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At least 991 records · Page 55

Final Report for ALCC Allocation: Predictive Simulation of Complex Flow in Wind Farms

This report documents work performed using ALCC computing resources granted under a proposal submitted in February 2016, with the resource allocation period spanning the period July 2016 through June 2017. The award allocation was 10.7 million processor-hours at the National Energy Research Scientific Computing Center. The simulations performed were in support of two projects: the Atmosphere to Electrons (A2e) project, supported by the DOE EERE office; and the Exascale Computing Project (ECP), supported by the DOE Office of Science. The project team for both efforts consists of staff scientists and postdocs from Sandia National Laboratories and the National Renewable Energy Laboratory. At the heart of these projects is the open-source computational-fluid-dynamics (CFD) code, Nalu. Nalu solves the low-Mach-number Navier-Stokes equations using an unstructured- grid discretization. Nalu leverages the open-source Trilinos solver library and the Sierra Toolkit (STK) for parallelization and I/O. This report documents baseline computational performance of the Nalu code on problems of direct relevance to the wind plant physics application - namely, Large Eddy Simulation (LES) of an atmospheric boundary layer (ABL) flow and wall-modeled LES of a flow past a static wind turbine rotor blade. Parallel performance of Nalu and its constituent solver routines residing in the Trilinos library has been assessed previously under various campaigns. However, both Nalu and Trilinos have been, and remain, in active development and resources have not been available previously to rigorously track code performance over time. With the initiation of the ECP, it is important to establish and document baseline code performance on the problems of interest. This will allow the project team to identify and target any deficiencies in performance, as well as highlight any performance bottlenecks as we exercise the code on a greater variety of platforms and at larger scales. The current study is rather modest in scale, examining performance on problem sizes of O(100 million) elements and core counts up to 8k cores. This will be expanded as more computational resources become available to the projects.

17 WIND ENERGY↗

Triaxial Swirl Injector Element for Liquid-Fueled Engines

A triaxial injector is a single bi-propellant injection element located at the center of the injector body. The injector element consists of three nested, hydraulic swirl injectors. A small portion of the total fuel is injected through the central hydraulic injector, all of the oxidizer is injected through the middle concentric hydraulic swirl injector, and the balance of the fuel is injected through an outer concentric injection system. The configuration has been shown to provide good flame stabilization and the desired fuel-rich wall boundary condition. The injector design is well suited for preburner applications. Preburner injectors operate at extreme oxygen-to-fuel mass ratios, either very rich or very lean. The goal of a preburner is to create a uniform drive gas for the turbomachinery, while carefully controlling the temperature so as not to stress or damage turbine blades. The triaxial injector concept permits the lean propellant to be sandwiched between two layers of the rich propellant, while the hydraulic atomization characteristics of the swirl injectors promote interpropellant mixing and, ultimately, good combustion efficiency. This innovation is suited to a wide range of liquid oxidizer and liquid fuels, including hydrogen, methane, and kerosene. Prototype testing with the triaxial swirl injector demonstrated excellent injector and combustion chamber thermal compatibility and good combustion performance, both at levels far superior to a pintle injector. Initial testing with the prototype injector demonstrated over 96-percent combustion efficiency. The design showed excellent high -frequency combustion stability characteristics with oxygen and kerosene propellants. Unlike the more conventional pintle injector, there is not a large bluff body that must be cooled. The absence of a protruding center body enhances the thermal durability of the triaxial swirl injector. The hydraulic atomization characteristics of the innovation allow the design to be rapidly scaled from small in-space applications [500-5,000 lbf (2.2 22.2 kN)] to large thrust engine applications [80,000 lbf (356 kN) and beyond]. The triaxial injector is also less sensitive to eccentricities, manufacturing tolerances, and gap width of many traditional coaxial and pintle injector designs. The triaxial-injector injection orifice configuration provides for high injection stiffness. The low parts count and relatively large injector design features are amenable to low-cost production.

