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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.

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At least 721 records · Page 40
All sourcesNASA NTRSDOE OSTI
DOE OSTI2020

Numerical Investigation of Fuel Property Effects on Mixed-Mode Combustion in a Spark-Ignition Engine

In this research, lean mixed-mode combustion is numerically investigated using computational fluid dynamics (CFD) in a spark-ignition engine. A new E30 fuel surrogate is developed using a neural network model with matched octane numbers. A skeletal mechanism is also developed by automated mechanism reduction and by incorporating a NO x submechanism. A hybrid approach that couples the G-equation model and the well-stirred reactor model is employed for turbulent combustion modeling. The developed CFD model is shown to well predict pressure and apparent heat release rate (AHRR) traces compared with experiment. Two types of combustion cycles (deflagration-only and mixed-mode cycles) are observed. The mixed-mode cycles feature early flame propagation and subsequent end-gas auto-ignition, leading to two distinctive AHRR peaks. The validated CFD model is then employed to investigate the effects of NO x chemistry. The NO x chemistry is found to promote auto-ignition through the residual gas, while the deflagration phase remains largely unaffected. Sensitivity analysis is finally performed to understand effects of fuel properties, including heat of vaporization (HoV) and laminar flame speed (S L ). An increased HoV tends to suppress auto-ignition through charge cooling, while the impact of HoV on flame propagation is insignificant. In contrast, an increased S L is found to significantly promote both flame propagation and end-gas auto-ignition. The promoting effect of S L on auto-ignition is not a direct chemical effect; it is rather caused by an advancement of the combustion phasing, which increases compression heating of the end-gas.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2023

Direct Numerical Simulation of Partial Fuel Stratification Assisted Lean Premixed Combustion for Assessment of Hybrid G-Equation/Well-Stirred Reactor Model

Partial fuel stratification (PFS) is a promising fuel injection strategy to stabilize lean premixed combustion in spark-ignition (SI) engines. PFS creates a locally stratified mixture by injecting a fraction of the fuel, just before spark timing, into the engine cylinder containing homogeneous lean fuel/air mixture. Further, this locally stratified mixture, when ignited, results in complex flame structure and propagation modes similar to partially premixed flames and allows for faster and more stable flame propagation than a homogeneous lean mixture. This study focuses on understanding the detailed flame structures associated with PFS-assisted lean premixed combustion. First, a two-dimensional direct numerical simulation (DNS) is performed using detailed fuel chemistry, experimental pressure trace, and realistic initial conditions mapped from a prior engine large-eddy simulation (LES), replicating practical lean SI operating conditions. DNS results suggest that the conventional triple flame structure is prevalent during the initial stage of flame kernel growth. Both premixed and nonpremixed combustion modes are present with the premixed mode contributing dominantly to the total heat release. Detailed analysis further reveals the effects of flame stretch and fuel pyrolysis on flame displacement speed. Based on the DNS findings, the accuracy of a hybrid G-equation/well-stirred reactor (WSR) combustion model is assessed for the PFS-assisted lean operation in the LES context. It is found that the G-equation model qualitatively captures the premixed branches of the triple flame, while the WSR model predicts the nonpremixed branch of the triple flame. Finally, potential needs for improvements to the hybrid G-equation/WSR modeling approach are discussed.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2024

PeleMP: The Multiphysics Solver for the Combustion Pele Adaptive Mesh Refinement Code Suite

