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NASA NTRSDate not supplied

Laser Beam Welding for in-Space Joining Demonstrated Under Vacuum on the Ground and By Parabolic Flight Experiments

High energy density electron beam welding enabled the first and, to date, only American weld performed in space during the M551 experiment on Skylab in 1973. Though welding is critical to 90% of durable goods manufacturing in America, there is not yet regular and reliable application of welding processes to the In-space Servicing, Assembly, and Manufacturing (ISAM) sector. Fundamental studies are needed to develop basic capabilities and to enhance fundamental process knowledge, which will support follow-on efforts to mature in-space welding for use in commercial, defense, and other aerospace applications. The current work seeks to build on past flights and improve understanding and quantification of materials joining in space conditions using laser beam welding (LBW). LBW offers several advantages over the electron beam welding of Skylab, amongst others: reduced electromagnetic interference, less exposure of operators to ionizing radiation, and flexible delivery through optical fibers supporting unique workpieces and joints. Since there is no orbital laboratory to mature laser beam welding for space, the current effort addresses maturation of laser beam welding through parabolic flights augmented with data collection to enable numerical modeling efforts that capture the physical effects of the space environment. This team has retrofitted an LBW experimental apparatus that can simulate the vacuum and, during a parabolic flight, the reduced gravity & microgravity conditions of in-space welding. A team of Capstone students modified the setup, originally developed by NASA Langley Research Center for electron beam free-form fabrication, to replace its electron gun with a 1 kW, 1070 nm Yb fiber laser. The apparatus was further instrumented with temperature sensing and high-speed welding cameras to monitor and record changes in the thermal state of the workpiece, the melt pool, the laser penetration level, and the development and orientation of spatter & plumes. The system will operate autonomously, demonstrating its utility to uncrewed missions. During upcoming parabolic flight campaigns expected summer 2024, this LBW equipment will weld common aerospace alloys of aluminum, stainless steel, and titanium under conditions representative of the space environment. This data will guide future computational modeling efforts of laser welding in space and help to qualify in-space welding as a viable ISAM technique.

laser beam welding↗
DOE OSTI2026

MULTI-FIDELITY MODELING AND UNCERTAINTY QUANTIFICATION OF INVERTER BASED RESOURCES IN INTEGRATED T&D SYSTEMS

Uncertainty quantification plays a pivotal role in improving the accuracy and reliability of inverter operation within modern power systems that are increasingly dominated by inverter-based resources (IBRs). IBRs, especially those operating under grid forming (GFM) control, rely heavily on a complex set of control parameters and system measurements to maintain voltage, frequency, and power balance. Traditional deterministic modeling approaches often fail to capture these parameter deviations, potentially resulting in suboptimal control actions, reduced system stability, or even instability under high penetration of IBRs. In this paper, we demonstrate the application of model calibration and uncertainty quantification (UQ) principles to an integrated transmission and distribution (T&D) model involving a GFM converter and provide a framework for prioritizing control improvements, guiding robust design, and informing adaptive strategies that can accommodate real-time variability in system conditions. The proposed approach could be valuable in enhancing the robustness of current and future power systems under increased IBR penetrations.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2023

Regulatory utility of physiologically based pharmacokinetic modeling for assessing food impact in bioequivalence studies: A workshop summary report

This workshop report summarizes the presentations and panel discussion related to the use of physiologically based pharmacokinetic (PBPK) modeling approaches for food effect assessment, collected from Session 2 of Day 2 of the workshop titled “Regulatory Utility of Mechanistic Modeling to Support Alternative Bioequivalence Approaches.” The US Food and Drug Administration in collaboration with the Center for Research on Complex Generics organized this workshop where this particular session titled “Oral PBPK for Evaluating the Impact of Food on BE” presented successful cases of PBPK modeling approaches for food effect assessment. Recently, PBPK modeling has started to gain popularity among academia, industries, and regulatory agencies for its potential utility during bioavailability (BA) and/or bioequivalence (BE) studies of new and generic drug products to assess the impact of food on BA/BE. Considering the promises of PBPK modeling in generic drug development, the aim of this workshop session was to facilitate knowledge sharing among academia, industries, and regulatory agencies to understand the knowledge gap and guide the path forward. This report collects and summarizes the information presented and discussed during this session to disseminate the information into a broader audience for further advancement in this area.

