SEARCH · Engineering Papers

Results for “high loading”

Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

SourceResearch connectionFrom yearThrough year

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 73 records · Page 4

All sources NASA NTRS DOE OSTI

NASA NTRS2011

Capability Extension to the Turbine Off-Design Computer Program AXOD With Applications to the Highly Loaded Fan-Drive Turbines

The axial flow turbine off-design computer program AXOD has been upgraded to include the outlet guide vane (OGV) into its acceptable turbine configurations. The mathematical bases and the techniques used for the code implementation are described and discussed in lengths in this paper. This extended capability is verified and validated with two cases of highly loaded fan-drive turbines, designed and tested in the V/STOL Program of NASA. The first case is a 4 1/2-stage turbine with an average stage loading factor of 4.66, designed by Pratt & Whitney Aircraft. The second case is a 3 1/2-stage turbine with an average loading factor of 4.0, designed in-house by the NASA Lewis Research Center (now the NASA Glenn Research Center). Both cases were experimentally tested in the turbine facility located at the Glenn Research Center. The processes conducted in these studies are described in detail in this paper, and the results in comparison with the experimental data are presented and discussed. The comparisons between the AXOD results and the experimental data are in excellent agreement.

Chen, Shu-cheng S.↗

NASA NTRS1976

Single-stage experimental evaluation of low aspect ratio, highly loaded blading for compressors. Part 9: Stage F and stage G, volume 1

Two single-stage, 0.77 hub/tip ratio axial-flow compressors were tested to evaluate the effectiveness of low aspect ratio blading as a means of obtaining higher stage loadings. One compressor, designated Stage F, was comprised of circular arc blading with an aspect ratio of 0.9 for both the rotor and stator. This compressor was tested with uniform inlet flow, hub radial, tip radial, and 180 deg arc circumferential inlet distortion. The second compressor, designated Stage G, was comprised of multiple circular arc blading with an aspect ratio of 1.0 for both the rotor and stator. This compressor was tested with uniform inlet flow only. Design rotor tip speeds for Rotor F and Rotor G were 285 m/sec (934 ft/sec) and 327 m/sec (1,074 ft/sec) respectively. Both stages operated at high loading levels with adequate efficiency and operating range. The peak efficiencies and corresponding average stage diffusion factors for Stages F and G at design rotor speed were 86.4% and 84.1% and 0.59 and 0.55 respectively. The surge margin at peak efficiency for Stage F was 12.6% and the corresponding value for Stage G was 16.5%. Both stages experienced a loss in efficiency with increasing rotor speed; however, the multiple circular arc rotor delayed the characteristic loss in efficiency within increasing Mach number to higher Mach number.

Cheatham, J. G.↗

DOE OSTI2025

Operando Neutron Imaging of Lithium Flux and Gradient Cathode Design for Enhanced Kinetics in High‐Loading All‐Solid‐State Li─S Batteries

All-solid-state Li–sulfur batteries (ASSLSBs) are considered promising candidates for next-generation energy storage owing to their inherent safety, high energy density, and abundant sulfur resources. However, slow redox kinetics greatly limit sulfur utilization during solid-solid sulfur reactions, leading to significant challenges to achieve efficient performance in high-mass-loading ASSLSBs. Here, operando neutron image is employed to directly visualize, for the first time, that sluggish Li + transport kinetics and the uneven distribution of Li + during cathodic reactions are critical factors limiting sulfur conversion. To address this issue, gradient cathode architectures comprising three and five layers are designed, in which catholyte concentrations are strategically varied to optimize Li-ion flux and enhance ionic conductivity of the whole composite cathode electrode. Operando neutron imaging distinctly visualizes and confirms that three-layer gradient approach significantly enhances Li-ion mobility, resulting in more uniform redox reactions and greatly improved sulfur utilization compared to traditional non-gradient structures. Consequently, the three-layer gradient cathode achieves superior rate performance and reduced electrode polarization at high sulfur mass loadings of 4.5 and 6.0 mg cm −2 . Furthermore, the applicability and scalability of this design are demonstrated in a five-layer gradient cathode architecture, achieving an impressive discharge specific capacity increase from 656 mAh g −1 (three-layer gradient) to 1232 mAh g −1 at 1/20 C for ultra-high sulfur loading of 7.5 mg cm −2 . In conclusion, this innovative gradient cathode design offers substantial advancements in understanding and overcoming Li-ion transport limitations, paving the way toward practical, high-energy-density ASSLSBs.