Combustion encompasses multiscale, multiphase reacting flow physics spanning a wide range of scales from the molecular scales, where chemical reactions occur, to the device scales, where the turbulent flow is affected by the geometry of the combustor. This scale disparity and the limited measurement capabilities from experiments make modeling combustion a significant challenge. Recent advancements in high-performance computing (HPC), particularly with the Department of Energy's Exascale Computing Project (ECP), have enabled high-fidelity simulations of practical applications to be performed. The major physics submodels, including chemical reactions, turbulence, sprays, soot, and thermal radiation, exhibit distinctive computational characteristics that need to be examined separately to ensure efficient utilization of computational resources. This paper presents the multiphysics solver for the Pele code suite, called PeleMP, which consists of models for spray, soot, and thermal radiation. Here, the mathematical and algorithmic aspects of the model implementations are described in detail as well as the verification process. The computational performance of these models is benchmarked on multiple supercomputers, including Frontier, an exascale machine. Results are presented from production simulations of a turbulent sooting ethylene flame and a bluff-body swirl stabilized spray flame with sustainable aviation fuels to demonstrate the capability of the Pele codes for modeling practical combustion problems with multiphysics. This work is an important step toward the exascale computing era for high-fidelity combustion simulations providing physical insights and data for predictive modeling of real-world devices.

42 ENGINEERING↗
DOE OSTI2016

Evolution and current understanding of physicochemical characterization of particulate matter from reactivity controlled compression ignition combustion on a multicylinder light-duty engine

Low-temperature compression ignition combustion can result in nearly smokeless combustion, as indicated by a smoke meter or other forms of soot measurement that rely on absorbance due to elemental carbon content. Highly premixed low-temperature combustion modes do not form particulate matter in the traditional pathways seen with conventional diesel combustion. Previous research into reactivity controlled compression ignition particulate matter has shown, despite a near zero smoke number, significant mass can be collected on filter media used for particulate matter certification measurement. In addition, particulate matter size distributions reveal that a fraction of the particles survive heated double-dilution conditions. This paper summarizes research completed at Oak Ridge National Laboratory to date on characterizing the nature, chemistry and aftertreatment considerations of reactivity controlled compression ignition particulate matter and presents new research highlighting the importance of injection strategy and fuel composition on reactivity controlled compression ignition particulate matter formation. Particle size measurements and the transmission electron microscopy results do show the presence of soot particles; however, the elemental carbon fraction was, in many cases, within the uncertainty of the thermal–optical measurement. Particulate matter emitted during reactivity controlled compression ignition operation was also collected with a novel sampling technique and analyzed by thermal desorption or pyrolysis gas chromatography mass spectroscopy. Particulate matter speciation results indicated that the high boiling range of diesel hydrocarbons was likely responsible for the particulate matter mass captured on the filter media. Finally, to investigate potential fuel chemistry effects, either ethanol or biodiesel were incorporated to assess whether oxygenated fuels may enhance particle emission reduction.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2024

A numerical study of ignition and flame development characteristics in GCI combustion using large eddy simulations and chemical explosive mode analysis

Here, this work investigates the ignition and flame development processes of low reactivity fuel combustion under compression ignition conditions based on the large eddy simulation approach. The chemical explosive mode analysis (CEMA) is employed to characterize the local combustion features, including gas-liquid fuel zone, auto-ignition, diffusion-assisted, extinction, cool flame and post-ignition zone, among which auto-ignition and post-ignition are found to play a key role in the overall heat release process. The local flame propagation modes in gasoline compression ignition (GCI) are determined by quantifying the relative magnitude of diffusion/chemistry at a representative progress variable in the pre-ignition zone. The results show that autoignition fronts and deflagration waves exist simultaneously in the ignition and intense high temperature heat release (HTHR) stages, but autoignition fronts dominate. In addition, the chemical kinetic processes of four heat release periods are analyzed. The heat release during the ignition period is found to be dominated by the reactions CH 3 + H (+M) <=> CH 4 (+M) and CH 3 CHO + H <=> CH 2 CHO + H 2 . The reaction CH 2 OH + OH <=> CH 2 O + H 2 O always plays an important role in the heat releases during the other three combustion stages including intense HTHR, moderate HTHR and post-combustion.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2014

Erosion-Corrosion of Iron and Nickel Alloys at Elevated Temperature in a Combustion Gas Environment

