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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 109 records · Page 6
All sourcesNASA NTRSDOE OSTI
DOE OSTI2023

Radial turbine rotor with complex cooling channels and method of making same

A turbine rotor includes a base and a plurality of blades. The base and the blades curve such that radially outward portions of the base and the blades extend in a direction with a greater component in a radial direction than in an axial direction. Radially central portions of the base and the blade extend in a direction with the two components being closer. Radially inner sections of the base and the blades extend in a direction with a greater component in the axial direction than in a radial direction. There is a cooling channel arrangement in the turbine rotor. The cooling channel arrangement includes impingement cooling for a nose and serpentine passages for cooling sections of the platform circumferentially intermediate the blades, and distinct serpentine passages for cooling the plurality of blades. A turbomachine and method are also disclosed.

Dai, Zhongtao↗
DOE OSTI2021

Doppler effect in rotating systems and Mössbauer rotor experiments

We address once more the problem of the physical interpretation of the Mössbauer effect in a rotating system in the view of the recently discovered extra energy shift (EES) between emitted and absorbed resonant radiation, which emerges in addition to the usual second order Doppler shift for an orbiting absorber. We highlight that both fractional components of the total energy shift have the same sign and correspond to the blueshift of the resonant radiation propagating from the rotational axis to the rotor rim. We indicate a possible way of understanding the origin of the EES in terms of combining metric effects in rotating systems with the quantum mechanical description of resonant nuclei confined in crystal cells by taking into account the recoil-free essence of the Mössbauer effect, where no energy is transmitted to the source (absorber) during the emission (absorption) of resonant radiation.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Additively manufactured and cast high-temperature aluminum alloys for electric vehicle brake rotor application

Electric vehicle brake rotors demand lightweight, high thermal conductivity materials with good resistance to wear, creep, salt corrosion, and thermal fade, all of which present challenges to the traditionally used cast iron. In this work, we investigated the braking performance of recently developed high-temperature aluminum alloys in both cast and 3D printed forms, that possess excellent microstructural and mechanical stability at elevated temperatures. Three aluminum alloys, Al-6Cu-Mn-Zr, Al-9Cu-Mn-Zr, and Al-Ce-Ni-Mn-Zr and a reference cast iron were tested on a sub-scale brake tester against a commercial brake pad material over a range of sliding speeds between 2 and 15 m/s. The performance of these alloys was evaluated for wear resistance, friction behavior, temperature elevation, and surface morphological change. Although all three candidate alloys had lower wear-resistance than cast iron, Al-Ce-Ni-Mn-Zr showed a significantly reduced wear rate in comparison to the Al-Cu-Mn-Zr alloys. Moreover, Al-Ce-Ni-Mn-Zr alloy had the most consistent friction behavior at all sliding speeds and good fade resistance, as the coefficient of friction did not dramatically decrease with temperature rise but stayed within a desirable range of 0.35–0.50 instead. The superior wear resistance and braking performance of the Al-Ce-Ni-Mn-Zr alloy were attributed to its higher hardness, and high temperature yield strength and creep resistance compared with the Al-Cu-Mn-Zr alloys. In conclusion, the results suggest that the braking performance of these aluminum alloys could be further enhanced by increasing the hardness and forming a more stable transfer layer on the sliding surface.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Emission Control from Transition Metal Dichalcogenide Monolayers by Aggregation-Induced Molecular Rotors

Organic–inorganic (O–I) heterostructures, consisting of atomically thin inorganic semiconductors and organic molecules, present synergistic and enhanced optoelectronic properties with a high tunability. Here, we develop a class of air-stable vertical O–I heterostructures comprising a monolayer of transition-metal dichalcogenides (TMDs), including WS 2 , WSe 2 , and MoSe 2 , on top of tetraphenylethylene (TPE) core-based aggregation-induced emission (AIE) molecular rotors. The created O–I heterostructures yields a photoluminescence (PL) enhancement of up to ~950%, ~500%, and ~330% in the top monolayer WS 2 , MoSe 2 , and WSe 2 as compared to PL in their pristine monolayers, respectively. The strong PL enhancement is mainly attributed to the efficient photogenerated carrier process in the AIE luminogens (courtesy of their restricted intermolecular motions in the solid state) and the charge-transfer process in the created type I O–I heterostructures. Moreover, we observe an improvement in photovoltaic properties of the TMDs in the heterostructures including the quasi-Fermi level splitting, minority carrier lifetime, and light absorption. Overall, this work presents an inspiring example of combining stable, highly luminescent AIE-based molecules, with rich photochemistry and versatile applications, with atomically thin inorganic semiconductors for multifunctional and efficient optoelectronic devices.