Muss, Jeff↗

Sensitivity analysis for aeroacoustic and aeroelastic design of turbomachinery blades

A new method for computing the effect that small changes in the airfoil shape and cascade geometry have on the aeroacoustic and aeroelastic behavior of turbomachinery cascades is presented. The nonlinear unsteady flow is assumed to be composed of a nonlinear steady flow plus a small perturbation unsteady flow that is harmonic in time. First, the full potential equation is used to describe the behavior of the nonlinear mean (steady) flow through a two-dimensional cascade. The small disturbance unsteady flow through the cascade is described by the linearized Euler equations. Using rapid distortion theory, the unsteady velocity is split into a rotational part that contains the vorticity and an irrotational part described by a scalar potential. The unsteady vorticity transport is described analytically in terms of the drift and stream functions computed from the steady flow. Hence, the solution of the linearized Euler equations may be reduced to a single inhomogeneous equation for the unsteady potential. The steady flow and small disturbance unsteady flow equations are discretized using bilinear quadrilateral isoparametric finite elements. The nonlinear mean flow solution and streamline computational grid are computed simultaneously using Newton iteration. At each step of the Newton iteration, LU decomposition is used to solve the resulting set of linear equations. The unsteady flow problem is linear, and is also solved using LU decomposition. Next, a sensitivity analysis is performed to determine the effect small changes in cascade and airfoil geometry have on the mean and unsteady flow fields. The sensitivity analysis makes use of the nominal steady and unsteady flow LU decompositions so that no additional matrices need to be factored. Hence, the present method is computationally very efficient. To demonstrate how the sensitivity analysis may be used to redesign cascades, a compressor is redesigned for improved aeroelastic stability and two different fan exit guide vanes are redesigned for reduced downstream radiated noise. In addition, a framework detailing how the two-dimensional version of the method may be used to redesign three-dimensional geometries is presented.

Lorence, Christopher B.↗

Impact Testing and Analysis of Composites for Aircraft Engine Fan Cases

The fan case in a jet engine is a heavy structure because of its size and because of the requirement that it contain a blade released during engine operation. Composite materials offer the potential for reducing the weight of the case. Efficient design, test, and analysis methods are needed to efficiently evaluate the large number of potential composite materials and design concepts. The type of damage expected in a composite case under blade-out conditions was evaluated using a subscale test in which a glass/epoxy composite half-ring target was impacted with a wedge-shaped titanium projectile. Fiber shearing occurred near points of contact between the projectile and target. Delamination and tearing occurred on a larger scale. These damage modes were reproduced in a simpler test in which flat glass/epoxy composites were impacted with a blunt cylindrical projectile. A surface layer of ceramic eliminated fiber shear fracture but did not reduce delamination. Tests on 3D woven carbon/epoxy composites indicated that transverse reinforcement is effective in reducing delamination. A 91 cm (36 in.) diameter full-ring sub-component was proposed for larger scale testing of these and other composite concepts. Explicit, transient, finite element analyses indicated that a full-ring test is needed to simulate complete impact dynamics, but simpler tests using smaller ring sections are adequate when evaluation of initial impact damage is the primary concern.

Roberts, Gary D.↗

Calculation of flight vibration levels of the AH-1G helicopter and correlation with existing flight vibration measurements

NASA-Langley is sponsoring a rotorcraft structural dynamics program with the objective to establish in the U.S. a superior capability to utilize finite element analysis models for calculations to support industrial design of helicopter airframe structures. In the initial phase of the program, teams from the major U.S. manufacturers of helicopter airframes will apply extant finite element analysis methods to calculate loads and vibrations of helicopter airframes, and perform correlations between analysis and measurements. The aforementioned rotorcraft structural dynamics program was given the acronym DAMVIBS (Design Analysis Method for Vibrations). Sikorsky's RDYNE Rotorcraft Dynamics Analysis used for the correlation study, the specifics of the application of RDYNE to the AH-1G, and comparisons of the predictions of the method with flight data for loads and vibrations on the AH-1G are described. RDYNE was able to predict trends of variations of loads and vibrations with airspeed, but in some instances magnitudes differed from measured results by factors of two or three to one. Sensitivities were studied of predictions to rotor inflow modeling, effects of torsional modes, number of blade bending modes, fuselage structural damping, and hub modal content.