This paper reports on the results of a study that compares the erosion-corrosion behavior of a variety of alloys (Fe- 2¼Cr 1Mo, 304 SS, 310 SS, Incoloy 800, Haynes 230 and a Fe 3 Al) in a combustion environment. Advanced coal combustion environments, with higher temperatures, are driving re-examination of traditional and examination of new alloys in these hostile environments. In order to simulate conditions in advanced coal combustion boilers, a special erosion apparatus was used to allow for impingement of particles under a low abrasive flux in a gaseous environment comprised of 20 % CO 2 , 0.05 % HCl, 77 % N 2 , 3 % O 2 , and 0.1 % SO 2 . Tests were conducted at room temperature and 700 °C with ~ 270 μm silica, using an impact velocity of 20 m/s in both air and the simulated combustion gas environment. The erosion-corrosion behavior was characterized by gravimetric measurements and by examination of the degraded surfaces optically and by scanning electron microscopy (SEM). At room temperature most of the alloys had similar loss rates. Not surprisingly, at 700 °C the lower chrome-iron alloy had a very high loss rate. The nickel alloys tended to have higher loss rates than the high chrome austenitic alloys.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2014

Recovery Act: Oxy-Combustion Technology Development for Industrial-Scale Boiler Applications. Task 4 - Testing in Alstom's 15 MW th Boiler Simulation Facility

Alstom Power Inc. (Alstom), under U.S. DOE/NETL Cooperative Agreement No. DE-NT0005290, is conducting a development program to generate detailed technical information needed for application of oxy-combustion technology. The program is designed to provide the necessary information and understanding for the next step of large-scale commercial demonstration of oxy combustion in tangentially fired boilers and to accelerate the commercialization of this technology. The main project objectives include: Design and develop an innovative oxyfuel system for existing tangentially-fired boiler units that minimizes overall capital investment and operating costs; Evaluate performance of oxyfuel tangentially fired boiler systems in pilot scale tests at Alstom’s 15 MWth tangentially fired Boiler Simulation Facility (BSF); Address technical gaps for the design of oxyfuel commercial utility boilers by focused testing and improvement of engineering and simulation tools; Develop the design, performance and costs for a demonstration scale oxyfuel boiler and auxiliary systems; Develop the design and costs for both industrial and utility commercial scale reference oxyfuel boilers and auxiliary systems that are optimized for overall plant performance and cost; and, Define key design considerations and develop general guidelines for application of results to utility and different industrial applications. The project was initiated in October 2008 and the scope extended in 2010 under an ARRA award. The project is scheduled for completion by April 30, 2014. Central to the project is 15 MWth testing in the BSF, which provided in-depth understanding of oxy-combustion under boiler conditions, detailed data for improvement of design tools, and key information for application to commercial scale oxy-fired boiler design. Eight comprehensive 15 MWth oxy-fired test campaigns were performed with different coals, providing detailed data on combustion, emissions, and thermal behavior over a matrix of fuels, oxy-process variables and boiler design parameters. Significant improvement of CFD modeling tools and validation against 15 MWth experimental data has been completed. Oxy-boiler demonstration and large reference designs have been developed, supported with the information and knowledge gained from the 15 MWth testing. This report addresses the results from the 15 MWth testing in the BSF.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2015

Combustion Safety Simplified Test Protocol Field Study

"9Combustions safety is an important step in the process of upgrading homes for energy efficiency. There are several approaches used by field practitioners, but researchers have indicated that the test procedures in use are complex to implement and provide too many false positives. Field failures often mean that the house is not upgraded until after remediation or not at all, if not include in the program. In this report the PARR and NorthernSTAR DOE Building America Teams provide a simplified test procedure that is easier to implement and should produce fewer false positives. A survey of state weatherization agencies on combustion safety issues, details of a field data collection instrumentation package, summary of data collected over seven months, data analysis and results are included. The project provides several key results. State weatherization agencies do not generally track combustion safety failures, the data from those that do suggest that there is little actual evidence that combustion safety failures due to spillage from non-dryer exhaust are common and that only a very small number of homes are subject to the failures. The project team collected field data on 11 houses in 2015. Of these homes, two houses that demonstrated prolonged and excessive spillage were also the only two with venting systems out of compliance with the National Fuel Gas Code. The remaining homes experienced spillage that only occasionally extended beyond the first minute of operation. Combustion zone depressurization, outdoor temperature, and operation of individual fans all provide statistically significant predictors of spillage.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2017

