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At least 991 records · Page 55

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NASA NTRSDate not supplied

Hot-Fire Testing Results of Additively Manufactured NASA HR-1 towards Large Scale Implementation of Channel Wall Nozzles

Additive manufacturing (AM) has provided new design and manufacturing opportunities to reduce cost and schedules, consolidate parts, and optimize performance. One technique being evaluated is Laser Powder Directed Energy Deposition (LP-DED), which provides a significant increase in scale compared to Laser Powder Bed Fusion (L-PBF). NASA along with industry partners have been developing the LP-DED process to demonstrate internal channel geometry and development components for use in liquid rocket engine channel cooled nozzles. One material that has been the focus of this development is NASA HR-1, an Iron-Nickel based superalloy optimized for use in high pressure hydrogen environments. Material properties and process characterization has been completed on the high density thin-wall material in addition to advancements of the supply chain. NASA has also completed fabrication of several subscale and full scale channel wall nozzles in LP-DED NASA HR-1 and completed hot-fire testing. This includes refinement of the process to produce thin-walls and various channel geometries to meet the requirements for channel wall nozzle applications. This paper will provide an overview of the LP-DED process development, material characterization and properties, component manufacturing, and hot-fire testing. Hot-fire testing was completed for a lander-class 7K-lbf thrust chamber using Liquid Oxygen (LOX)/Methane. The design overview and results from hot-fire testing will be presented in addition to hardware development for future testing on 2K-lbf and 35k-lbf thrust chambers and large-scale manufacturing technology demonstrators.

Paul Gradl↗

NASA NTRSDate not supplied

Proof Testing Aluminum and Titanium Thin-Walled Tubes for Aerospace Applications

Proof testing aerospace components aids in verifying the structural integrity of flight hardware. This process is often an important step in the certification process for critical parts. Though proof testing is a common practice at NASA and in industry, there is often a need to understand better the effectiveness of proof testing pressure systems discovering cracklike flaws or defects. Often proof tests are used in requirements and in practice as technical rationale for screening critical defects in a part in lieu of performing a non-destructive inspection. The intent of this work is to define proof test failure envelopes for thin-walled tubes composed of two materials: aluminum and titanium. Both materials are common in aerospace thin-walled tubing applications which is why these were the materials chosen for this study. The fracture mechanics software NASGRO was used to perform a parametric study on the effect of defects in thin-walled tubes subjected to proof testing. For both materials, the parameters varied in the NASGRO analyses were aspect ratio, proof test pressure, thickness, diameter, and flaw multiplier. With each case defined as a through crack or failure, the results were then pulled into MATLAB in order to parse through the data and produce failure envelope plots. Failure envelopes were created by meshing a surface in between the minimum proof pressure failing data points. As expected, based on material properties, the plots indicated the aluminum material would fail at much lower proof tests than the titanium. The parametric data and failure envelopes may be used as general qualitative insight on the effectiveness of proof testing thin-walled tubes of similar alloys.

Leah B Davis↗

NASA NTRSDate not supplied

Comparison between Computational and Experimental Wall-Shear Stress and Pressure Measurements in a Supersonic Wind Tunnel

We study the performance of two selected RANS models (SST-$k$-$\omega$ and Baldwin-Lomax) to simulate the mean wall-shear and pressure data obtained from a distributed-roughness-related experimental campaign conducted at Ahmic Aerospace, LLC, located in Ohio, US. A structured compressible Navier-Stokes in-house solver, DPLR, is used to conduct the RANS simulations. As the final objective is to perform the studies under high-enthalpy flow conditions, such as inside the AHF facility at NASA-Ames Research Center (ARC), the current investigation focuses on the low-enthalpy cases using Ahmic's high-Reynolds-number supersonic wind tunnel as the initial step to simplify the flow physics. Furthermore, the wind tunnel simulations are conducted with perfectly-smooth walls to further simplify the problem and perform the initial testing of different solver-based RANS models. The Baldwin-Lomax model is observed to be more accurate than the SST model. However, when these RANS models and their roughness augmentation models are utilized to study their accuracy with respect to the experimental datasets, where the roughness effects are activated, both models perform well for a low roughness height case. However, as the roughness height increases, the SST model more accurately predicts the wall data (shear and pressure) than the Baldwin-Lomax model. Therefore, this present work has built a solid foundation for selecting the best RANS model to study the wall data under high-enthalpy flow conditions at the AHF facility soon.