25 ENERGY STORAGE↗

DOE OSTI2025

Laser ablation of high-loading Li-ion battery electrodes improves accessible capacity and cycle life for Behind-the-Meter Storage

Adoption of Behind-the-Meter Storage (BTMS) requires design of batteries that enable high safety, long cycle life, and low cost at the system level. Pairing Li 4 Ti 5 O 12 (LTO) with LiMn 2 O 4 (LMO) achieves targets related to safety and cycle life, but these materials' low energy densities contribute to higher cost at the system scale. Increasing electrode loading is a simple approach to improve energy density, but comes with a trade-off in electrode utilization due to long, tortuous Li + diffusion pathways. Here, laser ablation is used to microstructure (pattern) high-loading electrodes to enhance electrode performance through improved Li + diffusion pathways. Four cell types, comprising combinations of standard or patterned anode and cathode, were prepared to evaluate the effects of laser ablation at each electrode. A rate test shows that patterning electrodes enhances active material utilization at ≳1C rates. Patterning the cathode yields the most benefit, as cells with a patterned cathode demonstrate a ~20% higher accessible capacity than those without at 1.4C. Additionally, 1C capacity retention of cells with patterned cathode (91% through 3000 cycles) is significantly improved over cells with only the anode patterned (64%) and non-patterned electrodes (50%). Characterization of post-mortem cells before and after refreshing their electrolyte suggests that 1C capacity retention is improved by mitigation of electrode "dry-out". We hypothesize that the microstructure acts as a reservoir of additional electrolyte, or a path for gas to escape, so that active material remains wetted throughout long-term cycling, and/or the microstructure may reduce localized, gas-forming overpotentials in the high-loading electrode.

25 ENERGY STORAGE↗

NASA NTRS2015

Effects of Unsteady Flow Interactions on the Performance of a Highly-Loaded Transonic Compressor Stage

The primary focus of this paper is to investigate the loss sources in an advanced GE transonic compressor design with high reaction and high stage loading. This advanced compressor has been investigated both experimentally and analytically in the past. The measured compressor efficiency is significantly lower than the efficiency calculated with various existing tools based on RANS and URANS. The general understanding is that some important flow physics in this modern compressor design are not represented in the current tools. To pinpoint the source of the efficiency miss, an advanced test with detailed flow traverse was performed for the front one and a half stage at the NASA Glenn Research Center. In the present paper, a Large Eddy Simulation (LES) is employed to determine whether a higher-fidelity simulation can pick up any additional flow physics that can explain past efficiency miss with RANS and URANS. The results from the Large Eddy Simulation were compared with the NASA test results and the GE interpretation of the test data. LES calculates lower total pressure and higher total temperature on the pressure side of the stator, resulting in large loss generation on the pressure side of the stator. On the other hand, existing tools based on the RANS and URANS do not calculate this high total temperature and low total pressure on the pressure side of the stator. The calculated loss through the stator from LES seems to match the measured data and the GE data interpretation. Detailed examination of the unsteady flow field from LES indicates that the accumulation of high loss near the pressure side of the stator is due to the interaction of the rotor wake with the stator blade. The strong rotor wake interacts quite differently with the pressure side of the stator than with the suction side of the stator blade. The concave curvature on the pressure side of the stator blade increases the mixing of the rotor wake with the pressure side boundary layer significantly. On the other hand, the convex curvature on the suction side of the stator blade decreases the mixing and the suction side blade boundary layer remains thin. The jet velocity in the rotor wake in the stator frame seems to magnify the curvature effect in addition to inviscid redistribution of wake fluid toward the pressure side of the blade.