Sopher, R.↗

Computational fluid dynamics analysis in support of the simplex turbopump design

Simplex is a turbopump that is being developed at NASA/Marshall Space Flight Center (MSFC) by an in-house team. The turbopump consists of a single-stage centrifugal impeller, vaned-diffuser pump powered by a single-stage, axial, supersonic, partial admission turbine. The turbine is driven by warm gaseous oxygen tapped off of the hybrid motor to which it will be coupled. Rolling element bearings are cooled by the pumping fluid. Details of the configuration and operating conditions are given by Marsh. CFD has been used extensively to verify one-dimensional (1D) predictions, assess aerodynamic and hydrodynamic designs, and to provide flow environments. The complete primary flow path of the pump-end and the hot gas path of the turbine, excluding the inlet torus, have been analyzed. All CFD analyses conducted for the Simplex turbopump employed the pressure based Finite Difference Navier-Stokes (FDNS) code using a standard kappa-epsilon turbulence model with wall functions. More detailed results are presented by Garcia et. al. To support the team, loading and temperature results for the turbine rotor were provided as inputs to structural and thermal analyses, and blade loadings from the inducer were provided for structural analyses.

Garcia, Roberto↗

Coupled rotor/fuselage dynamic analysis of the AH-1G helicopter and correlation with flight vibrations data

Under a research program designated Design Analysis Methods for VIBrationS (DAMVIBS), existing analytical methods are used for calculating coupled rotor-fuselage vibrations of the AH-1G helicopter for correlation with flight test data from an AH-1G Operational Load Survey (OLS) test program. The analytical representation of the fuselage structure is based on a NASTRAN finite element model (FEM), which has been developed, extensively documented, and correlated with ground vibration test. One procedure that was used for predicting coupled rotor-fuselage vibrations using the advanced Rotorcraft Flight Simulation Program C81 and NASTRAN is summarized. Detailed descriptions of the analytical formulation of rotor dynamics equations, fuselage dynamic equations, coupling between the rotor and fuselage, and solutions to the total system of equations in C81 are included. Analytical predictions of hub shears for main rotor harmonics 2p, 4p, and 6p generated by C81 are used in conjunction with 2p OLS measured control loads and a 2p lateral tail rotor gearbox force, representing downwash impingement on the vertical fin, to excite the NASTRAN model. NASTRAN is then used to correlate with measured OLS flight test vibrations. Blade load comparisons predicted by C81 showed good agreement. In general, the fuselage vibration correlations show good agreement between anslysis and test in vibration response through 15 to 20 Hz.

Corrigan, J. C.↗

Notched fatigue of single crystal PWA 1480 at turbine attachment temperatures

The focus is on the lower temperature, uncoated and notched features of gas turbine blades. Constitutive and fatigue life prediction models applicable to these regions are being developed. Fatigue results are presented which were obtained thus far. Fatigue tests are being conducted on PWA 1480 single crystal material using smooth strain controlled specimens and three different notched specimens. Isothermal fatigue tests were conducted at 1200, 1400, and 1600 F. The bulk of the tests were conducted at 1200 F. The strain controlled tests were conducted at 0.4 percent per second strain rate and the notched tests were cycled at 1.0 cycle per second. A clear orientation dependence is observed in the smooth strain controlled fatigue results. The fatigue lifes of the thin, mild notched specimens agree fairly well with this smooth data when elastic stress range is used as a correlating parameter. Finite element analyses were used to calculate notch stresses. Fatigue testing will continue to further explore the trends observed thus far. Constitutive and life prediction models are being developed.