60 APPLIED LIFE SCIENCES↗
DOE OSTI2024

Critical Literature Review of Low Global Warming Potential (GWP) Refrigerants and their Environmental Impact

Refrigeration and air conditioning currently account for ~20% of the total electricity consumption in buildings around the world. Over the next three decades as global temperatures are projected to increase, urbanization and economic growth will lead to an increased demand for refrigeration and cooling. Most commonly used refrigerants belong to the five following classes: (i) chlorofluorocarbons, (ii) hydrochlorofluorocarbons, (iii) hydrofluorocarbons (HFCs), (iv) hydrofluoroolefins (HFOs), and (v) natural refrigerants. Over the past century, there have been shifts in which compounds were used for refrigeration to improve safety and durability, allow for ozone protection, and, most recently, to reduce global warming potential (GWP). Although technological advances have led to increased cooling capacity and safer refrigerants, emissions from refrigeration systems can affect the environment by contributing to greenhouse gas emissions or by depleting the ozone layer, depending on the gas emitted. The focus is increasingly on adopting compounds that are both efficient at cooling and effective for reducing emissions and other adverse environmental impacts. Because of policy and regulatory changes to avert ozone depletion and global climate change, much discussion has centered on the environmental impacts of next-generation refrigerants. Of particular interest are the fluorinated refrigerants, HFCs and HFOs, most of which are defined as per- and polyfluoroalkyl substances (PFAS) and their breakdown products (especially trifluoroacetic acid). The US Environmental Protection Agency in 2021 drafted a Strategic Roadmap for PFAS, which has already resulted in an increase in investment in research on these compounds and has restricted the release of PFAS into the environment through the implementation of monitoring and reporting requirements. A critical evaluation of fluorinated refrigerants and their breakdown products with respect to persistence, biodegradation and toxicity, and global warming potential is needed to guide environmental regulations. This document aims to perform a critical review of the relevant scientific data on the most common refrigerants currently used, their degradation products, and their alternatives. Where available, estimates of precursor production quantities and existing environmental regulatory information are reviewed. Key data of interest for the evaluation include physicochemical properties, environmental fate parameters, ecological or human health toxicity/risk information, and GWP for compounds of interest.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2024

Critical Literature Review of Low Global Warming Potential (GWP) Refrigerants and their Environmental Impact

Refrigeration and air conditioning currently account for ~20% of the total electricity consumption in buildings around the world. Over the next three decades as global temperatures are projected to increase, urbanization and economic growth will lead to an increased demand for refrigeration and cooling. Most commonly used refrigerants belong to the five following classes: (i) chlorofluorocarbons, (ii) hydrochlorofluorocarbons, (iii) hydrofluorocarbons (HFCs), (iv) hydrofluoroolefins (HFOs), and (v) natural refrigerants. Over the past century, there have been shifts in which compounds were used for refrigeration to improve safety and durability, allow for ozone protection, and, most recently, to reduce global warming potential (GWP). Although technological advances have led to increased cooling capacity and safer refrigerants, emissions from refrigeration systems can affect the environment by contributing to greenhouse gas emissions or by depleting the ozone layer, depending on the gas emitted. The focus is increasingly on adopting compounds that are both efficient at cooling and effective for reducing emissions and other adverse environmental impacts. Because of policy and regulatory changes to avert ozone depletion and global climate change, much discussion has centered on the environmental impacts of next-generation refrigerants. Of particular interest are the fluorinated refrigerants, HFCs and HFOs, most of which are defined as per- and polyfluoroalkyl substances (PFAS) and their breakdown products (especially trifluoroacetic acid). The US Environmental Protection Agency in 2021 drafted a Strategic Roadmap for PFAS, which has already resulted in an increase in investment in research on these compounds and has restricted the release of PFAS into the environment through the implementation of monitoring and reporting requirements. A critical evaluation of fluorinated refrigerants and their breakdown products with respect to persistence, biodegradation and toxicity, and global warming potential is needed to guide environmental regulations. This document aims to perform a critical review of the relevant scientific data on the most common refrigerants currently used, their degradation products, and their alternatives. Where available, estimates of precursor production quantities and existing environmental regulatory information are reviewed. Key data of interest for the evaluation include physicochemical properties, environmental fate parameters, ecological or human health toxicity/risk information, and GWP for compounds of interest.