LES↗

NASA NTRS1996

Scuffing Characteristics of High-Load Rolling/Sliding Contacts Operating in Liquid Oxygen: Effects of Materials and Surface Roughness

This research reports on an experimental study of the effects of materials and surface roughness on the scuffing characteristics of rolling/sliding contacts cooled and lubricated with liquid oxygen. Experiments were carried out under heavy loading with a Hertzian pressure in the range of 2.0 GPa to 3.0 GPa and with a high rolling velocity of up to 48 m/s. For contacts between AISI 440 C stainless-steel elements, the results showed that the scuffing behavior of the system was fairly consistent under a wide range of rolling velocity. Scuffing commenced at a small slide-to-roll ratio of around 0.02, and the scuffing behavior of the contact was not sensitive to surface roughness for the test-sample RMS roughness ranging from 0.02 microns to 0.10 microns. For contacts between 440 C and Si3N4 elements, on the other hand, the scuffing behavior of the system was not very consistent and somewhat unpredictable. The results were sensitive to surface roughness particularly that of the Si3N4 test sample. With well polished test samples, consistent results were obtained; the level of traction was lower than that with a 440 C toroid and scuffing did not take place up to a slide-to-roll ratio of near 0.03. The results strongly suggest that significant hydrodynamic effect can be generated by liquid oxygen under heavy loading and high velocity conditions. The results also suggest that the hydrodynamic action is likely generated by the conventional viscous mechanism as it can be largely destroyed by a narrow circumferential surface scratch running through the central region of the contact.

Chang, L.↗

DOE OSTI2023

Extraction of Nitric Acid and Uranium with DEHiBA under High Loading Conditions

We report the mechanism by which high concentrations (1.5 M in n-dodecane) of N,N-di-2-ethylhexylisobutyramide (DEHiBA) extracts HNO 3 and UO 2 (NO 3 ) 2 is under examination. Most prior studies have examined the extractant and the mechanism at a concentration of 1.0 M in n-dodecane, however under the higher loading conditions that can be achieved by a higher concentration of extractant this mechanism could change. Increased extraction of both nitric acid and uranium is observed with an increased concentration of DEHiBA. The mechanisms are examined by thermodynamic modeling of distribution ratios, 15 N NMR, and FTIR spectroscopy coupled with Principal Component Analysis (PCA). Speciation diagrams produced through thermodynamic modeling have been qualitatively reproduced through PCA of the FTIR spectra. The predominant extracted species of HNO 3 (DEHiBA), HNO 3 (DEHiBA) 2 , and UO 2 (NO 3 ) 2 (DEHiBA) 2 are in good agreement with prior literature reports for 1.0 M DEHiBA systems. Evidence for an additional species of either UO 2 (NO 3 ) 2 (DEHiBA) or UO 2 (NO 3 ) 2 (DEHiBA) 2 (HNO 3 ) also contributing to the extraction of uranium species is given.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2025

High-Loading Single-Atom Catalyst via On-Surface Synthesis of a Metal-Covalent Organic Framework for Oxygen Reduction Reaction

The development of active catalysts with both high metal efficiency and use of earth abundant metals is the ultimate goal for advancing the required commercially viable and sustainable energy conversion technologies of the future. Metal-organic frameworks (MOFs) have emerged as promising candidates due to their high surface area and tunable active sites. Here, this study aims to fabricate a new type of high metal loading single-atom catalysts (SACs) based on 2D metal-organic covalent organic frameworks (MCOFs) with uniform, active and stable Fe-N 3 sites. The MCOFs were synthesized through an on-surface polymerization process using Fe and melamine as precursors. The polymerization steps were characterized using operando high-pressure scanning tunneling microscopy (HP-STM), in situ X-ray photoelectron spectroscopy (XPS), low-temperature STM (LT-STM), and computational calculations. The synthesized MCOFs demonstrated favorable adsorption and activation of O 2 at the Fe-N 3 sites, and it is predicted to be active for the oxygen reduction reaction (ORR). The surface chemistry and functionality of 2D MCOFs can be rationally designed by varying the metal atoms and organic linkers, offering a versatile platform for diverse applications.

