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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

Verifying Diagnostic Software

Livingstone PathFinder (LPF) is a simulation-based computer program for verifying autonomous diagnostic software. LPF is designed especially to be applied to NASA s Livingstone computer program, which implements a qualitative-model-based algorithm that diagnoses faults in a complex automated system (e.g., an exploratory robot, spacecraft, or aircraft). LPF forms a software test bed containing a Livingstone diagnosis engine, embedded in a simulated operating environment consisting of a simulator of the system to be diagnosed by Livingstone and a driver program that issues commands and faults according to a nondeterministic scenario provided by the user. LPF runs the test bed through all executions allowed by the scenario, checking for various selectable error conditions after each step. All components of the test bed are instrumented, so that execution can be single-stepped both backward and forward. The architecture of LPF is modular and includes generic interfaces to facilitate substitution of alternative versions of its different parts. Altogether, LPF provides a flexible, extensible framework for simulation-based analysis of diagnostic software; these characteristics also render it amenable to application to diagnostic programs other than Livingstone.

Lindsey, Tony↗

An experimental and one-dimensional modeling analysis of turbulent gas ejection in pre-chamber engines

In this work, experimental results from a study on the evolution of gas jets ejected through the orifices of a pre-chamber in a heavy-duty optical engine are presented. The work examines conditions without fuel inside the main-chamber, which helps to describe the dynamics of the ejected gas jets without the interference of subsequent combustion in the main-chamber. Experimental diagnostics consist of high-speed visible intensified imaging and low-speed infrared imaging. Additionally a one-dimensional gas jet model is used to characterize the spatial distribution of the ejected flow, including parameters such as tip penetration, which are then validated based on experimental results. Different stages in the ejection of pre-chamber jets are identified, with chemical activity restricted to a maximum distance of 5 to 10 orifice diameters downstream of the orifice as indicated by the recorded visible radiation. Sensitivity of cycle-to-cycle variations in pre-chamber jet development to the air-to-fuel ratio in the pre-chamber observed in the experiments is in most part attributed to the variations in the timing of combustion initiation in the pre-chamber. The influence of the ejection flow on the penetration of the gas jet on a cycle-to-cycle basis is presented using the one-dimensional model. The one-dimensional model also indicates that the local flow exhibits highest sensitivity to operating conditions during the start of ejection until the timing when maximum flow is attained. Differences that exist during the decreasing mass-flow ejection time-period tend to smear out in part due to the transient slowdown of the ejection process.

1-D gas jet model↗

Predicting Nugget Size of Resistance Spot Welds Using Infrared Thermal Videos With Image Segmentation and Convolutional Neural Network

Resistance spot welding (RSW) is a widely adopted joining technique in automotive industry. Recent advancement in sensing technology makes it possible to collect thermal videos of the weld nugget during RSW using an infrared (IR) camera. The effective and timely analysis of such thermal videos has the potential of enabling in situ nondestructive evaluation (NDE) of the weld nugget by predicting nugget thickness and diameter. Deep learning (DL) has demonstrated to be effective in analyzing imaging data in many applications. However, the thermal videos in RSW present unique data-level challenges that compromise the effectiveness of most pre-trained DL models. We propose a novel image segmentation method for handling the RSW thermal videos to improve the prediction performance of DL models in RSW. The proposed method transforms raw thermal videos into spatial-temporal instances in four steps: video-wise normalization, removal of uninformative images, watershed segmentation, and spatial-temporal instance construction. The extracted spatial-temporal instances serve as the input data for training a DL-based NDE model. The proposed method is able to extract high-quality data with spatial-temporal correlations in the thermal videos, while being robust to the impact of unknown surface emissivity. Overall, our case studies demonstrate that the proposed method achieves better prediction of nugget thickness and diameter than predicting without the transformation.

