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At least 973 records · Page 54

The Effect of Gravity on the Combustion Synthesis of Porous Biomaterials

Production of highly porous composite materials by traditional materials processing is limited by difficult processing techniques. This work investigates the use of self propagating high temperature (combustion) synthesis (SHS) to create porous tricalcium phosphate (Ca3(PO4)2), TiB-Ti, and NiTi in low and microgravity. Combustion synthesis provides the ability to use set processing parameters to engineer the required porous structure suitable for bone repair or replacement. The processing parameters include green density, particle size, gasifying agents, composition, and gravity. The advantage of the TiB-Ti system is the high level of porosity achieved together with a modulus that can be controlled by both composition (TiB-Ti) and porosity. At the same time, NiTi exhibits shape memory properties. SHS of biomaterials allows the engineering of required porosity coupled with resorbtion properties and specific mechanical properties into the composite materials to allow for a better biomaterial.

Castillo, M.↗

Ignition and combustion characteristics of metallized propellants

Experimental and analytical investigations focusing on secondary atomization and ignition characteristics of aluminum/liquid hydrocarbon slurry propellants were conducted. Experimental efforts included the application of a laser-based, two-color, forward-scatter technique to simultaneously measure free-flying slurry droplet diameters and velocities for droplet diameters in the range of 10-200 microns. A multi-diffusion flame burner was used to create a high-temperature environment into which a dilute stream of slurry droplets could be introduced. Narrowband measurements of radiant emission were used to determine if ignition of the aluminum in the slurry droplet had occurred. Models of slurry droplet shell formation were applied to aluminum/liquid hydrocarbon propellants and used to ascertain the effects of solids loading and ultimate particle size on the minimum droplet diameter that will permit secondary atomization. For a 60 weight-percent Al slurry, the limiting critical diameter was predicted to be 34.7 microns which is somewhat greater than the 20-25 micron limiting diameters determined in the experiments. A previously developed model of aluminum ignition in a slurry droplet was applied to the present experiments and found to predict ignition times in reasonable agreement with experimental measurements. A model was also developed that predicts the mechanical stress in the droplet shell and a parametric study was conducted. A one-dimensional model of a slurry-fueled rocket combustion chamber was developed. This model includes the processes of liquid hydrocarbon burnout, secondary atomization, aluminum ignition, and aluminum combustion. Also included is a model for radiant heat transfer from the hot aluminum oxide particles to the chamber walls. Exercising this model shows that only a modest amount of secondary atomization is required to reduce residence times for aluminum burnout, and thereby maintain relatively short chamber lengths. The model also predicts radiant heat transfer losses to the walls to be only approximately 3 percent of the fuel energy supplied. Additional work is required to determine the effects of secondary atomization on two-phase losses in the nozzle.

Turns, Stephen R.↗

A Full-Scale Fire Program to Evaluate New Furnishings and Textile Materials Developed by the National Aeronautics and Space Administration