25 ENERGY STORAGE↗

DOE OSTI2023

A 5 V-class cobalt-free battery cathode with high loading enabled by dry coating

“Thick electrode using high voltage cathode” can be considered, since this research focuses on high voltage cathode materials.

25 ENERGY STORAGE↗

NASA NTRS2015

Unsteady Loss in the Stator Due to the Incoming Rotor Wake in a Highly-Loaded Transonic Compressor

The present paper reports an investigation of unsteady loss generation in the stator due to the incoming rotor wake in an advanced GE transonic compressor design with a high-fidelity numerical method. This advanced compressor with high reaction and high stage loading has been investigated both experimentally and analytically in the past. The measured efficiency in this advanced compressor is significantly lower than the design intention/goal. The general understanding is that the current generation of compressor design/analysis tools miss some important flow physics in this modern compressor design. To pinpoint the source of the efficiency miss, an advanced test with a detailed flow traverse was performed for the front one and a half stage at the NASA Glenn Research Center. Detailed data-match analysis by GE identified an unexpected high loss generation in the pressure side of the stator passage. Higher total temperature and lower total pressure are measured near the pressure side of the stator. Various analyses based on the RANS and URANS of the compressor stage do not calculate the measured higher total temperature and lower total pressure on the pressure side of the stator. In the present paper, a Large Eddy Simulation (LES) is applied to find the fundamental mechanism of this unsteady loss generation in the stator due to the incoming rotor wake. The results from the LES were first compared with the NASA test results and the GE interpretation of the test data. LES calculates lower total pressure and higher total temperature on the pressure side of the stator, as the measured data showed, resulting in large loss generation on the pressure side of the stator. Detailed examination of the unsteady flow field from LES shows that the rotor wake, which has higher total temperature and higher total pressure relative to the free stream, interacts quite differently with the pressure side of the blade compared to the suction side of the blade. The higher temperature in the wake remains high as the wake passes through the pressure side of the blade. On the other hand, the total temperature diffuses as it passes through near the suction surface. For the presently investigated compressor, the classical intra-stator wake transport to the pressure side of the blade by the slip velocity in the wake seems to be minor. The main causes of this phenomenon are three-dimensional unsteady vortex interactions near the blade surface. The stabilizing effect of the concave curvature on the suction side keeps the rotor wake thin. On the other hand, the destabilizing effect of the convex curvature of the pressure side makes the rotor wake thicker, which results in a higher total temperature measurement at the stator exit. Additionally, wake stretching through the stator seems to contribute to the redistribution of the total temperature and the loss generation.

Efficiency↗

NASA NTRS2015

Unsteady Loss in the Stator Due to the Incoming Rotor Wake in a Highly-Loaded Transonic Compressor

Compressor↗

DOE OSTI2026

Catalytic disproportionation on carbon superstructures enables long-life, high-loading Li–S batteries