42 ENGINEERING↗

Soot Formation and Ignition Characteristics of Ethanol/Gasoline Blends in a Rapid Compression Machine

With the ever-increasing demand for sustainable energy, alcohol fuels have garnered interest for use in heavy duty engines. The significant infrastructure for ethanol production and blending of ethanol with gasoline make these fuels/fuel blends desirable candidates. However, development of heavy duty engine technology that is capable of burning alcohol fuels while retaining the advantages of traditional diesel combustion requires an improved understanding of the soot formation for these fuels under conditions relevant to mixing-controlled combustion. This work uses an extinction diagnostic to study the sooting tendency of ethanol and gasoline/ethanol blends ranging from E10 to E98 during ignition in a homogeneous environment. Experiments were conducted in a rapid compression machine (RCM) for compressed conditions of 20 ± 1 bar and an approximately constant temperature (± 10K) which was unique for each fuel. For a given soot volume fraction, a linear relationship was observed between ethanol content and the equivalence ratio in which that soot volume fraction was formed. Accounting for the oxygenated nature of ethanol, E85 and E98 fuels produced similar amounts of soot at a given Φ ox, , suggesting other factors outside of fuel oxygen content, such as fuel morphology, impact soot formation. Ignition delay data is reported for compressed pressures of 20 ± 1 bar and compressed temperatures ranging from 633 – 670 K for E10 and 771 – 789 K for E98. Varying pressures for E10 and E98 at conditions producing similar soot volume fractions demonstrated a linear dependence of soot formation on pressure, regardless of if the pressure considered was at top dead center or peak combustion pressure. Furthermore, the data gleaned from this work will be used to select soot models and chemical kinetic mechanisms for RCM simulations to ultimately model heavy duty engine technology with the studied fuels.

33 ADVANCED PROPULSION SYSTEMS↗

Recent Experimental Results Related to Ejector Mode Studies of Rocket-Based Combined Cycle (RBCC) Engines

Contents include the folloving: 1. Motivation. Support NASA's 3d generation launch vehicle technology program. RBCC is promising candidate for 3d generation propulsion system. 2. Approach. Focus on ejector mode p3erformance (Mach 0-3). Perform testing on established flowpath geometry. Use conventional propulsion measurement techniques. Use advanced optical diagnostic techniques to measure local combustion gas properties. 3. Objectives. Gain physical understanding of detailing mixing and combustion phenomena. Establish an experimental data set for CFD code development and validation.

Cramer, J. M.↗

Fundamental Technology Development for Gas-Turbine Engine Health Management

Integrated vehicle health management technologies promise to dramatically improve the safety of commercial aircraft by reducing system and component failures as causal and contributing factors in aircraft accidents. To realize this promise, fundamental technology development is needed to produce reliable health management components. These components include diagnostic and prognostic algorithms, physics-based and data-driven lifing and failure models, sensors, and a sensor infrastructure including wireless communications, power scavenging, and electronics. In addition, system assessment methods are needed to effectively prioritize development efforts. Development work is needed throughout the vehicle, but particular challenges are presented by the hot, rotating environment of the propulsion system. This presentation describes current work in the field of health management technologies for propulsion systems for commercial aviation.

Mercer, Carolyn R.↗

Codes for sub-resolution modeling of the apparent mass loss in quantitative broadband X-ray radiography

SAND2022-3463 O This code is intended to accompany the journal manuscript, “Sub-resolution modeling of the apparent mass loss in quantitative broadband X-ray radiography." The manuscript covers in detail how to improve the quantitative mass distribution measurements made for optical diagnostics of multiphase flows. The code contains four separate script files in MATLAB format to support the objective of improving mass measurements. Sandia National Laboratories is a multimission laboratory managed and operated by National Technology & Engineering Solutions of Sandia, LLC, a wholly owned subsidiary of Honeywell International Inc., for the U.S. Department of Energy’s National Nuclear Security Administration under contract DE-NA0003525.

