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DOE OSTI2024

50 MW Segmented Ultralight Morphing Rotors for Wind Energy

A multi-institutional team designed a 50 Megawatt (MW) rated wind turbine featuring downwind aeroelastic morphing to reduce blade loads and allow an ultralight segmented rotor (mass reduction of about 25% compared to a conventional upwind rotor). The team used a control co-design approach with state-of-the art simulations including for the rotor and tower design using non-linear fluid-structure interactions and control algorithms, and the team also designed, built, and field-tested an aeroelastically-scaled downwind rotor to demonstrate this novel technology and validate the design tool fidelity. In a follow-on phase, these results were used along with an updated Levelized Cost Of Energy (LCOE) methodology to co-design a more detailed set of 25 MW rated turbine designs (including individual pitch control) based on minimum LCOE with highly flexible blades for an Atlantic Ocean offshore fixed-bottom design targeted towards market technology evaluation. A set of upwind and downwind designs at 25 MW rated scales were found to provide the best LCOE, with strong improvements over all previous offshore reference turbines (NREL 5MW, DTU 10 MW and IEA 15 MW). The optimized design would represent the world’s largest offshore turbine design, which combines several state-of-the-art structural, aerodynamic, and control technologies into a new and optimized system concept.

17 WIND ENERGY↗

DOE OSTI2022

Computational studies of hydraulic stressors for biological performance assessment in a hydropower plant with Kaplan turbine

We report Hydropower is currently one of the preeminent sources of renewable energy in the United States and globally. Hydropower plants also have detrimental impacts on the environment and ecology, including direct impacts to anadromous fish populations. The computational fluid dynamics (CFD) – based Biological Performance Assessment (BioPA) toolset is used for biological evaluations of fish passage through hydropower plants. The hydraulic environment of a hydropower plant was evaluated using CFD coupled with discrete element method (DEM) simulations. The predicted flow field and particle collision rate were validated against the experimental data in a water flume that has an idealized hydroturbine distributor geometry. Flow simulations were conducted to evaluate the hydraulic stressors, such as nadir pressure, fluid shear, runner collision, in a physical scale in a hydropower plant with Kaplan turbine which are responsible for injury and mortality of fish in a downstream migration. The cumulative exposure probability for the nadir pressure and collision with turbine runner was found to decrease with increased discharge rate. The lowest discharge rate shows the higher value of cumulative shear exposure probability. The maximum value of collision velocity increases with increased discharge rate. We offer the conclusions that will help in understanding various hydraulic stressors for biological assessment for environmentally sustainable hydroturbine passage.

13 HYDRO ENERGY↗

DOE OSTI2024

Accelerated Lifetime Testing of Main Shaft Seals for Tidal Turbine Rotors

This document will briefly discuss the observations and results from an NREL conducted accelerated lifetime testing of the main shaft seal for the Verdant Power fifth generation Gen5 underwater Tidal Energy Converter (TEC) turbine, which successfully performed at the RITE project in 2020-2021. In order to evaluate a 5-year Service Interval ( SI) for this component, testing at NREL operated the main shaft seal nearly continuously for over 135 (text says 130 days on page 5 and 125 days on page 7 and 137 days on page 11) days at a rotational velocity of 160 rpm while the test stand recorded water pressure, barrier fluid pressure, temperature, and number of cycles., representing ~ 40% of the SI. An additional separate test was conducted to measure the aging behavior of the rubber drive rings. The water pressure reservoir was held constant as 29 psi. Barrier fluid pressure remained relatively constant throughout the duration of the test but was seen to sink to as low as 10.1 psi. No barrier fluid leakage was observed throughout the test. A sudden failure occurred within the seal after the power to test machine was interrupted for a scheduled building maintenance procedure. Upon restarting, the main shaft seal lost all ability to prevent water ingress. The exact cause is not known but is believed to be either a seal assembly issue or a change in the alignment of the seal components during or following the power outage. Following seal disassembly, significant wear was seen on one of the graphite sealing rings. Based on these results it is recommended that a follow-on TEAMER be conducted to rectify protocol and assembly issues to further evaluate SI of this component. The support and participation of Verdant Power Inc, Dovetail Solutions LLC and Garlock Manufacturing Inc were instrumental in understanding the results. NREL thanks them for their significant effort.

13 HYDRO ENERGY↗

DOE OSTI2024

Design of Novel Hot Gas Path Component for Gas Turbine Engines Enabled by Materials and Additive Manufacturing Process Development

This report covers the activities associated with the development and evaluation of two high-γ’ superalloys that were designed by external partners on this project, namely Carpenter Technologies Corporation and the University of California-Santa Barbra. One alloy was GammaPrint-700, a cobalt-base superalloy, and the other a nickel-base (Ni-base) superalloy GammaPrint-1100. Both were found to be printable through laser powder bed fusion (LPBF) additive manufacturing, with optimal process parameter sets being identified for each alloy. Further, high temperature mechanical testing was conducted on each alloy that showed both materials performed better than the comparative baseline (LPBF Hastelloy X), with the Ni-base superalloy being down-selected for scaling and printing of the tip shoe components.