The plans for the present series of full-scale experimental fires were initiated at the suggestion of NASA following the presentation of a film and discussion illustrating Battelle-Columbus' recent work in fire research. That film showed bedroom-type fires carried out as a part of a program to determine the influence of the cyclic characteristics of real fires under limited ventilation on the burning and pyrolysis properties of the room furnishings. A new series of fires was suggested by NASA designed to show the performance of new fire resistant and fire retardant materials by providing comparative fire and smoldering environmental conditions. More recently, the goal for the new series of fires was written in a meeting with NASA personnel and others at Battelle on May 3 and 4, 1972. The goal was as follows: To establish the need for special materials of improved fire safety in domiciliary settings of public concern, and to assess, in a professionally acceptable manner, the potential of materials arising from the new space-age technology for this purpose. It was anticipated that some new materials arising from the space-age technology and not yet available through conventional commercial channels might provide significant improvements in fire safety if the best of the commercially available materials showed important shortcomings in this area. It was the intent of this program to assess the benefits that could accrue from the use of these new materials. Fire safety is a matter requiring the evaluation of a number of factors. For example, fire resistance and fire spread, visibility during the fire, toxicity of evolved gases, and the fire-fighting problem that is created must be evaluated before the relative hazard can be assessed. The plan of the program provided for sampling and instrumentation to evaluate these factors, consistent with the goal of technological utilization that has been specified. Arrangements were made with the Columbus Fire Department to use an existing six-story concrete building', designed and used as a fire training tower, as the site for the experimental fires. The visual evidence provided by TV and photographic coverage of the four experimental room fires showed clearly that the rooms responded very differently to a common ignition condition. In particular: (1) The Typical room, furnished from conventional retail sources, ignited easily and burned rapidly so that after 8 minutes the contents of the room were nearly destroyed. (2) The Improved room, furnished with materials selected as being among the best commercially available, showed substantial improvement over the Typical room in that there was slower fire spread. However, the relatively complete destruction of the room contents that resulted, and the large amounts of smoke, made it clear that substantial further improvements were needed. This fire was stopped after 29 minutes. (3) The Space-age room, furnished completely with new materials that were not yet commercially available, did not ignite under the common ignition condition and soon demonstrated the substantial improvement in fire resistance available for those components close to the ignition source. A second and larger ignition arrangement showed that this room can burn, but the difficulty with which this was brought about confirmed the improved fire resistance available with use of these materials. (4) The Mixed room ensemble, furnished with 'materials identical to the Typical room except for the substitution of the bed from the Space-age room, illustrated the improvement in control of fire spread available by careful placement of fire materials in the important paths of fire development of an otherwise ordinary room. The most significant hazards at early times in each fire were due to the rapid rise in heat flux and the abrupt obscuration of vision by smoke. The most consistent toxicity hazard was due to CO and its importance would depend on the ability of the occupant to survive the initial heat and smoke menace which characterized each fire room. Other gases and vapors were shown to reach hazardous levels in certain fire rooms and, again, their significance to an occupant, would relate to the times in which such hazards occurred, and probably to the synergistic nature of the hazard arising from mixtures of such gases. Fire retardant items in the room are caused to pyrolyze by the heat of burning from other items in the room and so contribute to combustible and toxic vapor accumulations, even though they may not have entered into the burning process. This effect of a mixture of combustible materials to produce burning and pyrolysis not characteristic of any one item individually we have chosen to call the "ensemble effect". Further full-scale fire trials may be expected to show the significant changes that control the burning and pyrolytic processes and in that event a programmed fire chamber should be developed to yield realistic laboratory results.

Hillenbrand, L. J.↗

Fabrication of High Thermal Conductivity NARloy-Z-Diamond Composite Combustion Chamber Liner for Advanced Rocket Engines

This paper describes the process development for fabricating a high thermal conductivity NARloy-Z-Diamond composite (NARloy-Z-D) combustion chamber liner for application in advanced rocket engines. The fabrication process is challenging and this paper presents some details of these challenges and approaches used to address them. Prior research conducted at NASA-MSFC and Penn State had shown that NARloy-Z-40%D composite material has significantly higher thermal conductivity than the state of the art NARloy-Z alloy. Furthermore, NARloy-Z-40 %D is much lighter than NARloy-Z. These attributes help to improve the performance of the advanced rocket engines. Increased thermal conductivity will directly translate into increased turbopump power, increased chamber pressure for improved thrust and specific impulse. Early work on NARloy-Z-D composites used the Field Assisted Sintering Technology (FAST, Ref. 1, 2) for fabricating discs. NARloy-Z-D composites containing 10, 20 and 40vol% of high thermal conductivity diamond powder were investigated. Thermal conductivity (TC) data. TC increased with increasing diamond content and showed 50% improvement over pure copper at 40vol% diamond. This composition was selected for fabricating the combustion chamber liner using the FAST technique.