Rahman, Naveed↗

Exploring the Effects of Varying Pre-Chamber Geometry in a Heavy-Duty Natural Gas Optical Engine under Dilution Conditions

Pre-chamber combustion is an advanced ignition strategy that has been shown to enhance spark ignition (SI) combustion stability in natural gas (NG) engines by providing distributed ignition sites from turbulent jets and enhancing main-chamber turbulence. Pre-chamber combustion has been proven especially advantageous compared to SI in ultra-lean and dilute operating conditions. This work involves experimental investigation of the effects of varying passive pre-chamber nozzle configuration on pre-chamber and main chamber combustion under simulated exhaust gas recirculation (EGR) dilution (0 and 20%) conditions in a heavy-duty, single-cylinder, optically accessible NG engine at stoichiometric fuel-air ratio. Pre-chamber nozzle configurations include four pre-chambers with constant nozzle area to pre-chamber volume ratio (A/V) with different nozzle sizes and orientations and one configuration with larger nozzles. The optical engine is operated in a skip-fire sequence consisting of 18 motored cycles followed by two consecutive fired cycles to elucidate the effect of combustion residuals (internal EGR) on combustion evolution. Pressure-based diagnostics are used to monitor pre-chamber and subsequent main chamber combustion, and optical diagnostics include high-speed OH* chemiluminescence to visualize the development of pre-chamber jets and the resulting ignition of the main chamber charge. Heat release analysis of the in-cylinder pressure data indicates that a faster pre-chamber pressure rise does not always translate into faster main-chamber combustion. The pre-chamber with the smallest nozzle diameter produced the highest pre-chamber pressure rise and fastest combustion under non-diluted conditions. However, dilution delays the main chamber ignition for smaller nozzles despite a comparable rise in pre-chamber pressure compared to configurations with larger nozzles. This effect is more pronounced for cycles with in-cylinder combustion residuals in addition to external dilution. Additionally, it was observed that pre-chambers with swirling nozzles have a faster pressure rise in the pre-chamber and main chamber under dilute conditions. Optical diagnostics suggest that the main reason for the delay between the pre-chamber pressure rise and main-chamber combustion lies in jet quenching and delayed re-ignition, which can even lead to misfire if jets emitted from small nozzles combined with dilution fail to re-ignite.

Dhotre, Akash [University Of Minnesota-Twin Cities↗

Active experiments in modifying spacecraft potential: Results from ATS-5 and ATS-6

Instruments on ATS-5 and ATS-6 were operated to study the phenomena of spacecraft charging. The ion engine neutralizers were operated in attempts to modify the spacecraft potentials. The neutralizer on ATS-5 is a hot filament emitting electrons, while the neutralizer on ATS-6 is a low energy plasma bridge. The diagnostics used were particle detectors, counting electrons and protons as a function of energy. Operations were conducted in daylight and eclipse. This report describes the processing data from these and other operations. Only preliminary analysis of some of this data has been carried out, with the following results: (1) electron emission does not perturb the status of a low potential satellite by more than 50 volts, (2) emission of a low energy plasma does not change low potentials by more than a few volts, (3) when ATS-6 enters eclipse in the presence of a high energy plasma, the neutralizer suppresses any rise in (within a few volts resolution), (4) when the electron emitter on ATS-5 is operated, it serves to discharge negative potentials from thousands to hundreds of volts.

Olsen, R.↗

Mechanical Components Branch Overview

Mr. James Zakrajsek, chief of the Mechanical Components Branch, presented an overview of research conducted by the branch. Branch members perform basic research on mechanical components and systems, including gears and bearings, turbine seals, structural and thermal barrier seals, and space mechanisms. The research is focused on propulsion systems for present and advanced aerospace vehicles. For rotorcraft and conventional aircraft, we conduct research to develop technology needed to enable the design of low noise, ultra safe geared drive systems. We develop and validate analytical models for gear crack propagation, gear dynamics and noise, gear diagnostics, bearing dynamics, and thermal analyses of gear systems using experimental data from various component test rigs. In seal research we develop and test advanced turbine seal concepts to increase efficiency and durability of turbine engines. We perform experimental and analytical research to develop advanced thermal barrier seals and structural seals for current and next generation space vehicles. In space mechanisms, we conduct fundamental research on lubricants, materials, components and mechanisms subjected to deep space and planetary environments.