36 MATERIALS SCIENCE↗

DOE OSTI2026

Novel Modular Heat Engines with sCO 2 Bottoming Cycle Utilizing Advanced Oil-Free Turbomachinery

This report presents the thermal, mechanical, and electric machine design of a 27krpm rotating test rig aimed at reducing technical risks with hermetic oil-free super-critical carbon dioxide (sCO 2 ) turbomachinery. The test rig rotor system is based on a conceptual turbomachine design discussed that evaluates a sCO 2 waste heat recovery (WHR) unit for land-based gas turbines at natural gas (NG) compressor stations. The key novelty of the hermetic sCO 2 turbomachine concept is the utilization of additively manufactured CO 2 gas bearings and a CO 2 -immersed direct-drive permanent magnet (PM) electric machine. The previous effort on conceptual design identified 3 main technical risks, which included thrust bearing load capacity, rotordynamics, and thermal performance of the system. Therefore, key requirements of the test vehicle include the ability to test the rotor system in a 400psi (27.6 bar) hermetic CO 2 operating environment, apply up to 1,500 lbs (6.7 kN) of rotor thrust loads, capability to assess rotordynamics with radial gas bearings, inclusion of instrumentation to assess thrust bearing load capability, and flexibility for varying secondary cooling flows to confirm thermal model predictions. Design topics such as rotordynamics, bearing design, and electric machine design are addressed, while highlighting critical elements. In addition, additive build trials for Inconel 718 radial and thrust bearings were performed to prove the manufacturability of the bearing design concepts. The results of the design efforts yield a test rig concept with ability to operate at 27,000 rpm, apply thrust loads to 1,500 lbs, deliver CO 2 up to 800psi, and modulate cooling flows.

03 NATURAL GAS↗

DOE OSTI2020

Modeling Assessment of Tidal Energy Extraction in the Western Passage

Numerical models have been widely used for the resource characterization and assessment of tidal instream energy. The accurate assessment of tidal stream energy resources at a feasibility or project-design scale requires detailed hydrodynamic model simulations or high-quality field measurements. This study applied a three-dimensional finite-volume community ocean model (FVCOM) to simulate the tidal hydrodynamics in the Passamaquoddy–Cobscook Bay archipelago, with a focus on the Western Passage, to assist tidal energy resource assessment. IEC Technical specifications were considered in the model configurations and simulations. The model was calibrated and validated with field measurements. Energy fluxes and power densities along selected cross sections were calculated to evaluate the feasibility of the tidal energy development at several hotspots that feature strong currents. When taking both the high current speed and water depth into account, the model results showed that the Western Passage has great potential for the deployment of tidal energy farms. The maximum extractable power in the Western Passage was estimated using the Garrett and Cummins method. Different criteria and methods recommended by the IEC for resource characterization were evaluated and discussed using a sensitivity analysis of energy extraction for a hypothetical tidal turbine farm in the Western Passage.

16 TIDAL AND WAVE POWER↗

NASA NTRS1966

Nuclear Rocket Technology Conference

The Lewis Research Center has a strong interest in nuclear rocket propulsion and provides active support of the graphite reactor program in such nonnuclear areas as cryogenics, two-phase flow, propellant heating, fluid systems, heat transfer, nozzle cooling, nozzle design, pumps, turbines, and startup and control problems. A parallel effort has also been expended to evaluate the engineering feasibility of a nuclear rocket reactor using tungsten-matrix fuel elements and water as the moderator. Both of these efforts have resulted in significant contributions to nuclear rocket technology. Many successful static firings of nuclear rockets have been made with graphite-core reactors. Sufficient information has also been accumulated to permit a reasonable Judgment as to the feasibility of the tungsten water-moderated reactor concept. We therefore consider that this technoIogy conference on the nuclear rocket work that has been sponsored by the Lewis Research Center is timely. The conference has been prepared by NASA personnel, but the information presented includes substantial contributions from both NASA and AEC contractors. The conference excludes from consideration the many possible mission requirements for nuclear rockets. Also excluded is the direct comparison of nuclear rocket types with each other or with other modes of propulsion. The graphite reactor support work presented on the first day of the conference was partly inspired through a close cooperative effort between the Cleveland extension of the Space Nuclear Propulsion Office (headed by Robert W. Schroeder) and the Lewis Research Center. Much of this effort was supervised by Mr. John C. Sanders, chairman for the first day of the conference, and by Mr. Hugh M. Henneberry. The tungsten water-moderated reactor concept was initiated at Lewis by Mr. Frank E. Rom and his coworkers. The supervision of the recent engineering studies has been shared by Mr. Samuel J. Kaufman, chairman for the second day of the conference, and Mr. Roy V. Humble. Dr. John C. Eward served as general chairman for the conference.