Bhat, Biliyar N.↗

Cryogenic Carbon Capture™ Technoeconomic Analysis

The Cryogenic Carbon Capture™ (CCC) process significantly decreases cost and energy demands for CO 2 separation and pressurization to 150 bar compared to alternatives. The process is a post-combustion technology that cools CO 2 -laden flue gas to desublimation temperatures (-100 to -135 °C), separates solid CO 2 —that forms from the flue gas—from the light gases, uses the cold products to cool incoming gases in a recuperative heat exchanger, compresses the solid/liquid CO 2 to final pressures (100–200 bar), and delivers a compressed CO 2 stream separated from an atmospheric pressure light-gas stream. The overall energy and economic costs are about 30-50% lower than most competing processes that involve air separation units (ASUs), solvents, or similar technologies. In addition, the CCC process enjoys several ancillary benefits, including (a) it is a minimally invasive Bolton technology, (b) it provides highly efficient removal of most pollutants (Hg, SOx, NO 2 , HCl, etc.), and (c) possible energy storage capacity. This report outlines the process details and economic and energy comparisons relative to other well-documented alternatives. This paper presents the results of a detailed techno-economic comparison of CCC with amine-based systems. The comparison uses identical financial and economic assumptions similar process assumptions as the detailed analyses published by US DOE in the greenfield analysis. Specifically, the comparison assumes power plants that produce the same net output, one equipped with and a second without carbon capture. Separately, the paper compares similar analyses for retrofitting existing systems using typical plant characteristics in the US (initial capital costs have been paid, high plant utilization), though there are no DOE estimates available for direct comparison. Financial and technical assumptions for all comparisons are maintained as close to the DOE reference studies as possible. The results demonstrate about 30-50% lower costs and energy demands for capture from greenfield coal plants. Natural gas plants produce substantially lower CO 2 concentrations which makes the cost of capturing a ton of CO 2 at the same capture rate as the coal plant higher for all processes while the cost of CO 2 capture per unit of power generation is lower. However, CCC maintains about the same absolute energy and cost advantages for NG as for coal compared to amine systems. Finally, the costs of retrofitting a station are compared to those of building a new station with and without capture. The retrofit costs are comparable to (slightly lower than) new plant costs without capture. In all cases operating and capital cost comparisons show that the CCC process can be retrofitted to a variety of plants to cost effectively reduce CO 2 emissions. Further process integration into the upstream processes and unique process features like water recovery, and integrated energy storage bring the effective cost of carbon capture using the CCC process down further and increase its advantages over alternatives. This technoeconomic analysis shows that the CCC process has the potential to the be lowest cost carbon capture technology under development today.

20 FOSSIL-FUELED POWER PLANTS↗

Mechanistic study of chemical looping reactions between solid carbon fuels and CuO

Copper (Cu) based chemical-looping combustion (CLC) is a promising process that utilizes solid carbon fuel such as coal and biomass. Understanding the reaction kinetics in this process can facilitate the industrial design of CLC units. Here, in this work, molecular dynamics (MD) simulations were performed to investigate the reaction kinetics of n-butane and two simplified solid carbon fuels (lignite and anthracite) with/without copper oxide (CuO) nanoparticle. In addition, experiments were conducted on the thermal characteristics, flammability, and flame speeds of CuO and solid carbon mixtures. For n-butane, oxidation on the CuO surface is the primary reaction since the activation energy of the surface reaction is much lower than that of oxygen (O 2 ) combustion (9.2 vs. 53.3 kcal/mol). On the other hand, for lignite, there is a smaller difference in the activation energy of O 2 combustion and surface reaction (23.04 vs. 6.34 kcal/mol). We hypothesize that some solid carbon fuels can have different reaction kinetics dependent upon temperature. This is proven by the case of a simplified anthracite coal: an Arrhenius plot shows that this solid carbon fuel has two different reaction kinetic regimes and the critical temperature for the change in kinetics is related to the oxygen uncoupling of the CuO nanoparticle. Like the modeling simulations, a change in activation energy is observed in the experimental results, where desorption of molecular oxygen from CuO becomes important.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

Cost and Life-Cycle Greenhouse Gas Implications of Integrating Biogas Upgrading and Carbon Capture Technologies in Cellulosic Biorefineries