Source record↗

Overview of Glenn Mechanical Components Branch Research

Mr. James Zakrajsek, chief of the Mechanical Components Branch, gave an overview of research conducted by the branch. Branch members perform basic research on mechanical components and systems, including gears and bearings, turbine seals, structural and thermal barrier seals, and space mechanisms. The research is focused on propulsion systems for present and advanced aerospace vehicles. For rotorcraft and conventional aircraft, we conduct research to develop technology needed to enable the design of low noise, ultra safe geared drive systems. We develop and validate analytical models for gear crack propagation, gear dynamics and noise, gear diagnostics, bearing dynamics, and thermal analyses of gear systems using experimental data from various component test rigs. In seal research we develop and test advanced turbine seal concepts to increase efficiency and durability of turbine engines. We perform experimental and analytical research to develop advanced thermal barrier seals and structural seals for current and next generation space vehicles. Our space mechanisms research involves fundamental investigation of lubricants, materials, components and mechanisms for deep space and planetary environments.

Zakrajsek, James↗

Modeling for Battery Prognostics

For any battery-powered vehicles (be it unmanned aerial vehicles, small passenger aircraft, or assets in exoplanetary operations) to operate at maximum efficiency and reliability, it is critical to monitor battery health as well performance and to predict end of discharge (EOD) and end of useful life (EOL). To fulfil these needs, it is important to capture the battery's inherent characteristics as well as operational knowledge in the form of models that can be used by monitoring, diagnostic, and prognostic algorithms. Several battery modeling methodologies have been developed in last few years as the understanding of underlying electrochemical mechanics has been advancing. The models can generally be classified as empirical models, electrochemical engineering models, multi-physics models, and molecular/atomist. Empirical models are based on fitting certain functions to past experimental data, without making use of any physicochemical principles. Electrical circuit equivalent models are an example of such empirical models. Electrochemical engineering models are typically continuum models that include electrochemical kinetics and transport phenomena. Each model has its advantages and disadvantages. The former type of model has the advantage of being computationally efficient, but has limited accuracy and robustness, due to the approximations used in developed model, and as a result of such approximations, cannot represent aging well. The latter type of model has the advantage of being very accurate, but is often computationally inefficient, having to solve complex sets of partial differential equations, and thus not suited well for online prognostic applications. In addition both multi-physics and atomist models are computationally expensive hence are even less suited to online application An electrochemistry-based model of Li-ion batteries has been developed, that captures crucial electrochemical processes, captures effects of aging, is computationally efficient, and is of suitable accuracy for reliable EOD prediction in a variety of operational profiles. The model can be considered an electrochemical engineering model, but unlike most such models found in the literature, certain approximations are done that allow to retain computational efficiency for online implementation of the model. Although the focus here is on Li-ion batteries, the model is quite general and can be applied to different chemistries through a change of model parameter values. Progress on model development, providing model validation results and EOD prediction results is being presented.

Prognostics↗

National Ignition Facility Opacity Time Resolved Spectrometer Systems Engineering Final Project

The National Ignition Facility (NIF) is the world’s largest and most energetic laser facility. The NIF system is designed to produce high energy density (temperature and pressure) conditions through the application of its 192 laser beams. One of the users of NIF is the opacity platform developed to study the opacities at temperatures and densities relevant to the solar interior and stellar evolution. The platform was developed to study iron (Fe) opacity at temperatures relevant to the solar interior. The opacity campaign uses spectrometers to gather data. Spectrometers utilize crystals to produce x-ray spectra that are recorded on time-integrated and time-resolved detectors. The opacity spectrometer (OpSpec) currently fielded and in use at NIF uses a time integrated film channel to collect data. The opacity spectrometer time resolved (OpSpecTR) will utilize novel hCMOS detectors to capture time resolved images of spectra of interest. The key stakeholders identified for OpSpecTR included the physicists responsible for OpSpec and OpSpecTR, the Target Area Science and Engineering (TASE) department at NIF, the NIF and Photon Science (NIF & PS) Opacity program, the Nevada National Security Site (NNSS) Physics and Engineering program, the Sandia hCMOS manufacturing and testing program, and the Los Alamos National Laboratory (LANL) program sponsor. The Target and Experimental Operations (TEXOPS) was identified as a key stakeholder because the group includes the individuals that will physically interact with the OpSpecTR system as it participates in NIF experiments. The opacity platform collects data in a unique orientation relative to the existing diagnostics fielded at NIF. The existing infrastructure at NIF uses a diagnostic manipulator (DIM) to insert the diagnostic near the target chamber center to collect data during a NIF shot. Existing diagnostics collect data through the center line of the DIM axis and collect relevant data perpendicular to this axis. The opacity platform requires crystals mounted in a specific orientation which requires data collection parallel to the DIM axis. This deviation from standard NIF practices was a key factor in developing requirements.