Source record↗

NASA NTRS1975

Coupling of Helmholtz resonators to improve acoustic liners for turbofan engines at low frequency

An analytical and test program was conducted to evaluate means for increasing the effectiveness of low frequency sound absorbing liners for aircraft turbine engines. Three schemes for coupling low frequency absorber elements were considered. These schemes were analytically modeled and their impedance was predicted over a frequency range of 50 to 1,000 Hz. An optimum and two off-optimum designs of the most promising, a parallel coupled scheme, were fabricated and tested in a flow duct facility. Impedance measurements were in good agreement with predicted values and validated the procedure used to transform modeled parameters to hardware designs. Measurements of attenuation for panels of coupled resonators were consistent with predictions based on measured impedance. All coupled resonator panels tested showed an increase in peak attenuation of about 50% and an increase in attenuation bandwidth of one one-third octave band over that measured for an uncoupled panel. These attenuation characteristics equate to about 35% greater reduction in source perceived noise level (PNL), relative to the uncoupled panel, or a reduction in treatment length of about 24% for constant PNL reduction. The increased effectiveness of the coupled resonator concept for attenuation of low frequency broad spectrum noise is demonstrated.

Dean, L. W.↗

NASA NTRS1980

External fuel vaporization study, phase 1

A conceptual design study was conducted to devise and evaluate techniques for the external vaporization of fuel for use in an aircraft gas turbine with characteristics similar to the Energy Efficient Engine (E(3)). Three vaporizer concepts were selected and they were analyzed from the standpoint of fuel thermal stability, integration of the vaporizer system into the aircraft engine, engine and vaporizer dynamic response, startup and altitude restart, engine performance, control requirements, safety, and maintenance. One of the concepts was found to improve the performance of the baseline E(3) engine without seriously compromising engine startup and power change response. Increased maintenance is required because of the need for frequent pyrolytic cleaning of the surfaces in contact with hot fuel.

Szetela, E. J.↗

NASA NTRS1980

Teetered, tip-controlled rotor - Preliminary test results from Mod-O 100-kW experimental wind turbine

A series of tests is currently being conducted using the DOE/NASA 100 kW Experimental Wind Turbine with a two-bladed, teetered rotor with 30% span tip control. Preliminary evaluation test results indicates that the teetered rotor significantly decreases loads on the yaw drive mechanism and reduces blade cyclic flapwise bending moments by 25% at the 20% span location when compared to rigid hub rotor. The teetered hub performed well but did impact the teeter stops on occasion as wind speed and/or direction varied rapidly. The tip-controlled rotor performed satisfactorily with some expected loss of control when compared to the full span pitchable blade. The performance results indicate that a review of techniques used to calculate rotor power is in order.

Glasgow, J. C.↗

NASA NTRS1981

The E3 combustors - Status and challenges

The technology programs for the Energy Efficient Engine (E3) combustors are outlined, status and test results to date are summarized, and present and future challenges indicated. The NASA-sponsored programs, which are being conducted at the General Electric Company and Pratt & Whitney Aircraft, are making important technology advances. Both combustor designs utilize an annular configuration with two-zone combustion for low emissions, advanced liners for improved durability, and short, curved-wall, dump prediffusers for compactness. Advanced cooling techniques and segmented construction characterize the advanced liners in both programs. Liner segments are made from castable, turbine-type materials. At this time, analysis and design activities have been completed; experimental evaluations are progressing. Test results are verifying both design concepts for combustion, cooling, and mechanical integrity. All goals appear capable of being met, with the exception of NO(x).

Sokolowski, D. E.↗

NASA NTRS1982

High-pressure LOX/hydrocarbon preburner injector investigation

The NASA-MSFC program to furnish a high-pressure LOX/hydrocarbon turbine drive combustor technology base for future booster engine programs is discussed. The program evaluated the LOX/RP-1 and LOX/methane preburner and gas generator performance and gas property prediction methods for fuel-rich and oxidizer-rich operating conditions. A small-scale hardware test program, which included 42 hot-fire tests of fuel-rich LOX/methane and LOX/RP-1 and oxidizer-rich LOX/methane, supplied information to reduce uncertainties in prediction techniques. The hot-fire results show that theoretical computer model features should be modified to support curves generated from experimental data.