Prakash Shrestha↗

NASA NTRSDate not supplied

Evaluating the performance of portable air filter walls for the James Webb Space Telescope launch campaign

The James Webb Space Telescope (JWST) launched from the Centre Spatial Guyanais (CSG) in December 2021. JWST’s requirements permitted processing in International Organization for Standardization (ISO) Class 7 or better facilities, but CSG was only equipped with ISO Class 8 facilities. To temporarily upgrade the air cleanliness in the Payload Processing Facility, Fueling Hall, and Final Assembly Building Encapsulation Hall, NASA provided two portable High Efficiency Particulate Air (HEPA) and carbon filter walls that were used in each location. The walls were comprised of stacks of two modules high and arranged in push-push configurations as shown to be most effective via Computational Fluid Dynamics simulations of expected floor layouts in each facility. After delivery to NASA’s Goddard Space Flight Center in 2020, the walls underwent initial verification measurements inside a cleanroom and validation testing in an uncontrolled area to quantify their improvement of air cleanliness and particle and molecular fallout. Validation testing showed improvements of 83-99% for airborne particle counts, 79-91% for particle fallout, and 50-90% for molecular fallout. The particle improvements were applied to the contamination budget analysis that tracked current and predicted future cleanliness against End-of-Life requirements for JWST’s critical surfaces. At CSG, the walls successfully maintained an ISO Class 7 environment or better within their envelope in each location, despite their presence in ISO Class 8 facilities with dense integration operations.

HEPA, Contamination Control, Filtration↗

NASA NTRS2022

Evaluating the Performance of Portable Air Filter Walls for the James Webb Space Telescope Launch Campaign

HEPA, Contamination Control, Filtration↗

NASA NTRSDate not supplied

Thin-wall Internal Channel Geometry and Surface Enhancements for Heat Exchangers using Laser Powder Directed Energy Deposition

Additive Manufacturing (AM) has offered many new design and manufacturing opportunities for components across various industries. As AM evolves there is a need to better understand outputs of the process including geometric limitations, surface texture, and post-processing surface enhancements for specific application requirements. One possible application area of AM are components using thin-wall (~1 mm) microchannel heat exchangers for subsystems across aerospace and industrial applications. Laser Powder Bed Fusion (L-PBF) is a common process for complex internal channels but the build diameter is limited to approximately 600 mm. Laser Powder Directed Energy Deposition (LP-DED) is being evaluated to produce thin-wall microchannel heat exchangers at scales beyond the L-PBF process. Successful deployment of the LP-DED technology requires characterization of geometric features from the process and potential improvements to the surface using post-processing. Surface texture, inclusive of roughness and waviness, is one of the critical attributes of AM that effects the friction factor and pressure drop within a heat exchanger and lacks data for the LP-DED process. This presentation will provide an overview of the characterization work completed of the LP-DED process for thin-walls and small channel geometry representative of various high performance alloys including NASA HR-1 and GRCop-42. An overview of the experiments conducted with varying LP-DED parameters, evaluation of various internal channel geometry, geometric build features, and resulting surface texture will be provided along with a summary of conclusions from these experiments. This study presents characterization of 2.5 mm microchannels using LP-DED, mechanisms that cause the surface texture which include powder adherence and material droop, and angled walls have a significant impact on the thickness and surface texture. Results will also be presented on various surface enhancement processes that allow for tuning of the wetting surface for friction factor, heat transfer, or fatigue life performance requirements.