42 ENGINEERING↗

Emissions and Flame Structure Assessment of Aeroengine Micromixing Injectors for Lean Direct Injection of Hydrogen and Hydrogen/Natural Gas Blends

Abstract The present study focuses on whether adapting low emissions liquid fuel injection concepts can be applied to gaseous mixtures. The goal is to develop an injector with specific geometric characteristics that will achieve the lowest emissions. This is conducted by evaluating emissions and flame diagnostics on a set of test hardware that has been developed for combustion of pure hydrogen and hydrogen/methane mixtures. The current test hardware adapts lean direct injection concepts from aeroengine injectors to a ground-based engine based on target flows associated with a Solar Turbines Industrial Engine gas turbine. A statistical test plan was developed to assess these geometric characteristics using a three level Box Behnken design. The test plan investigates the effect of injector flow splits, air swirl, fuel swirl, pressure drop, preheat temperature, fuel composition, and the adiabatic flame temperature on the flame structure and emissions performance. A total of 16 injectors were considered for a total of 688 test points for emission and imaging data. Emissions data were reported on a mass basis in ng/J and chemical reactor network analysis were conducted to further interpret emissions behavior. Images were also captured to analyze the flame structure features of interest including reaction volume, flame length, flame spread, and flame width. With these results, a predictive model for emissions was made to conclude the most optimal injector configuration is to have the highest level of air split (more volume of air through the injector plate versus the injector) and air swirl angle for both methane and hydrogen gas mixtures. The predictive emissions level for all of these cases were below 10 ng/J.

08 HYDROGEN↗

Calculations Document

Figure 1 shows a simplified model schematic of the Tetracage target design. In this figure the green lines represent the Tetracage yarns, which consist of two parallel yarns on the top and two parallel yarns on the bottom with the pairs in a cross hatched pattern. For simplicity, as we are only considering vertical forces, we will perform calculations without consideration for the two pairs of yarns being perpendicular to each other. Also worth noting is the model shows the yarns extending directly to the capsule then closely hugging it – in reality, the yarns behave as you would expect where they hug the capsule only as much as the geometry of their deflection allows, similarly to if you held a tennis ball with a pair of parallel strings anchored at opposing ends. The dashed black lines show the path the yarns take straight across from slot glue point to slot glue point before the target is closed and the capsule deforms them. The variable r corresponds to the capsule outer radius. The variable L corresponds to the hohlraum inner radius. The variable a corresponds to the yarn offset from the center of the diagnostic band. The variable d corresponds to the wire deflection vertically.

42 ENGINEERING↗

Overview of aerothermodynamic loads definition study

Over the years, NASA has been conducting the Advanced Earth-to-Orbit (AETO) Propulsion Technology Program to provide the knowledge, understanding, and design methodology that will allow the development of advanced Earth-to-orbit propulsion systems with high performance, extended service life, automated operations, and diagnostics for in-flight health monitoring. The objective of the Aerothermodynamic Loads Definition Study is to develop methods to more accurately predict the operating environment in AETO propulsion systems, such as the Space Shuttle Main Engine (SSME) powerhead. The approach taken consists of 2 parts: to modify, apply, and disseminate existing computational fluid dynamics tools in response to current needs and to develop new technology that will enable more accurate computation of the time averaged and unsteady aerothermodynamic loads in the SSME powerhead. The software tools are detailed. Significant progress was made in the area of turbomachinery, where there is an overlap between the AETO efforts and research in the aeronautical gas turbine field.

Gaugler, Raymond E.↗

Lean burn combustor technology at GE Aircraft Engines

This presentation summarizes progress to date at GE Aircraft Engines in demonstration of a lean combustion system for the High Speed Civil Transport (HSCT). These efforts were supported primarily by NASA contracts, with the exception of initial size and weight estimates and development of advanced diagnostics which were conducted under GE Independent Research and Development projects. Key accomplishments to date are summarized below.

Dodds, Willard J.↗