Final Report - Low Temperature Combustion Chemistry And Fuel Component Interactions

Recent research into combustion chemistry has shown that reactions at “low temperatures” (700 – 1100 K) have a dramatic influence on ignition and combustion of fuels in virtually every practical combustion system. A powerful class of laboratory-scale experimental facilities that can focus on fuel chemistry in this temperature range is the rapid compression facility (RCF), which has proven to be a versatile tool to examine the details of fuel chemistry in this important regime. An RCF was used in this project to advance our understanding of low temperature chemistry of important fuel compounds. We show how factors including fuel molecular structure, the presence of unsaturated C=C bonds, and the presence of alkyl ester groups influence fuel auto-ignition and produce variable amounts of negative temperature coefficient behavior of fuel ignition. We report new discoveries of synergistic ignition interactions between alkane and alcohol fuels, with both experimental and kinetic modeling studies of these complex interactions. The results of this project quantify the effects of molecular structure on combustion chemistry including carbon bond saturation, through low temperature experimental studies of esters, alkanes, alkenes, and alcohols.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2017

High temperature high velocity direct power extraction using an open-cycle oxy-combustion system

The implementation of oxy-fuel technology in fossil-fuel power plants may contribute to increased system efficiencies and a reduction of pollutant emissions. One technology that has potential to utilize the temperature of undiluted oxy-combustion flames is open-cycle magnetohydrodynamic (MHD) power generators. These systems can be configured as a topping cycle and provide high enthalpy, electrically conductive flows for direct conversion of electricity. This report presents the design and modeling strategies of a MHD combustor operating at temperatures exceeding 3000 K. Throughout the study, computational fluid dynamics (CFD) models were extensively used as a design and optimization tool. A lab-scale 60 kWth model was designed, manufactured and tested as part of this project. A fully-coupled numerical method was developed in ANSYS FLUENT to characterize the heat transfer in the system. This study revealed that nozzle heat transfer may be predicted through a 40% reduction of the semi-empirical Bartz correlation. Experimental results showed good agreement with the numerical evaluation, with the combustor exhibiting a favorable performance when tested during extended time periods. A transient numerical method was employed to analyze fuel injector geometries for the 60-kW combustor. The ANSYS FLUENT study revealed that counter-swirl inlets achieve a uniform pressure and velocity ratio when the ports of the injector length to diameter ratio (L/D) is 4. An angle of 115 degrees was found to increase distribution efficiency. The findings show that this oxy-combustion concept is capable of providing a high-enthalpy environment for seeding, in order to render the flow to be conductive. Based on previous findings, temperatures in the range of 2800-3000 K may enable magnetohydrodynamic power extraction. The heat loss fraction in this oxy-combustion system, based on CFD and analytical calculations, at optimal operating conditions, was estimated to be less than 10 percent. Furthermore, the heat transfer design removed approximately 7 MW/m2. The results observed in the lab-scale system were employed to develop a 1-MW scaled prototype. Scaling methods were based on critical design criteria found in similar systems, aimed at replicating combustion flow fields and reducing possible instabilities. A numerical simulation of the combustor wall was developed for a combined thermal steady model and static structural model. This combined model was developed predict combined stress parameters within the wall during testing conditions. Both models were developed within ANSYS FEA software package. The relative accuracy presented as well major performance parameters are discussed to assess the design's validity and ensure safety. The scaled prototype was manufactured through selective laser melting (SLM)-based additive manufacturing to reduce lead times and increase geometrical complexity. Additional CFD models were developed to optimize coolant manifold system parameters and perform a parametric study on channel geometry. An investigation on coolant manifold geometry demonstrated improvements in channel flow distribution when enlarging manifold lengths and increasing the number of tubes feeding into the flow. A three-dimensional model based on a single channel was developed to capture the effect of variable properties and thermal stratification. All cases in the simulation exhibited higher wall temperatures and lower convective coefficients than those determined through 1-D analytical equations. This implies that pressure and velocity safety factors must be implemented during system operation. Overall, the findings made in this investigation are thought to be of value to researchers and industrial practitioners when designing oxy-fuel direct power extraction systems operating at temperatures exceeding 3000 K. In addition to this, the implementation of the developed technology at pilot and commercial scales could result in a significant improvement in the efficiencies of heritage and next-generation power cycles.