54 ENVIRONMENTAL SCIENCES↗
NASA NTRS1984

SMP: A solid modeling program

A prototype solid modeling program, SMP, developed by CSC for Langley Research Center (LaRC) is documented in this paper. The SMP software is employed by the System and Experiments Branch (SEB) of the Space Systems Division (SSD) for preliminary space station design, but is intended as a general purpose tool. The SMP document provides details concerning: the basic geometric modeling primitives and associated operators, the data representation scheme utilized to structure the geometric model, the available commands for both editing and displaying the solid model, the interactive user interface and the input/output interfaces to external software, and the utility of the package in the LaRC computing environment. The document is sufficiently detailed to serve both as a user's guide and reference manual.

Randall, D. P.↗
NASA NTRS2008

NASA/GE Highly-Loaded Turbine Research Program

An overview of the NASA/GE Highly-Loaded Turbine Research Program at the NASA Glenn Research Center is presented. The program is sponsored by the Subsonic Fixed Wing Project of the Fundamental Aeronautics Program. The goals of the turbine research program are presented along with their relationship to the higher-level program goals. Two turbine research programs are described; the highly-loaded, single-stage high pressure turbine (HPT) and the highly loaded low pressure turbine (LPT). The HPT program is centered on an extremely high pressure ratio single-stage turbine with an engine stage pressure ratio of 5.5. It was designed with a 33% increase in stage loading. It has shown performance levels 2 points better than current engines operating at the higher work level. Some advantages of the turbine include reduced weight and parts count. Optimization of the blade shape to reduce shock losses is described. The LPT program utilizes a four-stage low pressure turbine with an integral first stage vane/transition duct strut; counterrotation; low-solidity blading; fully optimized flowpath including vanes, blades, and endwalls; and a fluidically controlled turbine vane frame/exit guide vane. The implementation of the LPT into GE s and NASA s test facilities is described. A description of NASA s Single Spool Turbine Facility that is currently under renovation is given. The new, upgraded facility is compared to its predecessor. Renovation design requirements are outlined. Facility limits on pressures, temperatures, flow rates, rotational speeds, and power absorption are described. The current renovation status is given.

Giel, Paul W.↗
DOE OSTI2023

Quick Talk: Resilient Communities, Maryland

Groundswell, Inc., in partnership with the Maryland Energy Administration (MEA), Ayika Solutions, the National Renewable Energy Lab (NREL), and the Baltimore Office of Sustainability, is advancing a vision for resilient, community-centered energy systems in Maryland. This effort aligns with Groundswell's commitment to a clean energy economy that equitably benefits all communities, closing gaps in representation, wages, and access to wealth generation, savings, and local jobs within a diverse energy supply chain. Project Vision and Objectives The project emphasizes "energy resilience," defined as a community’s capacity to anticipate, adapt to, and swiftly recover from power disruptions through inclusive planning and technical solutions. The approach centers on Resilience Hubs—designated community facilities equipped to support residents before, during, and after power-related disruptions. These hubs offer emergency resources, coordinate communications, and deliver essential services while reducing carbon emissions, ultimately enhancing residents' quality of life. Additionally, Resilience Hubs foster social connections, support disaster preparedness, and provide spaces for community programming and everyday use. The goals of Resilient Communities Maryland include: Developing a replicable framework for community energy resilience, applicable beyond Maryland. Defining community-led indicators of social impact and resilience. Establishing equitable decision-making processes in project design and implementation. Informing MEA of practical, community-based resilience strategies to shape future state initiatives. Approach Groundswell and its partners prioritize collaborative engagement with local stakeholders, ensuring that solutions are responsive to each community's unique needs. By integrating feedback from residents, local organizations, and government entities, the team has developed a holistic model for resilience that balances immediate benefits, such as improved emergency response, with long-term gains in social equity and environmental sustainability. Key Outcomes This initiative has produced valuable resources and insights, including: A Community Energy Resilience Framework: Designed to guide other communities in establishing energy resilience strategies tailored to their specific needs. Case Studies: Documenting best practices and lessons learned from pilot projects to serve as models for future resilience efforts. Community-Driven Impact Metrics: Highlighting the positive social impacts that resilience initiatives can bring, such as improved social connectedness and local decision-making power. Recommendations for MEA: Offering evidence-based insights to inform policies and funding opportunities that support resilient energy infrastructure in vulnerable communities. Next Steps Groundswell's final report will detail findings, including the potential for scaling resilience hubs across Maryland and other regions, with a focus on equitable access and community-driven outcomes. This project underscores the importance of aligning energy resilience with social equity, reinforcing community agency, and building systems that withstand and recover from future challenges effectively and sustainably.

