structural benchmark tests have been completed in support of a heater head life assessment. Testing is underway to evaluate the key epoxy bond of the permanent magnets to the linear alternator stator lamination stack. GRC has completed over 10,000 hours of extended duration testing of the Stirling convertors for the SRG110, and a three-year test of two Stirling convertors in a thermal vacuum environment will be starting shortly. GRC is also developing advanced technology for Stirling convertors, aimed at substantially improving the specific power and efficiency of the convertor and the overall generator. Sunpower, Inc. has begun the development of a lightweight Stirling convertor, under a NASA Research Announcement (NRA) award, that has the potential to double the system specific power to about 8 We/kg. GRC has performed random vibration testing of a lower-power version of this convertor to evaluate robustness for surviving launch vibrations. STC has also completed the initial design of a lightweight convertor. Status of the development of a multi-dimensional computational fluid dynamics code and high-temperature materials work on advanced superalloys, refractory metal alloys, and ceramics are also discussed.

Thieme, Lanny G.↗

Supporting Development for the Stirling Radioisotope Generator and Advanced Stirling Technology Development at NASA Glenn

A high-efficiency, 110-W(sub e) (watts electric) Stirling Radioisotope Generator (SRG110) for possible use on future NASA Space Science missions is being developed by the Department of Energy, Lockheed Martin, Stirling Technology Company (STC), and NASA Glenn Research Center (GRC). Potential mission use includes providing spacecraft onboard electric power for deep space missions and power for unmanned Mars rovers. GRC is conducting an in-house supporting technology project to assist in SRG110 development. One-, three-, and six-month heater head structural benchmark tests have been completed in support of a heater head life assessment. Testing is underway to evaluate the key epoxy bond of the permanent magnets to the linear alternator stator lamination stack. GRC has completed over 10,000 hours of extended duration testing of the Stirling convertors for the SRG110, and a three-year test of two Stirling convertors in a thermal vacuum environment will be starting shortly. GRC is also developing advanced technology for Stirling convertors, aimed at substantially improving the specific power and efficiency of the convertor and the overall generator. Sunpower, Inc. has begun the development of a lightweight Stirling convertor, under a NASA Research Announcement (NRA) award, that has the potential to double the system specific power to about 8 W(sub e) per kilogram. GRC has performed random vibration testing of a lowerpower version of this convertor to evaluate robustness for surviving launch vibrations. STC has also completed the initial design of a lightweight convertor. Status of the development of a multi-dimensional computational fluid dynamics code and high-temperature materials work on advanced superalloys, refractory metal alloys, and ceramics are also discussed.

Thieme, Lanny G.↗

Influence of bulk turbulence and entrance boundary layer thickness on the curved duct flow field

The objective of this investigation was the experimental evaluation of bulk turbulence and boundary thickness influence on the secondary flow development in a square, 90 deg turning duct. A three dimensional laser velocimetry system was utilized to measure the mean and fluctuating components of velocity in the large curved duct facility. The three dimensional development of the viscous shear layers in the curved duct has a strong influence on the complete flow field. Since ducted three dimensional flows are found in many engineering applications, including gas turbine engines, and contain high turbulence levels and high wall heat transfer rates, they present a difficult challenge to computational fluid mechanics codes. Turbulence modeling remains one of constraints to CFD advance due to inadequate physical understanding and experimental definition of turbulent shear flows. The results of this investigation expand the curved duct data base to higher turbulence levels and thicker entrance boundary layers. The experimental results provide a challenging benchmark data base for computational fluid dynamics code development and validation. The variation of inlet bulk turbulence intensity provides additional information to aid in turbulence model evaluation.

Crawford, Roger A.↗

Influence of bulk turbulence and entrance boundary layer thickness on the curved duct flow field

The objective of this investigation was the experimental evaluation of bulk turbulence and boundary thickness influence on the secondary flow development in a square, 90 deg turning duct. A three dimensional laser velocimetry system was utilized to measure the mean and fluctuating components of velocity in the large curved duct facility. The three dimensional development of the viscous shear layers in the curved duct has a strong influence on the complete flow field. Since ducted three dimensional flows are found in many engineering applications, including gas turbine engines, and contain high turbulence levels and high wall heat transfer rates, they present a difficult challenge to computational fluid mechanics codes. Turbulence modeling remains one of constraints to CFD advance due to inadequate physical understanding and experimental definition of turbulent shear flows. The results of this investigation expand the curved duct data base to higher turbulence levels and thicker entrance boundary layers. The experimental results provide a challenging benchmark data base for computational fluid dynamics code development and validation. The variation of inlet bulk turbulence intensity provides additional information to aid in turbulence model evaluation.

Shohadaee, Ahmad A.↗

Seals Flow Code Development

In recognition of a deficiency in the current modeling capability for seals, an effort was established by NASA to develop verified computational fluid dynamic concepts, codes, and analyses for seals. The objectives were to develop advanced concepts for the design and analysis of seals, to effectively disseminate the information to potential users by way of annual workshops, and to provide experimental verification for the models and codes under a wide range of operating conditions.

Source record↗

STAGS Developments for Residual Strength Analysis Methods for Metallic Fuselage Structures

A summary of advances in the Structural Analysis of General Shells (STAGS) finite element code for the residual strength analysis of metallic fuselage structures, that were realized through collaboration between the structures group at NASA Langley, and Dr. Charles Rankin is presented. The majority of the advancements described were made in the 1990's under the NASA Airframe Structural Integrity Program (NASIP). Example results from studies that were conducted using the STAGS code to develop improved understanding of the nonlinear response of cracked fuselage structures subjected to combined loads are presented. An integrated residual strength analysis methodology for metallic structure that models crack growth to predict the effect of cracks on structural integrity is demonstrated

Young, Richard D.↗