Meyer, T. G.↗

Pebble Fuel Handling and Reactivity Control for Salt-Cooled High Temperature Reactors

This report documents the work completed on the X-PREX facility under NEUP Project 11- 3172. This project seeks to demonstrate the viability of pebble fuel handling and reactivity control for fluoride salt-cooled high-temperature reactors (FHRs). The research results also improve the understanding of pebble motion in helium-cooled reactors, as well as the general, fundamental understanding of low-velocity granular flows. Successful use of pebble fuels in with salt coolants would bring major benefits for high-temperature reactor technology. Pebble fuels enable on-line refueling and operation with low excess reactivity, and thus simpler reactivity control and improved fuel utilization. If fixed fuel designs are used, the power density of salt- cooled reactors is limited to 10 MW/m 3 to obtain adequate duration between refueling, but pebble fuels allow power densities in the range of 20 to 30 MW/m 3 . This can be compared to the typical modular helium reactor power density of 5 MW/m3. Pebble fuels also permit radial zoning in annular cores and use of thorium or graphite pebble blankets to reduce neutron fluences to outer radial reflectors and increase total power production. Combined with high power conversion efficiency, compact low-pressure primary and containment systems, and unique safety characteristics including very large thermal margins (>500°C) to fuel damage during transients and accidents, salt-cooled pebble fuel cores offer the potential to meet the major goals of the Advanced Reactor Concepts Development program to provide electricity at lower cost than light water reactors with improved safety and system performance.This report presents the facility description, experimental results, and supporting simulation methods of the new X-Ray Pebble Recirculation Experiment (X-PREX), which is now operational and being used to collect data on the behavior of slow dense granular flows relevant to pebble bed reactor core designs. The X-PREX facility uses novel digital x-ray tomography methods to track both the translational and rotational motion of spherical pebbles, which provides unique experimental results that can be used to validate discrete element method (DEM) simulations of pebble motion. The validation effort supported by the X-PREX facility provides a means to build confidence in analysis of pebble bed configuration and residence time distributions that impact the neutronics, thermal hydraulics, and safety analysis of pebble bed reactor cores. Experimental and DEM simulation results are reported for silo drainage, a classical problem in the granular flow literature, at several hopper angles. These studies include conventional converging and novel diverging geometries that provide additional flexibility in the design of pebble bed reactor cores. Excellent agreement is found between the X-PREX experimental and DEM simulation results. This report also includes results for additional studies relevant to the design and analysis of pebble bed reactor cores including the study of forces on shut down blades inserted directly into a packed bed and pebble flow in a cylindrical hopper that is representative of a small test reactor.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

Reynolds number influences in aeronautics

Reynolds number, a measure of the ratio of inertia to viscous forces, is a fundamental similarity parameter for fluid flows and therefore, would be expected to have a major influence in aerodynamics and aeronautics. Reynolds number influences are generally large, but monatomic, for attached laminar (continuum) flow; however, laminar flows are easily separated, inducing even stronger, non-monatomic, Reynolds number sensitivities. Probably the strongest Reynolds number influences occur in connection with transitional flow behavior. Transition can take place over a tremendous Reynolds number range, from the order of 20 x 10(exp 3) for 2-D free shear layers up to the order of 100 x 10(exp 6) for hypersonic boundary layers. This variability in transition behavior is especially important for complex configurations where various vehicle and flow field elements can undergo transition at various Reynolds numbers, causing often surprising changes in aerodynamics characteristics over wide ranges in Reynolds number. This is further compounded by the vast parameterization associated with transition, in that any parameter which influences mean viscous flow development (e.g., pressure gradient, flow curvature, wall temperature, Mach number, sweep, roughness, flow chemistry, shock interactions, etc.), and incident disturbance fields (acoustics, vorticity, particulates, temperature spottiness, even electro static discharges) can alter transition locations to first order. The usual method of dealing with the transition problem is to trip the flow in the generally lower Reynolds number wind tunnel to simulate the flight turbulent behavior. However, this is not wholly satisfactory as it results in incorrectly scaled viscous region thicknesses and cannot be utilized at all for applications such as turbine blades and helicopter rotors, nacelles, leading edge and nose regions, and High Altitude Long Endurance and hypersonic airbreathers where the transitional flow is an innately critical portion of the problem.