Electrocatalysis has been widely explored as an effective strategy to accelerate polysulfide (PS) conversion and suppress the shuttle effect in lithium–sulfur (Li–S) batteries. However, the underlying mechanisms remain elusive, and electrocatalytic reactions are inactive during cell resting. In this work, we reveal and quantitatively analyze a previously unrecognized sulfur reduction route (SRR) driven by catalytic disproportionation at the carbon cathode surface—fundamentally distinct from conventional electrocatalysis. Unlike conventional stepwise pathways, this SRR enables high-order polysulfides (Sₓ²⁻, x = 5–8) to directly convert into S₈ and Li₂S₂, bypassing low-order intermediates. This sulfur-reduction shortcut is systematically elucidated through high-performance liquid chromatography, revealing the intrinsic catalytic contribution of carbon frameworks and the dynamic evolution of PS species. We demonstrate that carbon superstructures (CSS-0.5), assembled from nanosheet subunits with abundant N/O functionalities and interconnected charge-migration channels, synergistically promote this catalytic process. Benefiting from these features, CSS-0.5 delivers superior electrochemical performance under practical conditions, enabling high sulfur loading (6.0 mg cm⁻²) pouch cells with 80.5% capacity retention over 210 cycles. This study provides the first quantitative evidence of electrocatalytic disproportionation in Li–S batteries, offering mechanistic insights and design principles for advanced sulfur cathodes.

25 ENERGY STORAGE↗

NASA NTRS1972

Highly loaded multi-stage fan drive turbine: Leaned stator configuration design

The results of the high lift blade configuration design study are reported. The three-stage constant-inside-diameter turbine utilizes a ten degree tangentially leaned stator in stage three. All other bladerows use plain blades. Analysis of the leaned stator is discussed, and detailed design data are summarized. Steady-state stresses are discussed, and the results of the mechanical design analysis are presented.

Evans, D. C.↗

NASA NTRS2005

High-Temperature, High-Load-Capacity Radial Magnetic Bearing

A radial heteropolar magnetic bearing capable of operating at a temperature as high as 1,000 F (=540 C) has been developed. This is a prototype of bearings for use in gas turbine engines operating at temperatures and speeds much higher than can be withstood by lubricated rolling-element bearings. It is possible to increase the maximum allowable operating temperatures and speeds of rolling-element bearings by use of cooling-air systems, sophisticated lubrication systems, and rotor-vibration- damping systems that are subsystems of the lubrication systems, but such systems and subsystems are troublesome. In contrast, a properly designed radial magnetic bearing can suspend a rotor without contact, and, hence, without need for lubrication or for cooling. Moreover, a magnetic bearing eliminates the need for a separate damping system, inasmuch as a damping function is typically an integral part of the design of the control system of a magnetic bearing. The present high-temperature radial heteropolar magnetic bearing has a unique combination of four features that contribute to its suitability for the intended application: 1. The wires in its electromagnet coils are covered with an insulating material that does not undergo dielectric breakdown at high temperature and is pliable enough to enable the winding of the wires to small radii. 2. The processes used in winding and potting of the coils yields a packing factor close to 0.7 . a relatively high value that helps in maximizing the magnetic fields generated by the coils for a given supplied current. These processes also make the coils structurally robust. 3. The electromagnets are of a modular C-core design that enables replacement of components and semiautomated winding of coils. 4. The stator is mounted in such a manner as to provide stable support under radial and axial thermal expansion and under a load as large as 1,000 lb (.4.4 kN).

Provenza, Andrew↗

NASA NTRS1978

Investigation of the jet-wake flow of a highly loaded centrifugal compressor impeller

Investigations, aimed at developing a better understanding of the complex flow field in high performance centrifugal compressors were performed. Newly developed measuring techniques for unsteady static and total pressures as well as flow directions, and a digital data analysis system for fluctuating signals were thoroughly tested. The loss-affected mixing process of the distorted impeller discharge flow was investigated in detail, in the absolute and relative system, at impeller tip speeds up to 380 m/s. A theoretical analysis proved good coincidence of the test results with the DEAN-SENOO theory, which was extended to compressible flows.

Eckardt, D.↗

NASA NTRS1993

Aerodynamic design and analysis of a highly loaded turbine exhaust

The aerodynamic design and analysis of a turbine exhaust volute manifold is described. This turbine exhaust system will be used with an advanced gas generator oxidizer turbine designed for very high specific work. The elevated turbine stage loading results in increased discharge Mach number and swirl velocity which, along with the need for minimal circumferential variation of fluid properties at the turbine exit, represent challenging volute design requirements. The design approach, candidate geometries analyzed, and steady state/unsteady CFD analysis results are presented.