We discuss gaseous streams in biorefineries that have been undervalued and underutilized. In cellulosic biorefineries, coproduced biogas is assumed to be combusted alongside lignin to generate process heat and electricity. Biogas can instead be upgraded to compressed biomethane and used as a transportation fuel. Capturing CO 2 -rich streams generated in biorefineries can also contribute to greenhouse gas (GHG) mitigation goals. We explore the economic and life-cycle GHG impacts of biogas upgrading and CO 2 capture and storage (CCS) at ionic liquid-based cellulosic ethanol biorefineries using biomass sorghum. Without policy incentives, biorefineries with biogas upgrading systems can achieve a comparable minimum ethanol selling price (MESP) and reduced GHG footprint ($1.38/liter gasoline equivalent (LGE) and 12.9 gCO 2e /MJ) relative to facilities that combust biogas onsite ($1.34/LGE and 24.3 gCO 2e /MJ). Incorporating renewable identification number (RIN) values advantages facilities that upgrade biogas relative to other options (MESP of $0.72/LGE). Incorporating CCS increases the MESP but dramatically decreases the GHG footprint (-21.3 gCO 2e /MJ for partial, -110.7 gCO 2e /MJ for full CCS). The addition of CCS also decreases the cost of carbon mitigation to as low as $52-$78/t CO 2 , depending on the assumed fuel selling price, and is the lowest-cost option if both RIN and California's Low Carbon Fuel Standard credits are incorporated.

09 BIOMASS FUELS↗

Shear coaxial injector instability mechanisms

There is no definitive knowledge of which of several concurrent processes ultimately results in unstable combustion within liquid rocket chambers employing shear coaxial injectors. Possible explanations are a detrimental change in the atomization characteristics due to a decrease in the gas-to-liquid velocity ratio, a change in the gas side injector pressure drop allowing acoustic coupling to the propellant feed system or the disappearance of a stabilizing recirculation region at the base of the LOX post. The aim of this research effort is to investigate these proposed mechanisms under conditions comparable to actual engine operation. Spray characterization was accomplished with flash photography and planar laser imaging to examine the overall spray morphology and liquid jet breakup processes and with a PDPA to quantify the spatial distribution of droplet size and mean axial velocity. A simplified stability model based on the Rayleigh criterion was constructed for the flow dynamics occurring within the chamber and injector to evaluate the potential coupling between the chamber and injector acoustic modes and was supported by high frequency measurements of chamber and injector pressure oscillations. To examine recirculation within the LOX post recess, velocity measurements were performed in the recess region by means of LDV. Present experiments were performed under noncombusting conditions using LOX/GH2 stimulants at pressures up to 4 MPa.

Puissant, C.↗

Combustion and Flammability Characteristics of Solids at Microgravity in very Small Velocity Flows

Fires still remain as one of the most important safety risks in manned spacecraft. This problem will become even more important in long endurance non orbital flights in which maintenance will be non existing or very difficult. The basic process of a fire is the combustion of a solid at microgravity conditions in O2/N2 mixtures. Although a large number of research programs have been carried out on this problem, especially on flame spreading, several aspects of these processes are not yet well understood. It may be mentioned, for example, the temperature and characteristic of low emissivity flames in the visual range that take place in some conditions at microgravity; and there exists a lack of knowledge on the influence of key parameters, such as convective flow velocities of the order of magnitude of typical oxygen diffusion velocities. The "Departamento de Motopropulsion y Termofluidodinamica" of the "Universidad Politecnica de Madrid, Escuela Tecnica Superior de Ingenieros Aeronauticos" is conducting a research program on the combustion of solids at reduced gravity conditions within O2/N2 mixtures. The material utilized has been polymethylmethacrylate (PMMA) in the form of rectangular slabs and hollow cylinders. The main parameters of the process have been small convective flow velocities (including velocity angle with the direction of the spreading flame) and oxygen concentration. Some results have also been obtained on the influence of material thickness and gas pressure.