03 NATURAL GAS↗
DOE OSTI2017

Advanced Oxy-combustion Technology for Pulverized Bituminous Coal Power Plants

The main objective of this study is to examine atmospheric pressure oxy-combustion technology options that have the largest potential to increase the system performance and/or to reduce the cost of electricity (COE). The costs and performances of the O 2 production technology and the CO 2 compression and purification system have the largest and most direct influence on the incremental costs associated with carbon capture using oxy-combustion technology. Other general process parameter improvements that enhance system efficiency also have a supplemental, albeit secondary, benefit on the costs by reducing the O 2 demand and the CO 2 throughput for a given power output. Accordingly, a total of eight advanced oxy-combustion systems based on advances in the four major areas of boiler design, oxygen production, flue gas treatment, and innovative CO 2 compression concepts were compared to a base case that reflects current oxy-combustion technology.

01 COAL, LIGNITE, AND PEAT↗
NASA NTRS1963

Ninth Symposium (International) on Combustion

The Ninth Symposium (International) on Combustion was held at Cornell University, Ithaca, New York, August 27 to September 1, 1962, under the auspices of the Combustion Institute. Registration was in excess of 600, with more than 100 attending from Australia, Belgium, Canada, France, Germany, Great Britain, Hungary, Israel, Italy, Japan, Netherlands, Spain and Sweden. Over 200 papers were submitted for consideration, of which 121 were placed on the program and 108 printed in the Proceedings. Two Discussions (Detonations, organized by Dr. D. R. White, General Electric Research Laboratory; Fundamental Flame Processes, organized by Dr. W. H. Avery, APL/The Johns Hopkins University) occupied 4 half-day sessions each. Preprints of all Discussions papers were available several weeks prior to the Symposium. Three Colloquia (Modeling Principles, organized by Professor D. 13. Spalding, Imperial College; Reactions and Phase Changes in Supersonic Plow, organized by Professor P. P. Wegener, Yale University; Reciprocating Engine Combustion Research, organized by Professor E. S. Starkman, University of California) occupied 2 or 3 half-day sessions each. Contributed Papers in many areas of the combustion field were presented in 10 half-day sessions. Comments on nearly every paper are included in the Proceedings.

Gas phase↗
NASA NTRS2016

Experimental Combustion Dynamics Behavior of a Multi-Element Lean Direct Injection (LDI) Gas Turbine Combustor

An experimental investigation of the combustion dynamic characteristics of a research multi-element lean direct injection (LDI) combustor under simulated gas turbine conditions was conducted. The objective was to gain a better understanding of the physical phenomena inside a pressurized flametube combustion chamber under acoustically isolated conditions. A nine-point swirl venturi lean direct injection (SV-LDI) geometry was evaluated at inlet pressures up to 2,413 kPa and non-vitiated air temperatures up to 867 K. The equivalence ratio was varied to obtain adiabatic flame temperatures between 1388 K and 1905 K. Dynamic pressure measurements were taken upstream of the SV-LDI, in the combustion zone and downstream of the exit nozzle. The measurements showed that combustion dynamics were fairly small when the fuel was distributed uniformly and mostly due to fluid dynamics effects. Dynamic pressure fluctuations larger than 40 kPa at low frequencies were measured at 653 K inlet temperature and 1117 kPa inlet pressure when fuel was shifted and the pilot fuel injector equivalence ratio was increased to 0.72.