Additive Manufacturing↗

NASA NTRSDate not supplied

Unsteady CFD Simulations of a Compression Corner Geometry Using Wall-Modeled LES Methods in Loci/CHEM

Several wall-modeled large eddy simulation (WMLES) methods are tested by simulating an unsteady Mach 2.0 compression corner geometry in Mississippi State’s Loci/CHEM solver. This study is conducted to evaluate the usage and requirements of these WMLES methods for applications regarding fluctuating pressure environments on launch vehicles with computational fluid dynamics (CFD). Two hybrid Reynolds-averaged Navier-Stokes (RANS)-large eddy simulation (LES) methods, Dynamic Hybrid RANS-LES (DHRL) and Improved Delayed Detached Eddy Simulation (IDDES), and one wall-stress-model, the Algebraic Wall Model for Wall-Modeled LES (AWMLES), are tested on varying grid and timestep refinement levels. These grid and timestep sizes are chosen to test the minimum requirements for successfully running these WMLES methods. The simulations are evaluated based on turbulent boundary layer properties in the developed boundary layer as well as unsteady quantities relating to fluctuating pressure environments in the region of the compression corner. The DHRL method shows good agreement with the comparison wind tunnel data and shows good grid and timestep convergence. The results from the IDDES and WMLES simulations show good agreement for several quantities with some discrepancies regarding others. The results presented in this paper will be used to inform further studies in predicting unsteady environments on higher-complexity geometries.

Bryson Frank↗

DOE OSTI2017

An assessment of CFD-based wall heat transfer models in piston engines

The lack of accurate submodels for in-cylinder heat transfer has been identified as a key shortcoming in developing truly predictive, physics-based computational fluid dynamics (CFD) models that can be used to develop combustion systems for advanced high-efficiency, low-emissions engines. Only recently have experimental methods become available that enable accurate near-wall measurements to enhance simulation capability via advancing models. Initial results show crank-angle dependent discrepancies with respect to previously used boundary-layer models of up to 100%. However, available experimental data is quite sparse (only few data points on engine walls) and limited (available measurements are those of heat flux only). Predictive submodels are needed for medium-resolution ("engineering") LES and for unsteady Reynolds-averaged simulations (URANS). Recently, some research groups have performed DNS studies on engine-relevant conditions using simple geometries. These provide very useful data for benchmarking wall heat transfer models under such conditions. Further, a number of new and more sophisticated models have also become available in the literature which account for these engine-like conditions. Some of these have been incorporated while others of a more complex nature, which include solving additional partial differential equations (PDEs) within the thin boundary layer near the wall, are underway. These models will then be tested against the available DNS/experimental data in both SI (spark-ignition) and CI (compression-ignition) engines.

33 ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2020

Towards an all-orders calculation of the electroweak bubble wall velocity

We analyze Higgs condensate bubble expansion during a first-order electroweak phase transition in the early Universe. The interaction of particles with the bubble wall can be accompanied by the emission of multiple soft gauge bosons. When computed at fixed order in perturbation theory, this process exhibits large logarithmic enhancements which must be resummed to all orders when the wall velocity is large. We perform this resummation both analytically and numerically at leading logarithmic accuracy. The numerical simulation is achieved by means of a particle shower in the broken phase of the electroweak theory. The two approaches agree to the 10$\%$ level. For fast-moving walls, we find the scaling of the thermal pressure exerted against the wall to be $P\sim \gamma^2T^4$, independent of the particle masses, implying a significantly slower terminal velocity than previously suggested.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗

DOE OSTI2023

Direct Numerical Simulation of Flame-Wall Interaction for Low-Carbon Gas Turbine Combustion

Green hydrogen (H2) and ammonia (NH3) are emerging as carbon free alternatives to hydrocarbon fuels. In gas turbines, flames interact with the combustor liner (wall), which affects the pollutant emissions, the burning efficiency, and the thermal load on the liner. We lack understanding of this important flame-wall interaction (FWI) for alternative fuels. FWI occurs at the scale of the flame thickness, and such scales are only resolved by direct numerical simulation. Here, we resolve the FWI for NH3 and H2 flames. Preliminary results of two distinct projects are presented: 2D laminar anchored V-flame, and 3D turbulent swirling flame. For the laminar flame, we show flame quenching at the wall and resulting leakage of NH3 and increased N2O, but decreased NO emissions. For the swirling flame, we show CO emissions, and comparison of flame shapes and location to experimental measurements. Ultimately we show that quenching and pollutant emissions strongly affected by fuel/air ratio, and that an inclined wall can stabilize very lean turbulent CH4/H2 flames, but prone to large CO emissions.