14 SOLAR ENERGY↗
NASA NTRS1987

Diagnostic emulation: Implementation and user's guide

The Diagnostic Emulation Technique was developed within the System Validation Methods Branch as a part of the development of methods for the analysis of the reliability of highly reliable, fault tolerant digital avionics systems. This is a general technique which allows for the emulation of a digital hardware system. The technique is general in the sense that it is completely independent of the particular target hardware which is being emulated. Parts of the system are described and emulated at the logic or gate level, while other parts of the system are described and emulated at the functional level. This algorithm allows for the insertion of faults into the system, and for the observation of the response of the system to these faults. This allows for controlled and accelerated testing of system reaction to hardware failures in the target machine. This document describes in detail how the algorithm was implemented at NASA Langley Research Center and gives instructions for using the system.

Becher, Bernice↗
DOE OSTI2026

Informing Robust Functional Relationship Benchmarks: An Evaluation of the Temperature Sensitivity of Ecosystem Respiration Across the Arctic-Boreal Region

During land model development, simulated carbon dynamics are often benchmarked against observational data sets to evaluate model performance. Functional relationship benchmarks are the relationship between a driving variable (e.g., temperature) and a response variable (e.g., ecosystem respiration) and are a promising tool for assessing model performance by evaluating modeled sensitivities to changing environmental conditions. However, observed functional relationships can be influenced by choices made during data collection and throughout the benchmarking process, impacting the inferred skill of land models. To avoid misrepresenting a model's true performance, it is necessary to systematically evaluate best practices when constructing functional relationship benchmarks. We developed a set of guidelines for constructing functional relationship benchmarks, considering the choice of data set, number of daily observations, temporal extent, and temporal resolution across Alaska and Canada over a 20-year period from 2001 to 2020. The temperature sensitivity of ecosystem respiration from observations, evaluated through an apparent Q 10 , is highly variable both spatially and as a result of the data processing approach applied in the benchmark formation. When benchmarking 13 models from the Warming Permafrost Model Intercomparison Project (WrPMIP), the range in inferred model skill is substantially impacted by the choices applied in constructing functional relationship benchmarks. The inferred performance of a given model is most sensitive to the number of daily observations and temporal extent, followed by choice of benchmark data set and temporal averaging. Results from this analysis can guide the development of consistent and robust functional relationships for future model evaluation studies.

Poe, Jeralyn [Northern Arizona University, Flagsta↗
DOE OSTI2021

An Economics-by-Design Approach Applied to a Heat Pipe Microreactor Concept

Microreactors present a potential paradigm shift in the nuclear industry. Emphasis thus far has been on large-scale multi-billion-dollar projects that cater solely to grid electricity market. These projects can be challenging to finance and execute. On the other hand, microreactors are intended to target a wide variety of smaller niche markets and are expected to be factory-fabricated and more readily deployable. While diseconomies of scale for microreactors may tend to raise their costs per energy output (MWh) relative to large nuclear plants, offsetting gains can be expected from standardization, simplification, passive safety, lower radionuclide inventories, factory fabrication, fast installation, and low financing costs. To adequately assess these contributions, designers should have a different perspective on cost drivers than for large nuclear plants and can utilize novel approaches for systematic cost reduction. To account for these important aspects of microreactors, this report proposes an economics-by-design approach that places economic considerations at the center of the design process. The methodology builds on existing frameworks such as design-to-cost and value engineering, expanding them to new markets (beyond the grid), new attributes (beyond costs alone), and introducing the approach at earlier points in the design cycle. Design parameters and technical specifications are systematically evaluated until costs meet market entry points, while also providing the high-priority performance attributes of the particular use case. Determining first-order estimates for different components early in the process enables designers to focus R&D efforts on the biggest overall cost contributors and components with the most cost uncertainty. The analysis is always guided by market needs and threshold prices. In addition to microreactors, the approach is expected to be useful for other classes of nuclear reactors as well. The analysis was applied to a concept found in the open literature (the Design A heat-pipe reactor). A comprehensive bottom-up estimate was generated by leveraging a new microreactor-specific code of accounts and a range of cost equations. The initial estimate for levelized cost of electricity (LCOE) unsurprisingly exceeded market ranges since the use case had prioritized technological readiness over economic considerations in design choices. An alternate concept was then proposed, with various assumptions/targets made to reduce the largest cost contributors. Changes in the neutron spectrum, the power output, and building structures were found to make even the first-of-a-kind of this modified concept competitive with diesel generation in some remote communities. Learning rate (LR) assumptions indicated cost reductions achieved from sequential unit deployments could expand the range of competitiveness to include additional markets as deployments proceed.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
NASA NTRS1982