Bushnell, Dennis M.↗

Effects of additively manufactured surface roughness on small diameter plenums with multiple side discharges for high temperature gas turbine blade cooling applications

Combined heat and power (CHP) applications have significant environmental and economic benefits that are consistent with the goals of the U.S. Department of Energy (DOE). One area that is currently being studied includes the potential benefits of CHP turbine operation at higher turbine inlet temperatures. Internal cooling concepts enabled by additive manufacturing (AM) are of primary interest. Here, the effectiveness of internal cooling is hindered by many factors such as velocity distribution of the cooling air to the hot surface considering impingement cooling. To simulate cooling air exiting from a series of orifices for internal cooling in an airfoil, a straight smooth wall tubing with multiple side discharging orifices is used and compared to additively manufactured tubing (Ti6Al4V Grade 23) with orifice size and spacing as well as inner and outer diameters identical to the smooth wall tubing. Similar to flow discharging form perforated pipes, the flow discharged from individual orifices along the tubes in this study is found to be nonuniformly distributed, and the horizontal (axial direction) momentum can be observed from the experimental data. Discharge velocities have been measured with two-dimensional (2D) particle imaging velocimetry (PIV) and single element hot wire anemometry. Numerical analysis has also been conducted to predict the velocity distributions along the orifices in the smooth wall and additive manufacturing (AM) tubing, which are inherited with surface roughness. Numerical and measured results in this study are compared, presented, and discussed.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

Parametric study and optimization trends for the Von-Kármán-sodium dynamo experiment

In this paper, we present magneto-hydrodynamic simulations of liquid sodium flow performed with the PLUTO compressible MHD code. We investigated the influence of the remanent magnetic field orientation and intensity, the impinging velocity field due to Ekman pumping as well as the impeller dimensions on the magnetic field collimation by helical flows in-between the impeller blades. For a simplified Cartesian geometry, we model the flow dynamics of a multi-blade impeller inspired by the Von-Kármán-Sodium experiment. This study shows that a remanent magnetic field oriented in the toroidal direction is the less efficient configuration to collimate the magnetic field, although if the radial or vertical components are not negligible, the collimation is significantly improved. As the intensity of the remanent magnetic field increases, the system magnetic energy becomes larger, but the magnetic field collimation efficiency remains the same, so the gain of magnetic energy is smaller as the remanent magnetic field intensity increases. The magnetic field collimation is modified if the impinging velocity field changes: the collimation is weaker if the impinging velocity increases from Γ = 0.8 to 0.9 and slightly larger if the impinging velocity decreases from Γ = 0.8 to 0.7. The analysis of the impeller dimensions points out that the most efficient configuration to collimate the magnetic field requires a ratio between the impeller blade height and the base longitude between 0.375 and 0.5. The largest enhancement of the hypothetical α 2 dynamo loop, compared to the hypothetical Ω-α dynamo loop, is observed for the model that mimics the TM 73 impeller configuration rotating in the unscooping direction with a remanent magnetic field of 10 –3 T orientated in the radial or vertical direction. Finally, the optimization trends obtained in the parametric analysis are also confirmed by simulations with a higher resolution and turbulence degree.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