Sanchez-Tarifa, C.↗

Combustion Performance and Emissions Optimization through Integration of Miniaturized High Temperature Multi Process Monitoring System

The main objective of this research program is to design, manufacture, and demonstrate a miniaturized, multi-process, monitoring system (mMPMS) for boiler condition management and easy system deployment to obtain a higher spatial resolution. This system will facilitate a Condition-Based Maintenance (CBM) philosophy that actively monitors the health of assets to predict and prevent failures and maximize availability and generating capacity at a reduced cost. CBM systems can provide boiler data that the advanced process control (APC) system can utilize for plant performance optimization, which is increasingly relevant as coal power plants shift from predominantly base-load operation to predominantly transient operation involving large load swings. The mMPMS is based on an electrochemical sensor that provides a real-time indication of the risk of damage to key locations in the radiant or convective section of a coal-fired boiler such as metal loss rates, heat flux, metal surface temperature, and deposit thickness. These indications can be utilized to optimize boiler performance as well as improve boiler availability in conjunction with corresponding operating conditions. This monitoring system was developed and tested in the high-temperature regions of coal-fired utility boilers in this project but can be applied to many other industries and applications as well. The new sensor design, leveraging the existing electrochemical noise-based monitoring system, is small enough to be installed through the webbing of the waterwalls without the need for long shut-downs to bend tubes and to make it feasible to obtain high spatial resolution in the boiler. Data can be transferred to the plant distributed control system (DCS) and any other control system. The sensor body that houses the sensor assembly was designed to ensure good conductive contact with boiler tubes to ensure the sensor is held at an identical temperature to the tube surface temperature. The data acquisition and signal conditioning modules were redesigned into a small footprint with optimized cooling of the module. System software was developed specifically for the new signal conditioning module and is compatible with plant PLCs. After the preliminary testing at a pilot-scale facility, five mMPMS were installed at a full-scale pulverized coal-fired plant, Basin Electric Power Cooperative’s Leland Olds Unit 1. The systems were demonstrated over a 6-week period during typical operation. Sensor measurements of deposit thickness were validated during the demonstration and subsequently leveraged to determine sensor-based boiler cleaning strategies. These strategies have the benefit of reduced thermal stresses on boiler tubes from over-cleaning and improved boiler water management. At the end of the project, continued development of the sensor technology was carried out at PacifiCorp’s Hunter Station. REI leveraged the permanent installation of the mMPMS in Unit 3 made possible by DOE funding on a separate program. The work at Hunter Plant focused on application of machine learning and artificial intelligence-based models for integration of sensor signals into control and optimization of Hunter Unit 3 processes.

Advanced Sensors, Corrosion, Ash Deposition, Optim↗

Droplet burning of n-butyl acetate/n-heptane mixtures in the standard atmosphere: experiments and numerical modeling

Blending petroleum fuels with oxygenates is a common approach to stem the depletion of crude oil while also mitigating the impact of their combustion on the environment. It has recently been considered that n-butyl acetate (BA, C6H12O2 , boiling point of 399K) could be a viable oxygenate additive to diesel fuel. In this application it is important to determine the influence of the fractional amount of BA on burning of the mixture. This presentation considers this problem from an experimental and computational approach using n-heptane (C7H14 , boiling point of 372K) as an essentially single component surrogate for diesel fuel. The burning configuration considered was ostensibly spherical symmetry as promoted by burning droplets under conditions where forced and natural convection effects were minimized. In this configuration the droplet and flame are concentric spheres and soot aggregates are trapped in a shell structure between the droplet and flame. Measurements were made of the droplet, flame and soot shell diameters through video imaging of the burning process. The experimental results were used to validate a detailed numerical model of the spherically symmetric droplet burning process that incorporated a consistent combustion kinetic mechanism for BA/heptane mixtures, comprised of 402 species and 16,872 reactions inclusive of soot chemistry. A model for soot formation was also included in the simulation to predict formation of the soot shell. The simulations agreed well with measured droplet and flame diameters. It was found both experimentally and computationally that adding BA to heptane had a minimal effect on the mixture burning rate, while the flame was positioned closer to the droplet surface and the simulated soot volume fraction decreased. The implications of these results are discussed for using BA as a potential additive to diesel fuel.