Modification of Altitude Wind Tunnel for Icing and Propulsion Research Study, Part B

This report describes the results of an engineering study conducted for NASA-Lewis Research Center on Modifications to the Altitude Wind Tunnel (AWT) for Icing and Propulsion Research by DSW Engineering Corporation, Orlando, Florida and DSMA International Inc., Toronto, Canada. The engineering study referred to as study 'Part B' has been carried out under authorization of NASA Contract NAS 3-22933 (Ref. 1). The scope of work defined in the Statement of Work 3-169855 (Ref. 2) Revised 2/20/81 was discussed in detail with NASA on October 2, 1981 and covers the following areas: - Fan and Fan Housing. This includes assessment of circuit loss analyses, fan aerodynamics and mechanical conceptual design of variable and fixed pitch fans considering fixed and variable inlet guide vanes. - Fan Drive Systems - considering fixed and variable speed drives with continuous rating of 30,000 HP with overload capability of 45,000. The drive shaft between the motor and fan is to be considered and also the existing foundations for the main drive motor. - 20 ft.Test Section Arrangement - having slotted wall configurations suitable for testing at transonic velocities, with various model support systems required for the anticipated models and tests. A model handling concept aimed for high productivity testing and means for quick access to the model in the test section between test runs. - 45 ft. Test Section - feasible and practical approach for model installation and removal.

Leonard, H. Wayne↗
DOE OSTI2026

A simple Rice-Ashby ductile–brittle transition temperature (DBTT) model based on dislocation mobility for body-centered cubic complex concentrated alloys

A simple Rice-Ashby type model for ductile–brittle transition temperature (DBTT) of body-centered cubic (bcc) complex concentrated alloys (structures) is presented. The effect of accumulation of dislocation density on DBTT is also analyzed. The model results are compared with experimental yield stress vs. temperature data for four complex concentrated alloys: Nb 45 Ta 25 Ti 15 Hf 15 (NTTH), MoNbTaW, HfNbTaTiZr, NbTiZr and two pure bcc metals, Fe and W. It is shown that the DBTT behavior of these alloys and pure metals are in agreement with the simple ductility model presented in this manuscript. The DBTT model presented in this manuscript along with yield strength models for bcc complex concentrated alloys described in the literature should serve as a useful guide for designing such alloys with good high temperature strength and significant room temperature ductility.

Crack tip processes↗
NASA NTRS2003

Basic and Applied Materials Science Research Efforts at MSFC Germane to NASA Goals

Presently, a number of investigations are ongoing that blend basic research with engineering applications in support of NASA goals. These include (1) "Pore Formation and Mobility (PFMI) " An ISS Glovebox Investigation" NASA Selected Project - 400-34-3D; (2) "Interactions Between Rotating Bodies" Center Director's Discretionary Fund (CDDF) Project - 279-62-00-16; (3) "Molybdenum - Rhenium (Mo-Re) Alloys for Nuclear Fuel Containment" TD Collaboration - 800-11-02; (4) "Fabrication of Alumina - Metal Composites for Propulsion Components" ED Collaboration - 090-50-10; (5) "Radiation Shielding for Deep-Space Missions" SD Effort; (6) "Other Research". In brief, "Pore Formation and Mobility" is an experiment to be conducted in the ISS Microgravity Science Glovebox that will systematically investigate the development, movement, and interactions of bubbles (porosity) during the controlled directional solidification of a transparent material. In addition to promoting our general knowledge of porosity physics, this work will serve as a guide to future ISS experiments utilizing metal alloys. "Interactions Between Rotating Bodies" is a CDDF sponsored project that is critically examining, through theory and experiment, claims of "new" physics relating to gravity modification and electric field effects. "Molybdenum - Rhenium Alloys for Nuclear Fuel Containment" is a TD collaboration in support of nuclear propulsion. Mo-Re alloys are being evaluated and developed for nuclear fuel containment. "Fabrication of Alumina - Metal Composites for Propulsion Components" is an ED collaboration with the intent of increasing strength and decreasing weight of metal engine components through the incorporation of nanometer-sized alumina fibers. "Radiation Shielding for Deep-Space Missions" is an SD effort aimed at minimizing the health risk from radiation to human space voyagers; work to date has been primarily programmatic but experiments to develop hydrogen-rich materials for shielding are planned. "Other Research" includes: BUNDLE (Bridgman Unidirectional Dendrite in a Liquid Experiment) activities (primarily crucible development), vibrational float-zone processing (with Vanderbilt University), use of ultrasonics in materials processing (with UAH), rotational effects on microstructural development, and application of magnetic fields for mixing.