Application of Aeroelastic Solvers Based on Navier Stokes Equations

The propulsion element of the NASA Advanced Subsonic Technology (AST) initiative is directed towards increasing the overall efficiency of current aircraft engines. This effort requires an increase in the efficiency of various components, such as fans, compressors, turbines etc. Improvement in engine efficiency can be accomplished through the use of lighter materials, larger diameter fans and/or higher-pressure ratio compressors. However, each of these has the potential to result in aeroelastic problems such as flutter or forced response. To address the aeroelastic problems, the Structural Dynamics Branch of NASA Glenn has been involved in the development of numerical capabilities for analyzing the aeroelastic stability characteristics and forced response of wide chord fans, multi-stage compressors and turbines. In order to design an engine to safely perform a set of desired tasks, accurate information of the stresses on the blade during the entire cycle of blade motion is required. This requirement in turn demands that accurate knowledge of steady and unsteady blade loading is available. To obtain the steady and unsteady aerodynamic forces for the complex flows around the engine components, for the flow regimes encountered by the rotor, an advanced compressible Navier-Stokes solver is required. A finite volume based Navier-Stokes solver has been developed at Mississippi State University (MSU) for solving the flow field around multistage rotors. The focus of the current research effort, under NASA Cooperative Agreement NCC3- 596 was on developing an aeroelastic analysis code (entitled TURBO-AE) based on the Navier-Stokes solver developed by MSU. The TURBO-AE code has been developed for flutter analysis of turbomachine components and delivered to NASA and its industry partners. The code has been verified. validated and is being applied by NASA Glenn and by aircraft engine manufacturers to analyze the aeroelastic stability characteristics of modem fans, compressors and turbines.

Keith, Theo G., Jr.↗

A Validated Finite Element Modeling Tool for Hydrodynamic Loading and Structural Analysis of Ocean Deployed Macroalgae Farms

The objective of this project was to develop and validate a fine-tuned, 3D computational modeling tool for high-fidelity simulations of macroalgae cultivation and harvest systems. To develop this tool, a full understanding of the geometric, material and hydrodynamic properties associated with farming kelp in exposed environments was necessary. Experiments and numerical modeling were done at increasing scales from 1) tank tests with a 1 m model, 2) to field tests with a 61 m culture line at a sheltered site, 3) to field tests with a 122 m culture line at an exposed site and to 4) a 5- line array at the exposed site with 186 m of culture length. The results of the experimental tank tests yielded a set of hydrodynamic drag-area coefficients for a 1 m aggregate based on densely grown kelp at 16 kg/m with a length up to 3 m as described in Fredriksson et al. This work provided the basis to model kelp as a 1 m aggregate based on in-situ geometric and material properties to include measurements of kelp blade length and width, number of blades, yield per m, material mass density and cantilever tests to obtain modulus of elasticity.

54 ENVIRONMENTAL SCIENCES↗

The J-2X Fuel Turbopump - Design, Development, and Test

Pratt and Whitney Rocketdyne (PWR), a NASA subcontractor, is executing the design, development, test, and evaluation (DDT&E) of a liquid oxygen, liquid hydrogen two hundred ninety four thousand pound thrust rocket engine initially intended for the Upper Stage (US) and Earth Departure Stage (EDS) of the Constellation Program Ares-I Crew Launch Vehicle (CLV). A key element of the design approach was to base the new J-2X engine on the heritage J-2S engine with the intent of uprating the engine and incorporating SSME and RS-68 lessons learned. The J-2S engine was a design upgrade of the flight proven J-2 configuration used to put American astronauts on the moon. The J-2S Fuel Turbopump (FTP) was the first Rocketdyne-designed liquid hydrogen centrifugal pump and provided many of the early lessons learned for the Space Shuttle Main Engine High Pressure Fuel Turbopumps. This paper will discuss the design trades and analyses performed for the current J-2X FTP to increase turbine life; increase structural margins, facilitate component fabrication; expedite turbopump assembly; and increase rotordynamic stability margins. Risk mitigation tests including inducer water tests, whirligig turbine blade tests, turbine air rig tests, and workhorse gas generator tests characterized operating environments, drove design modifications, or identified performance impact. Engineering design, fabrication, analysis, and assembly activities support FTP readiness for the first J-2X engine test scheduled for July 2011.