09 BIOMASS FUELS↗

Toward a microgravity research strategy

Recommendations of the Committee on Microgravity Research (CMGR) of the Space Studies Board of the National Research Council are found in the Summary and Recommendations in the front of the report. The CMGR recommends a long-range research strategy. The main rationale for the microgravity research program should be to improve our fundamental scientific and technical knowledge base, particularly in the areas that are likely to lead to improvements in processing and manufacturing on earth. The CMGR recommends research be categorized as Biological science and technology, Combustion, Fluid science, Fundamental phenomena, Materials, and Processing science and technology. The committee also recommends that NASA apply a set of value criteria and measurement indicators to define the research and analysis program more clearly. The CMGR recommends that the funding level for research and analysis in microgravity science be established as a fixed percentage of the total program of NASA's Microgravity Science and Applications Division in order to build a strong scientific base for future experiments. The committee also recommends a cost-effective approach to experiments. Finally the CMGR recommends that a thorough technical review of the centers for commercial development of space be conducted to determine the quality of their activities and to ascertain to what degree their original mission has been accomplished.

Source record↗

Field Effects of Buoyancy on Lean Premixed Turbulent Flames

The study of field effects of buoyancy on premixed turbulent flames is directed towards the advancement of turbulent combustion theory and the development of cleaner combustion technologies. Turbulent combustion is considered the most important unsolved problem in combustion science and laboratory studies of turbulence flame processes are vital to theoretical development. Although buoyancy is dominant in laboratory flames, most combustion models are not yet capable to consider buoyancy effects. This inconsistency has impeded the validation of theories and numerical simulations with experiments. Conversely, the understanding of buoyancy effects is far too limited to help develop buoyant flame models. Our research is also relevant to combustion technology because lean premixed combustion is a proven method to reduce the formation of oxides of nitrogen (NOx). In industrial lean premixed combustion systems, their operating conditions make them susceptible to buoyancy thus affecting heat distribution, emissions, stability, flashback and blowoff. But little knowledge is available to guide combustion engineers as to how to avoid or overcome these problems. Our hypothesis is that through its influence on the mean pressure field, buoyancy has direct and indirect effects on local flame/turbulence interactions. Although buoyancy acts on the hot products in the farfield the effect is also felt in the nearfield region upstream of the flame. These changes also influence the generation and dissipation of turbulent kinetic energy inside the flame brush and throughout the flowfield. Moreover, the plume of an open flame is unstable and the periodic fluctuations make additional contributions to flame front dynamics in the farfield. Therefore, processes such as flame wrinkling, flow acceleration due to heat release and flame- generated vorticity are all affected. Other global flame properties (e.g. flame stabilization limits and flame speed) may all be coupled to buoyancy. This problem poses major challenges to combustion modeling due to its need for a computation domain extending into the farfield and full specifications of upstream, wall and downstream boundary conditions.

Cheng, R. K.↗

A Theoretical Evaluation of Secondary Atomization Effects on Engine Performance for Aluminum Gel Propellants

A one-dimensional model of a gel-fueled rocket combustion chamber has been developed. This model includes the processes of liquid hydrocarbon burnout, secondary atomization. aluminum ignition, and aluminum combustion. Also included is a model of radiative heat transfer from the solid combustion products to the chamber walls. Calculations indicate that only modest secondary atomization is required to significantly reduce propellant burnout distances, aluminum oxide residual size and radiation heat wall losses. Radiation losses equal to approximately 2-13 percent of the energy released during combustion were estimated. A two-dimensional, two-phase nozzle code was employed to estimate radiation and nozzle two-phase flow effects on overall engine performance. Radiation losses yielded a 1 percent decrease in engine I(sub sp). Results also indicate that secondary atomization may have less effect on two-phase losses than it does on propellant burnout distance and no effect if oxide particle coagulation and shear induced droplet breakup govern oxide particle size. Engine I(sub sp) was found to decrease from 337.4 to 293.7 seconds as gel aluminum mass loading was varied from 0-70 wt percent. Engine I(sub sp) efficiencies, accounting for radiation and two-phase flow effects, on the order of 0.946 were calculated for a 60 wt percent gel, assuming a fragmentation ratio of 5.