Source record↗
NASA NTRS2007

NASA/GE Highly-Loaded Turbine Research Program

An overview of the NASA/GE Highly-Loaded Turbine Research Program at the NASA Glenn Research Center is presented. The program is sponsored by the Subsonic Fixed Wing Project of the Fundamental Aeronautics Program. The goals of the turbine research program are presented along with their relationship to the higher-level program goals. Two turbine research programs are described; the highly-loaded, single-stage high pressure turbine (HPT) and the highly loaded low pressure turbine (LPT). The HPT program is centered on an extremely high pressure ratio single-stage turbine with an engine stage pressure ratio of 5.5. It was designed with a 33% increase in stage loading. It has shown performance levels 2 points better than current engines operating at the higher work level. Some advantages of the turbine include reduced weight and parts count. Optimization of the blade shape to reduce shock losses is described. The LPT program utilizes a four-stage low pressure turbine with an integral first stage vane/transition duct strut; counter-rotation; low-solidity blading; fully optimized flowpath including vanes, blades, and endwalls; and a fluidically controlled turbine vane frame/exit guide vane. The implementation of the LPT into GE s and NASA s test facilities is described. A description of NASA's Single Spool Turbine Facility that is currently under renovation is given. Facility limits on pressures, temperatures, flow rates, rotational speeds, and power absorption are described. The current renovation status is given.

Giel, Paul W.↗
NASA NTRS2012

Processing and Damage Tolerance of Continuous Carbon Fiber Composites Containing Puncture Self-Healing Thermoplastic Matrix

Research at NASA Langley Research Center (NASA LaRC) has identified several commercially available thermoplastic polymers that self-heal after ballistic impact and through-penetration. One of these resins, polybutadiene graft copolymer (PB(sub g)), was processed with unsized IM7 carbon fibers to fabricate reinforced composite material for further evaluation. Temperature dependent characteristics, such as the degradation point, glass transition (T(sub g)), and viscosity of the PBg polymer were characterized by thermogravimetric analysis (TGA), differential scanning calorimetry (DSC), and dynamic parallel plate rheology. The PBg resin was processed into approximately equal to 22.0 cm wide unidirectional prepreg tape in the NASA LaRC Advanced Composites Processing Research Laboratory. Data from polymer thermal characterization guided the determination of a processing cycle used to fabricate quasi-isotropic 32-ply laminate panels in various dimensions up to 30.5cm x 30.5cm in a vacuum press. The consolidation quality of these panels was analyzed by optical microscopy and acid digestion. The process cycle was further optimized based on these results and quasi-isotropic, [45/0/-45/90]4S, 15.24cm x 15.24cm laminate panels were fabricated for mechanical property characterization. The compression strength after impact (CAI) of the IM7/pBG composites was measured both before and after an elevated temperature and pressure healing cycle. The results of the processing development effort of this composite material as well as the results of the mechanical property characterization are presented in this paper.