Tellier, James G.↗

Coastal Ohio Wind Project

The Coastal Ohio Wind Project intends to address problems that impede deployment of wind turbines in the coastal and offshore regions of Northern Ohio. The project evaluates different wind turbine designs and the potential impact of offshore turbines on migratory and resident birds by developing multidisciplinary research, which involves wildlife biology, electrical and mechanical engineering, and geospatial science. Firstly, the project conducts cost and performance studies of two- and three-blade wind turbines using a turbine design suited for the Great Lakes. The numerical studies comprised an analysis and evaluation of the annual energy production of two- and three-blade wind turbines to determine the levelized cost of energy. This task also involved wind tunnel studies of model wind turbines to quantify the wake flow field of upwind and downwind wind turbine-tower arrangements. The experimental work included a study of a scaled model of an offshore wind turbine platform in a water tunnel. The levelized cost of energy work consisted of the development and application of a cost model to predict the cost of energy produced by a wind turbine system placed offshore. The analysis found that a floating two-blade wind turbine presents the most cost effective alternative for the Great Lakes. The load effects studies showed that the two-blade wind turbine model experiences less torque under all IEC Standard design load cases considered. Other load effects did not show this trend and depending on the design load cases, the two-bladed wind turbine showed higher or lower load effects. The experimental studies of the wake were conducted using smoke flow visualization and hot wire anemometry. Flow visualization studies showed that in the downwind turbine configuration the wake flow was insensitive to the presence of the blade and was very similar to that of the tower alone. On the other hand, in the upwind turbine configuration, increasing the rotor blade angle of attack reduced the wake size and enhanced the vortices in the flow downstream of the turbine-tower compared with the tower alone case. Mean and rms velocity distributions from hot wire anemometer data confirmed that in a downwind configuration, the wake of the tower dominates the flow, thus the flow fields of a tower alone and tower-turbine combinations are nearly the same. For the upwind configuration, the mean velocity shows a narrowing of the wake compared with the tower alone case. The downwind configuration wake persisted longer than that of an upwind configuration; however, it was not possible to quantify this difference because of the size limitation of the wind tunnel downstream of the test section. The water tunnel studies demonstrated that the scale model studies could be used to adequately produce accurate motions to model the motions of a wind turbine platform subject to large waves. It was found that the important factors that affect the platform is whether the platform is submerged or surface piercing. In the former, the loads on the platform will be relatively reduced whereas in the latter case, the structure pierces the wave free surface and gains stiffness and stability. The other important element that affects the movement of the platform is depth of the sea in which the wind turbine will be installed. Furthermore, the wildlife biology component evaluated migratory patterns by different monitoring systems consisting of marine radar, thermal IR camera and acoustic recorders. The types of radar used in the project are weather surveillance radar and marine radar. The weather surveillance radar (1988 Doppler), also known as Next Generation Radar (NEXRAD), provides a network of weather stations in the US. Data generated from this network were used to understand general migratory patterns, migratory stopover habitats, and other patterns caused by the effects of weather conditions. At a local scale our marine radar was used to complement the datasets from NEXRAD and to collect additional monitoring parameters such as passage rates, flight paths, flight directions, and flight altitudes of nocturnal migrating species. Our work focused on the design and development of custom built marine radar that used t-bar and parabolic dish antennas. The marine radar used in the project was Furuno (XANK250) which was coupled with a XIR3000B digitizing card from Russell Technologies for collection of the radar data. The radar data was processed by open source radR processing software using different computational techniques and methods. Additional data from thermal IR imaging cameras were collected to detect heat emitted from objects and provide information on movements of birds and bats, data which we used for different animal flight behavior analysis. Lastly, the data from the acoustic recorders were used to provide the number of bird calls for assessing patterns and peak passage rates during migration. The development of the geospatial database included collection of different data sources that are used to support offshore wind turbine development. Many different data sets were collected and organized using initial version of web-based repository software tools that can accommodate distribution of rectified pertinent data sets such as the lake depth, lake bottom engineering parameters, extent of ice, navigation pathways, wind speed, important bird habitats, fish efforts and other layers that are relevant for supporting robust offshore wind turbine developments. Additional geospatial products developed during the project included few different prototypes for offshore wind farm suitability which can involve different stakeholders and participants for solving complex planning problems and building consensus. Some of the prototypes include spatial decision support system (SDSS) for collaborative decision making, a web-based Participatory Geographic Information System (PGIS) framework for evaluating importance of different decision alternatives using different evaluation criteria, and an Android application for collection of field data using mobile and tablet devices . In summary, the simulations of two- and three-blade wind turbines suggested that two-bladed machines could produce comparable annual energy as the three-blade wind turbines but have a lighter tower top weight, which leads to lower cost of energy. In addition, the two-blade rotor configuration potentially costs 20% less than a three blade configuration that produces the same power at the same site. The cost model analysis predicted a potential cost savings of approximately 15% for offshore two-blade wind turbines. The foundation design for a wind turbine in Lake Erie is likely to be driven by ice loads based on the currently available ice data and ice mechanics models. Hence, for Lake Eire, the cost savings will be somewhat smaller than the other lakes in the Great Lakes. Considering the size of cranes and vessels currently available in the Great Lakes, the cost optimal wind turbine size should be 3 MW, not larger. The surveillance data from different monitoring systems suggested that bird and bat passage rates per hour were comparable during heavy migrations in both spring and fall seasons while passage rates were significantly correlated to wind directions and wind speeds. The altitude of migration was higher during heavy migrations and higher over water relative to over land. Notable portions of migration on some spring nights occurred parallel the shoreline, often moving perpendicular to southern winds. The birds approaching the Western basin have a higher propensity to cross than birds approaching the Central basin of Lake Erie and as such offshore turbine development might be a better option further east towards Cleveland than in the Western basin. The high stopover density was more strongly associated with migration volume the following night rather than the preceding night. The processed mean scalar wind speeds with temporal resolutions as fine as 10-minute intervals near turbine height showed that August is the month with the weakest winds while December is the month, which typically has the strongest winds. The ice data suggests that shallow western basin of Lake Erie has higher ice cover duration many times exceeding 90 days during some winters.