adaptive mesh refinement↗

DOE OSTI2023

Calibration technique of wall shear stress sensors using oscillating plate

Disclosed are a system and methods for calibrating wall shear stress sensors. The system includes an oscillating plate coupled to an actuator and mounted on a rolling elements, and one or more sensors coupled to a height adjusting device. The system can further comprise a height control rod coupled to a height control base and a sensor holder configured to house the one or more sensors and supported on a connector, the connector configured to be rotatably disposed about the height control rod. The system can be calibrated by causing the actuator to oscillate the oscillating plate at a frequency, sensing, using the one or more sensors, shear stress at a wall, the shear stress at the wall being associated with a velocity field, and determining a theoretical wall shear stress based on fluid properties, the frequency, and the height of the one or more sensors above the oscillating plate.

Freidkes, Brett R.↗

DOE OSTI2016

A spectral cascade-transport turbulence model for wall-bounded flows

A spectral cascade-transport model has been developed and applied to turbulent channel flows (Re{sub τ} = 550, 950, and 2000 based on friction velocity, u{sub τ}; or Re{sub δ} = 8,500; 14,800 and 31,000, based on the mean velocity and channel half-width). This model is an extension of a spectral model previously developed for homogeneous single and two-phase decay of isotropic turbulence and uniform shear flows; and a spectral turbulence model for wall-bounded flows without resolving the boundary layer. A direct numerical simulation (DNS) of turbulent channel flow was used to help develop this model and to assess its performance in the 1D direction across the channel width. The resultant spectral model is capable of predicting the mean velocity, turbulent kinetic energy and energy spectrum distributions for single-phase wall-bounded flows all the way to the wall, where the model source terms have been developed to account for the wall influence. The model is in the process of implementation into the 3D multiphase CFD code NPHASE-CMFD and the latest results are within reasonable error of the 1D predictions. (authors)

42 ENGINEERING↗

DOE OSTI2021

Vortex Domain Walls in Ferroelectrics

Controlling the domain formation in ferroelectric materials at the nanoscale is a fertile ground to explore emergent phenomena and their technological prospects. For example, charged ferroelectric domain walls in BiFeO 3 and ErMnO 3 exhibit significantly enhanced conductivity which could serve as the foundation for next-generation circuits. In this work, we describe a concept in which polar vortices perform the same role as a ferroelectric domain wall in classical domain structures with the key difference being that the polar vortices can accommodate charged (i.e., head-to-head and tail-to-tail) domains, for example, in ferroelectric PbTiO 3 /dielectric SrTiO 3 superlattices. Such a vortex domain wall structure can be manipulated in a reversible fashion under an external applied field.

36 MATERIALS SCIENCE↗

DOE OSTI2018

Two types of cellulose synthesis complex knit the plant cell wall together

Plant secondary cell walls (SCWs) compose most of Earth’s renewable fibers and biomass (1), and they have irreplaceable roles in the plant lifestyle, ecosystem cycles, carbon sequestration, and human industry. Nonetheless, much remains unknown about how these strong, cellulose-rich polymer networks are synthesized and assembled. Watanabe et al. (2) generate key insights into the dynamic regulation of the cellulose synthase (CESA) enzyme family during the transition between the synthesis of the primary cell wall (PCW), which surrounds all expanding plant cells, and the SCW, which confers specialized functions to some cells. The PCW and SCW become unified despite being successively synthesized and having different matrix polymers and cellulose content. This structural coherency is related to the little-explored “transition period” of cell wall synthesis (3–6), the focus of Watanabe et al.’s research (2). Here, their results provide clues about how differences in SCW properties of diverse plants may arise and point to the isomer-specific regulation of intracellular membrane protein trafficking, leading to important future research directions.