Huber, F. W.↗

DOE OSTI2025

Experimental Investigation of Air-Fuel Equivalence Ratio Effects on Advanced Dual-fuel Diesel/Ammonia Combustion on a Single-Cylinder Medium-Duty Diesel Engine at High Load

Ammonia (NH3) has gathered a lot of interest as a low-lifecycle-carbon fuel in sectors with high weight and distance requirements, such as shipping. The International Maritime Organization (IMO) mandates a 70-80% greenhouse gas (GHG) reduction by 2040, which is only possible with advanced engine technologies and fuels like NH3. Prior research studies at the US Department of Energy’s Oak Ridge National Laboratory have shown strong performance with NH3 under dual-fuel mode using conventional diesel combustion (CDC) manifold air pressure (MAP) settings. Diesel airflow was initially used to simplify retrofitting (no turbocharger modification), which resulted in air-fuel equivalence ratios (λ) greater than 1.5. To characterize potential improvements in dual-fuel NH3 combustion performance at richer in-cylinder conditions, a global λ sweep using a diesel pilot ignition (DPI) strategy with diesel fuel injected near top-dead center (TDC) and a reactivity-controlled compression ignition (RCCI) injection strategy with diesel fuel injected earlier during the compression stroke were compared. The experiments were conducted at 1200 RPM and 12.6 bar (75% load), and λ was varied by decreasing the commanded air flow to the engine at greater than 90% ammonia energy substitution (AES) level. A diesel injection timing sweep was conducted for both the combustion modes at fixed λ, and the timing with the lowest engine-out N2O emissions was identified. The results indicated an optimal balance between CO2, eq and thermal efficiency benefits for both DPI and RCCI injection strategy cases compared to CDC at a λ of 1.4. The indicated N-based emissions exhibited a strong correlation to the ratio of CA5–50 and ignition delay for DPI, but no apparent trend emerged for the RCCI injection strategy at the tested boundary conditions.

Tyrewala, Daanish [ORNL] (ORCID:0000000208599324)↗

DOE OSTI2025

Experimental investigation of air-fuel equivalence ratio effects on advanced dual-fuel ammonia/diesel combustion on a single-cylinder medium-duty diesel engine at high load

Ammonia (NH 3 ) has garnered significant interest as an alternative fuel for meeting international emissions reduction mandates in sectors with high weight and distance requirements, such as shipping. Technical barriers and unanswered questions remain on the combustion strategies that can maximize ammonia utilization and minimize emissions. Prior research studies at the US Department of Energy’s Oak Ridge National Laboratory have shown strong performance with NH 3 under dual-fuel mode using conventional diesel combustion (CDC) manifold air pressure settings. Diesel airflow was initially used to simplify retrofitting (no turbocharger modification), which resulted in air-fuel equivalence ratios (λ) greater than 1.5. To characterize potential improvements in dual-fuel NH 3 combustion performance at richer in-cylinder conditions, a global λ sweep compared the use of early (E-pilot) and late (L-pilot) single diesel injections. The experiments were conducted at 1200 RPM and 12.8 ± 0.2 bar (75 % load), and λ was varied by decreasing the commanded air flow to the engine at greater than 90 % ammonia energy substitution level. A diesel injection timing sweep was conducted for both the injection strategies at fixed λ, and the timing with the lowest engine-out N 2 O emissions was identified. The results indicated an optimal balance between CO 2,eq and thermal efficiency benefits both E-pilot and l-pilot injection strategy cases compared with CDC at a λ of 1.4. In conclusion, the indicated nitrogen-based emissions exhibited a strong correlation to the ratio of CA5–50 and ignition delay for l-pilot, but no apparent trend emerged for the E-pilot injection strategy at the tested boundary conditions.

Ammonia↗