dynamics↗
NASA NTRSDate not supplied

Development and Testing of Pulse Guns for Combustion Instability Testing

Combustion stability requirements of a liquid propellant rocket engine are most commonly verified by evaluating the oscillatory pressure or vibration characteristics following an artificial disturbance of the combustion in the combustion chamber. Two types of devices are most commonly used for dynamic stability rating – nondirectional bombs and pulse guns. Bombs have historically been used most often, especially for the large engines developed around the Apollo era. However, bombs in recent years have become much more expensive and difficult to procure, and their transportation and handling requirements have become more demanding. Pulse guns, with inherently less expensive materials, and far less restrictive handling and shipping requirements, have become an attractive alternative. The NASA Marshall Space Flight Center has developed a pulse gun for use during future development programs at the center, and as a design reference for interested commercial users. The objective of this paper is to present the different variants of the pulse gun and characterize performance over a range of parameters. The parameters include the breech diameter and corresponding volume, barrel length, amount of gun powder used, the method of containing the gunpowder within the breech, and the pressure rating of the burst disk. In total, 44 tests were conducted with the pulse gun firing into a test chamber pressurized to 2300 psig with gaseous nitrogen. The best experimental results – including the highest and most consistent peak pressure amplitudes recorded by dynamic pressure sensors in the test chamber – were from a configuration consisting of a 0.40” inner-diameter breech, 15-16 grains of gunpowder wrapped in cigarette paper, and a 24,000 psid burst disk. With this configuration, the zero-to-peak overpressures recorded in the test chamber ranged from about 37% to 58% of the 2300 psig mean pressure, which is adequate for typical combustion stability rating. To complement the data analysis, the acoustics of the pressure waves as they propagated through the pulse gun and into the test chamber were modeled. A more comprehensive final report of this pulse gun development program is planned to be available in the near future.

Pulse Gun↗
NASA NTRS2023

High-Pressure, Normal-Gravity Droplet Combustion Experimental Hardware

The High-Pressure, Trans-Critical (HPTC) 1-g Liquid Droplet Combustion Experiments will assess the autoignition and combustion of liquid fuel droplets at elevated temperatures and pressures. These experiments are being conducted at the NASA Glenn Research Center in a manner similar to experiments performed in Glenn’s Zero Gravity Research Facility (ZGF) using the B drop vehicle. The modification to the test capabilities of the ZGF experiments in the new experimental configuration will allow researchers to continue performing normal-gravity liquid droplet combustion experiments without requiring the use of the ZGF test equipment. These normal-gravity experiments will be conducted at lower pressures than in the ZGF because the pressure vessel for this setup is limited to a maximum working pressure of 7.74 atm (99.1 psig) at 366.5 K (200 °F). This experimental configuration will enable development of a similar capability for conducting high-pressure combustion and supercritical oxidation research on the International Space Station. Experiments will be conducted with the capability of altering the ambient pressure, temperature, and gas concentrations, as well as the fuel type for each test. For these experiments, the test vessel operates at pressures up to 7.5 atm (95.5 psig), temperatures up to 1,073 K (1,472 °F) inside the insulated oven, and oxygen concentrations up to 30 percent.

Droplet Combustion↗
NASA NTRSDate not supplied

Analysis of Additively Manufactured Inconel 718 Combustion Behavior in Promoted Oxygen Environments

Promoted combustion testing is a vital tool for engineers to establish the combustion and flammability characteristics of materials (metallic or otherwise) in oxygen enriched environments. Historically, much of the established data for metallic promoted combustion has been with regards to cast and wrought forms. However, with the emergence of additive manufacturing as a preferred method of fabrication, the need exists to evaluate how metals in that form behave. This paper will serve as a review of the work that has been done and an analysis of the nickel-based superalloy Inconel 718, a material popular for aerospace applications such as liquid fueled rocket components and turbine engines. Promoted combustion testing (per the ASTM G124 standard) was conducted on samples of both wrought and selective laser melted fabrication, to provide comparison of flammability response between materials produced by each manufacturing method. Additionally, post-build treatments were applied to test samples to identify any effects on performance provided by hot isostatic pressing, oxygen-getting wrap during HIP, stress relieving, and solutionizing/aging heat treatments. This study will utilize optical and scanning electron microscopy, energy dispersive spectroscopy, x-ray diffraction, and metallography to identify the differences in behavior of additively manufactured and wrought Inconel 718.