59 BASIC BIOLOGICAL SCIENCES↗

DOE OSTI2021

Dynamic Transcriptomic and Phosphoproteomic Analysis During Cell Wall Stress in Aspergillus nidulans

The fungal cell-wall integrity signaling (CWIS) pathway regulates cellular response to environmental stress to enable wall repair and resumption of normal growth. This complex, interconnected, pathway has been only partially characterized in filamentous fungi. To better understand the dynamic cellular response to wall perturbation, a β-glucan synthase inhibitor (micafungin) was added to a growing A. nidulans shake-flask culture. From this flask, transcriptomic and phosphoproteomic data were acquired over 10 and 120 min, respectively. To differentiate statistically-significant dynamic behavior from noise, a multivariate adaptive regression splines (MARS) model was applied to both data sets. Over 1800 genes were dynamically expressed and over 700 phosphorylation sites had changing phosphorylation levels upon micafungin exposure. Twelve kinases had altered phosphorylation and phenotypic profiling of all non-essential kinase deletion mutants revealed putative connections between PrkA, Hk-8–4, and Stk19 and the CWIS pathway. Our collective data implicate actin regulation, endocytosis, and septum formation as critical cellular processes responding to activation of the CWIS pathway, and connections between CWIS and calcium, HOG, and SIN signaling pathways.

59 BASIC BIOLOGICAL SCIENCES↗

DOE OSTI2023

Deuterium recycling and wall retention characteristics during boron powder injection in EAST

Boron (B), as a low-Z material, is widely employed for wall conditioning to enhance plasma performance in fusion devices. In the Experimental Advanced Superconducting Tokamak, a series of experiments involving real-time B powder injection has been conducted to investigate fuel particle behavior. It was observed that fuel particle recycling decreased with an increase in the amount of B powder injected, resulting in an increase in short-term fuel retention. The fuel recycling decreased by up to 80%, as indicated by divertor neutral pressure and D α line emission. Furthermore, each B atom exhibited a trapping capacity of 0.3 D particles during B powder injection at a typical flow rate. The real-time B injection had no wall hysteresis effect on D retention, implying that cumulative B injection and deposited film did not affect long-term D retention. The possible mechanism for D retention is the formation of B-C-O-D compounds and co-deposition between B and D particles during discharges. This investigation would be valuable for evaluating T retention when B is used as wall conditioning material in future fusion reactor devices.

36 MATERIALS SCIENCE↗

DOE OSTI2022

Mitigating Moisture with High-R Walls

Energy-efficient building enclosures are key to decreasing energy load demand and enabling advanced space-conditioning systems for high-performance homes. One efficient enclosure design solution is high-R walls, which feature increased insulation levels as an effective solution for reducing air leakage and permeance of material layers. To increase builder confidence and encourage greater market adoption of high-R walls, Home Innovation Research Labs sought to demonstrate the long-term moisture performance of several high-R wall configurations in cold climate zones. The team monitored 22 newly constructed, occupied homes located throughout climate zones 4–7, where a substantial vapor drive to the exterior is present during the winter.

buildings↗

DOE OSTI2020

Unexpected Giant Microwave Conductivity in a Nominally Silent BiFeO 3 Domain Wall

Nanoelectronic devices based on ferroelectric domain walls (DWs), such as memories, transistors, and rectifiers, have been shown in recent years. Practical high-speed electronics, on the other hand, usually demand operation frequencies in the gigahertz (GHz) regime, where the effect of dipolar oscillation is important. Herein, an unexpected giant GHz conductivity on the order of 10 3 S m -1 is observed in certain BiFeO 3 DWs, which is about 100 000 times greater than the carrier-induced direct current (dc) conductivity of the same walls. Surprisingly, the nominal configuration of the DWs precludes the alternating current (ac) conduction under an excitation electric field perpendicular to the surface. Theoretical analysis reflects that the inclined DWs are stressed asymmetrically near the film surface, whereas the vertical walls in a control sample are not. The resultant imbalanced polarization profile can then couple to the out-of-plane microwave fields and induce power dissipation, which is confirmed by the phase-field modeling. Since the contributions from mobile-carrier conduction and bound-charge oscillation to the ac conductivity are equivalent in a microwave circuit, the research on local structural dynamics may open a new avenue to implement DW nano-devices for radio-frequency applications.

36 MATERIALS SCIENCE↗