Mueller, D. C.↗

Numerical Investigation of Ammonia/n-Heptane Dual-Fuel Spray Flames Using Large Eddy Simulations

Diesel engines are extensively used in heavy-duty transportation, power generation, and marine vehicles due to their superior thermal efficiency and extended high-load operability compared to spark ignition (SI) engines. However, combustion in diesel engines is generally characterized by locally rich fuel–air mixtures and high combustion temperatures, causing significant amounts of soot and NO x emissions from these engines. Utilizing carbon-free alternative fuels and enhancing fuel efficiency represent promising strategies to mitigate greenhouse gas (GHG) and other emissions in the heavy-duty transportation sector. In this context, ammonia (NH 3 ), as a hydrogen carrier, has received significant attention as a viable substitute for hydrocarbon fuels due to its carbon-free composition, relatively high energy density, and well-established infrastructure. Many previous studies have considered combustion and emission characteristics of ammonia-hydrocarbon fuel blends in engines and simplified flames. But, detailed investigations on the effects of ammonia on the performance of hydrocarbon fuels under engine conditions are lacking. In the present study, we perform large eddy simulations (LES) of the ignition and flame processes in a constant-volume combustion reactor, where n-heptane is injected in an ammonia/air ambient mixture in a diesel-like environment. A detailed and validated reaction mechanism containing 302 species and 1981 reactions is employed. The Engine Combustion Network Spray H experimental data is used to validate the spray model under both non-reacting and reacting conditions. Dual-fuel combustion is simulated using the well-stirred reactor (WSR) approach. Results are presented for two spray cases: (1) single fuel (SF) with n-heptane injected into a mixture of air and combustion products and (2) dual-fuel (DF) with the injection of n-heptane in a mixture of air, ammonia, and combustion products. It is observed that the presence of ammonia has a significant effect on the ignition and flame development processes. With ammonia addition, both the first- and second-stage ignition delay times increase, but the effect of ammonia on the second-stage ignition is significantly more prominent. In addition, the ignition kernel size and growth rate decrease noticeably. For SF spray, the main ignition is characterized by multiple ignition kernels near the spray tip, whereas for DF spray, a single relatively small ignition kernel forms and grows slowly in the downstream direction. The flame development and the final quasi-steady flame structure are also modified due to ammonia. Here, the outcome of this research would enable a better understanding of ammonia–diesel dual-fuel spray flame behavior and guide the development of associated engine combustion strategies.

ammonia↗

Additive Manufacturing and Hot-Fire Testing of Bimetallic GRCop-84 and C-18150 Channel-Cooled Combustion Chambers Using Powder Bed Fusion and Inconel 625 Hybrid Directed Energy Deposition

Additive manufacturing (AM) is an advanced fabrication technique that is demonstrating tremendous potential to reduce fabrication lead times and costs for liquid rocket engine components. The additive manufacturing technology lends itself to fabricate components with complex features such as internal coolant channels in combustion chambers that would otherwise require complex manufacturing operations. A requirement for high performance engines is to use high conductivity, high strength materials such as copper-alloys for combustion chamber liners to provide adequate wall temperatures and meet subsequent structural margins. A further requirement of this configuration is to minimize weight by defining and fabricating material in discrete locations as required. NASA and Industry partner, Virgin Orbit, have been working to advance these technologies through development of bimetallic additive manufacturing techniques under a public-private partnership through NASA’s Announcement of Collaborative Opportunity (ACO). This partnership is advancing a bimetallic hybrid additively manufactured combustion chamber that integrates Powder Bed Fusion (PBF), specifically Selective Laser Melting (SLM), and Directed Energy Deposition (DED) blown powder techniques to optimize the chamber materials and subsequent assembly. The SLM process is being developed for the combustion chamber liner to use copper-alloys GRCop-84 (Copper-Chrome-Niobium) or C-18150 (Copper-Chrome-Zirconium). The hybrid DED blown powder technology is used to apply an integrated structural jacket and manifolds using an Inconel 625 superalloy on the outer surface of the SLM copper liner. The hybrid DED technology being used on this program is a DMG Mori Seiki AM machining center which integrates the DED blown powder with an integral subtractive (traditional) machining to minimize overall setups. A series of chambers were fabricated using these techniques with GRCop-84/Inconel 625 and C-18150/Inconel and hot-fire tested at NASA Marshall Space Flight Center (MSFC) in LOX/Kerosene (RP-1). This paper describes the process development to integrate these AM technologies into an integrated bimetallic assembly, the design of the chamber, results from hot-fire testing, and further development.

Gradl, Paul R.↗