Grimsley, Brian W.↗
NASA NTRS2019

Analysis of the Honeywell Uncertified Research Engine (HURE) with Ice Crystal Cloud Ingestion at Simulated Altitudes

The Honeywell Uncertified Research Engine (HURE), a research version of a turbofan engine that never entered production, was tested in the NASA Propulsion System Laboratory (PSL), an altitude test facility at the NASA Glenn Research Center. The PSL is a facility that is equipped with water spray bars capable of producing an ice cloud consisting of ice particles, having a controlled particle diameter and concentration in the air flow. To develop the test matrix of the HURE, numerical analysis of flow and ice particle thermodynamics was performed on the compression system of the turbofan engine to predict operating conditions that could potentially result in a risk of ice accretion due to ice crystal ingestion. The goal of the test matrix was to have ice accrete in two regions of the compression system: region one, which consists of the fan-stator through the inlet guide vane (IGV), and region two which is the first stator within the high pressure compressor. The predictive analyses were performed with the mean line compressor flow modeling code (COMDES-MELT) which includes an ice particle model. The HURE engine was tested in PSL with the ice cloud over the range of operating conditions of altitude, ambient temperature, simulated flight Mach number, and fan speed with guidance from the analytical predictions. The engine was fitted with video cameras at strategic locations within the engine compression system flow path where ice was predicted to accrete, in order to visually confirm ice accretion when it occurred. In addition, traditional compressor instrumentation such as total pressure and temperature probes, static pressure taps, and metal temperature thermocouples were installed in targeted areas where the risk of ice accretion was expected. The current research focuses on the analysis of the data that was obtained after testing the HURE engine in PSL with ice crystal ingestion. The computational method (COMDES-MELT) was enhanced by computing key parameters through the fan-stator at multiple span wise locations, in order to increase the fidelity with the current mean-line method. The Icing Wedge static wet bulb temperature thresholds were applicable for determining the risk of ice accretion in the fan-stator, which is thought to be an adiabatic region. At some operating conditions near the splitter-lip region, other sources of heat (non-adiabatic walls) were suspected to be the cause of accretion, and the Icing Wedge was not applicable to predict accretion at that location. A simple order-of-magnitude heat transfer model was implemented into the COMDES-MELT code to estimate the wall temperature minimum and maximum thresholds that support ice accretion, as observed by video confirmation. The results from this model spanned the range of wall temperatures measured on a previous engine that experienced ice accretion at certain operating conditions.

Veres, Joseph P.↗
NASA NTRS2019

Analysis of the Honeywell Uncertified Research Engine (HURE) with Ice Crystal Cloud Ingestion at Simulated Altitudes

The Honeywell Uncertified Research Engine (HURE), a research version of a turbofan engine that never entered production, was tested in the NASA Propulsion System Laboratory (PSL), an altitude test facility at the NASA Glenn Research Center. The PSL is a facility that is equipped with water spray bars capable of producing an ice cloud consisting of ice particles, having a controlled particle diameter and concentration in the air flow. To develop the test matrix of the HURE, numerical analysis of flow and ice particle thermodynamics was performed on the compression system of the turbofan engine to predict operating conditions that could potentially result in a risk of ice accretion due to ice crystal ingestion. The goal of the test matrix was to have ice accrete in two regions of the compression system: region one, which consists of the fan-stator through the inlet guide vane (IGV), and region two which is the first stator within the high pressure compressor. The predictive analyses were performed with the mean line compressor flow modeling code (COMDES-MELT) which includes an ice particle model. The HURE engine was tested in PSL with the ice cloud over the range of operating conditions of altitude, ambient temperature, simulated flight Mach number, and fan speed with guidance from the analytical predictions. The engine was fitted with video cameras at strategic locations within the engine compression system flow path where ice was predicted to accrete, in order to visually confirm ice accretion when it occurred. In addition, traditional compressor instrumentation such as total pressure and temperature probes, static pressure taps, and metal temperature thermocouples were installed in targeted areas where the risk of ice accretion was expected. The current research focuses on the analysis of the data that was obtained after testing the HURE engine in PSL with ice crystal ingestion. The computational method (COMDES-MELT) was enhanced by computing key parameters through the fan- stator at multiple span wise locations, in order to increase the fidelity with the current mean-line method. The Icing Wedge static wet bulb temperature thresholds were applicable for determining the risk of ice accretion in the fan-stator, which is thought to be an adiabatic region. At some operating conditions near the splitter-lip region, other sources of heat (non-adiabatic walls) were suspected to be the cause of accretion, and the Icing Wedge was not applicable to predict accretion at that location. A simple order-of-magnitude heat transfer model was implemented into the COMDES-MELT code to estimate the wall temperature minimum and maximum thresholds that support ice accretion, as observed by video confirmation. The results from this model spanned the range of wall temperatures measured on a previous engine that experienced ice accretion at certain operating conditions.

Veres, Joseph P.↗