17 WIND ENERGY↗

Test and Analysis of Sub-Components of Aluminum-Lithium Alloy Cylinders

Integrally machined blade-stiffened panels subjected to an axial compressive load were tested and analyzed to observe the buckling, crippling, and postcrippling response of the panels. The panels were fabricated from aluminum-lithium alloys 2195 and 2050, and both alloys have reduced material properties in the short transverse material direction. The tests were designed to capture a failure mode characterized by the stiffener separating from the panel in the postbuckling range. This failure mode is attributed to the reduced properties in the short transverse direction. Full-field measurements of displacements and strains using three-dimensional digital image correlation systems and local measurements using strain gages were used to capture the deformation of the panel leading up to the failure of the panel for specimens fabricated from 2195. High-speed cameras were used to capture the initiation of the failure. Finite element models were developed using an isotropic strain-hardening material model. Good agreement was observed between the measured and predicted responses for both alloys.

Haynie, Waddy T.↗

Custom-designed heat treatment simultaneously resolves multiple challenges facing 3D-printed single-crystal superalloys

Single-crystal Ni-based superalloys are currently the material of choice for turbine blade applications, especially with the emerging additive manufacturing (AM) that facilitates the manufacture/repair of these single crystals. This promising AM route, however, comes with a dilemma: in the fusion and heat affected zones after e-beam or laser induced melting, one needs a solutionizing annealing to relieve the residual stresses and homogenize the chemical/microstructure. The super-solvus solutionizing temperature is usually adopted from the protocol for the cast superalloys, which almost always causes recrystallization and stray grain growth, resulting in a polycrystalline microstructure and degrading the high-temperature mechanical performance. Here, in this paper, we demonstrate a custom-designed post-printing heat treatment to replace the conventional super-solvus one. The recovery and relatively low temperature diminish the driving force for recrystallization and the movement of stray grain boundaries, without suffocating the chemical/microstructural homogenization thanks to the narrow dendrite width and short element segregation distance. The optimal duration of the heat treatment is proposed to achieve atomic-diffusion mediated chemical homogenization while limiting γ'-particle coarsening in the interdendritic regions. Our strategy makes it practically feasible to resolve several bottleneck problems with one processing/treatment, removing a seemingly formidable obstacle to effective additive manufacturing of superalloy single crystal products.

36 MATERIALS SCIENCE↗