Additively Manufactured↗
NASA NTRSDate not supplied

Promoted Combustion Behavior of 316 Stainless Steel and 6061 Aluminum Alloys in Elevated Pressure Nitrox Environments

Promoted combustion testing (outlined in the ASTM G124 “Standard Test Method for Determining the Combustion Behavior of Metallic Materials in Oxygen Enriched Atmospheres”) refers to a useful testing method to evaluate how metallic materials will behave when combusted in environments with high oxygen concentrations, elevated pressure, or both. These tests yield data which is useful for engineers and scientists from a variety of industries who need and rely on oxygen systems. Oxygen Compatibility Assessments (OCA’s) are vital for ensuring that materials will be safe for use, and these assessments rely on data from OCA’s or interpolation if a desired pressure/concentration is outside of previously tested bounds. It was identified that these bounds leave out significant areas of data for materials which are tested at high pressures (above 1500 psi) and variable oxygen concentrations (with nitrogen as the diluent gas). For this reason, the authors posited that conducting promoted combustion testing on materials above 1500 psi and in various concentrations of oxygen would be incredibly useful in future analyses for oxygen compatibility with similar environments (such as breathing air) as well as for further understanding of how materials behave at very high pressures (such as 10000 psi). Two materials were selected which are commonly used in industry today - 316 stainless steel and 6061 aluminum – and they were tested and analyzed for the purposes of this study.

oxygen compatibility↗
NASA NTRSDate not supplied

Expanding the Capability of A Legacy Combustion Flametube to Test High Temperature Engine Materials in Relevant Environments

New materials and component designs are needed to advance gas turbine engine technology and provide the performance and efficiency needs for future applications. In order to advance these materials, testing in combustion environments is a critical step prior to engine testing. In this work, we detail the design and the fabrication of a materials test sector in a flametube combustor facility. The facility simulates a combustion environment similar to that experienced by components in gas turbine engines. The flow regime is characterized by a combination of high-temperature, high-velocity, high-heat flux, and high-velocity that components experience in gas turbine engines. Exposure of components in this facility allows for the study of combined environmental effects and the impact on both coating and substrate durability. The test facility may operate across a wide range of pressures from 275-400 psig (1,896-2,758 kPa) and an air flow rate of 5 lb/s (2.27 kg/s). While combustion gas temperature is expected in excess of 3,000°F (1,649°C), 900°F (482°C) cooling air may be supplied to the backside of components or test articles. The flametube combustor was previously used to evaluate fuel injectors and combustion products, and the new test configuration will also allow for materials exposure to complex, engine-like conditions. The interior of the Test Section was additively manufactured from GRCop-84 and cryogenically fit and brazed to a stainless steel 304 housing. The use of a copper liner minimizes welds and with active cooling, is expected to provide better durability over traditional hardware using stainless steel or Inconel with a ceramic liner. The Test Section has two opposing removable windows approximately 230 mm x 80 mm that can accommodate articles up to 85 mm tall. This modular design allows for custom platforms to hold coupons, panels, or airfoil shapes to be tested with minimal re-engineering or fabrication. The bolted joint and sealing remains consistent, so any new testing only needs to work within the existing design footprint. This paper will provide an overview of the facility capabilities, design considerations, as well as thermal and structural analysis of the hardware. Future testing of ceramic matrix composite (CMC) airfoils and advanced environmental barrier coatings (EBCs) will also be discussed.

Combustion↗