Huebner, A. W.↗

NASA NTRS1982

Multifuel evaluation of rich/quench/lean combustor

The fuel flexible combustor technology was developed for application to the Model 570-K industrial gas turbine engine. The technology, to achieve emission goals, emphasizes dry NOx reduction methods. Due to the high levels of fuel-bound nitrogen (FBN), control of NOx can be effected through a staged combustor with a rich initial combustion zone. A rich/quench/lean variable geometry combustor utilizes the technology presented to achieve low NOx from alternate fuels containing FBN. The results focus on emissions and durability for multifuel operation.

Notardonato, J. J.↗

NASA NTRS1984

Ceramic composite liner material for gas turbine combustors

Advanced commercial and military gas turbine engines may operate at combustor outlet temperatures in excess of 1920 K (3000 F). At these temperatures combustors liners experience extreme convective and radiative heat fluxes. The ability of a plasma sprayed ceramic coating to reduce liner metal temperature has been recognized. However, the brittleness of the ceramic layer and the difference in thermal expansion with the metal substrate has caused cracking, spalling and some separation of the ceramic coating. Research directed at turbine tip seals (or shrouds) has shown the advantage of applying the ceramic to a compliant metal pad. This paper discusses recent studies of applying ceramics to combustor liners in which yttria stabilized zirconia plasma sprayed on compliant metal substrates which were exposed to near stoichiometric combustion, presents performance and durability results, and describes a conceptual design for an advanced, small gas turbine combustor. Test specimens were convectively cooled or convective-transpiration cooled and were evaluated in a 10 cm square flame tube combustor at inlet air temperatures of 533 K (500 F) and at a pressure of 0.5 MPa (75 psia). The ceramics were exposed to flame temperatures in excess of 2000 K (3320 F). Results appear very promising with all 30 specimens surviving a screening test and one of two specimens surviving a cyclic durability test.

Ercegovic, D. B.↗

NASA NTRS1984

Broad specification fuels combustion technology program

Design and development efforts to evolve promising aircraft gas turbine combustor configurations for burning broadened-properties fuels were discussed. Design and experimental evaluations of three different combustor concepts in sector combustor rig tests was conducted. The combustor concepts were a state of the art single-annular combustor, a staged double-annular combustor, and a short single-annular combustor with variable geometry to control primary zone stoichiometry. A total of 25 different configurations of the three combustor concepts were evaluated. Testing was conducted over the full range of CF6-80A engine combustor inlet conditions, using four fuels containing between 12% and 14% hydrogen by weight. Good progress was made toward meeting specific program emissions and performance goals with each of the three combustor concepts. The effects of reduced fuel hydrogen content, including increased flame radiation, liner metal temperature, smoke, and NOx emissions were documented. The most significant effect on the baseline combustor was a projected 33% life reduction, for a reduction from 14% to 13% fuel hydrogen content, due to increased liner temperatures.

Dodds, W. J.↗

NASA NTRS1985

Elevated temperature crack growth

The objective of the Elevated Temperature Crack Growth Project is to evaluate proposed nonlinear fracture mechanics methods for application to combustor liners of aircraft gas turbine engines. During the first year of this program, proposed path-independent (P-I) integrals were reviewed for such applications. Several P-I integrals were implemented into a finite-element postprocessor which was developed and verified as part of the work. Alloy 718 was selected as the analog material for use in the forthcoming experimental work. A buttonhead, single-edge notch specimen was designed and verified for use in elevated-temperature strain control testing with significant inelastic strains. A crack mouth opening displacement measurement device was developed for further use.

Yau, J. F.↗

NASA NTRS1984

Ceramic components for gas turbine engines

The ceramic component design, manufacturing and inspection technologies under development for the AGT 100 automotive gas turbine promise to meet marketplace cost and performance criteria. Especially consequential developments are noted toward this goal in the case of net and near-net shape component fabrication. Integral turbine rotors, scrolls, combustors, support structures and heat exchangers have been successfully produced and evaluated. Consistency of material properties have yet to be achieved for the processing methods in question, however.

Heitman, P. W.↗

NASA NTRS1985

Constitutive modeling for isotropic materials

The first year of progress on a NASA-Lewis contract with the General Electric Co is documented. The purpose of this contract (NAS3-23927) is to develop and evaluate unified constitutive equations for applications to hot-path components of aircraft gas turbine engines such as high pressure turbine blades and vanes. To accomplish this goal, uniaxial, notched, and multiaxial specimens made of conventionally cast Rene 80 are being tested under conditions that simulate engine operating conditions. To reduce the raw data, automated data reduction techniques are being developed that produce computer files containing the information needed to analyze proposed constitutive theories. Described are the analytical methods being developed to determine the parameters for these nonlinear unified theories by using the reduced data files. In another activity, a dedicated finite-element computer code is being developed to use unified theories in the structural analysis of hot-section components. This code was extensively verified for one such theory by successfully predicting the strain histories measured experimentally at the notch root of complex specimens taken from complex laboratory specimens.

Ramaswamy, V. G.↗