14 SOLAR ENERGY↗
DOE OSTI2020

Bat Impact Minimization Technology: An Improved Bat Deterrent for the Full Swept Rotor Area of Any Wind Turbine

The growth in the number of wind turbine generators has led to a significant number of fatal interactions with bat species. The need to reduce the number of bat fatalities while minimizing power losses is the greatest conservation challenge for wind energy development in parts of the country, according to the American Wind Wildlife Institute. Technological solutions that can also allow turbines to operate normally would generate the maximum electricity and avoid financial losses. Bats use echolocation to perceive their surroundings by listening to features of echoes from their high frequency vocal signals reflecting from targets. In this project, Frontier Wind built on previous research demonstrating that ultrasonic noise can mask echolocation and act as a repellent or deterrent to bat flight activity. Whereas the initial study only broadcast ultrasonic transmissions from the center of the turbine, the Strike Free™ system developed for this project extended the ultrasonic coverage to the entire area swept by the turbine blades. Frontier Wind designed the system components and their integration and then tested them in the lab and in the field at Pattern Energy’s Hatchet Ridge Wind Facility near Redding, California. The researchers used an acoustic model to determine the optimal configuration of transmitters along the blades to provide sound transmission coverage across the turbine rotor swept area volume. The custom ultrasonic transmitters were designed specifically for the echolocation frequencies of the four main bat species that have been shown to have died at Hatchet Ridge, although the transmitters can be customized for different frequencies as needed in other geographic locations. The Strike Free™ system shows promise for reducing bat fatalities, and the path to commercialization requires further testing to validate and optimize performance in the field.

17 WIND ENERGY↗
DOE OSTI2021

Laboratory Wind Turbine Blade Static Testing of the Sandia National Rotor Testbed 13-Meter Wind Turbine Blade

The Sandia National Laboratories (SNL or Sandia) National Rotor Testbed (NRT) blade is a new design for experimental research and development at the Sandia Scaled Wind Farm Technology (SWiFT) facility, located at Texas Tech University’s National Wind Institute Research Center in Lubbock, TX. Four NRT blades were manufactured, with three blades for operation at the SWiFT facility, and one blade intended for structural validation. A series of structural validation tests including property testing, static strength testing, and fatigue testing were performed at the National Renewable Energy Laboratory (NREL). This report documents the static and fatigue load cases applied to the NRT blade.

17 WIND ENERGY↗
DOE OSTI2022

Land-based wind turbines with flexible rail-transportable blades – Part 2: 3D finite element design optimization of the rotor blades

Abstract. Increasing growth in land-based wind turbine blades to enable higher machine capacities and capacity factors is creating challenges in design, manufacturing, logistics, and operation. Enabling further blade growth will require technology innovation. An emerging solution to overcome logistics constraints is to segment the blades spanwise and chordwise, which is effective, but the additional field-assembled joints result in added mass and loads, as well as increased reliability concerns in operation. An alternative to this methodology is to design slender flexible blades that can be shipped on rail lines by flexing during transport. However, the increased flexibility is challenging to accommodate with a typical glass-fiber, upwind design. In a two-part paper series, several design options are evaluated to enable slender flexible blades: downwind machines, optimized carbon fiber, and active aerodynamic controls. Part 1 presents the system-level optimization of the rotor variants as compared to conventional and segmented baselines, with a low-fidelity representation of the blades. The present work, Part 2, supplements the system-level optimization in Part 1 with high-fidelity blade structural optimization to ensure that the designs are at feasible optima with respect to material strength and fatigue limits, as well as global stability and structural dynamics constraints. To accommodate the requirements of the design process, a new version of the Numerical Manufacturing And Design (NuMAD) code has been developed and released. The code now supports laminate-level blade optimization and an interface to the International Energy Agency Wind Task 37 blade ontology. Transporting long, flexible blades via controlled flapwise bending is found to be a viable approach for blades of up to 100 m. The results confirm that blade mass can be substantially reduced by going either to a downwind design or to a highly coned and tilted upwind design. A discussion of active and inactive constraints consisting of material rupture, fatigue damage, buckling, deflection, and resonant frequencies is presented. An analysis of driving load cases revealed that the downwind designs are dominated by loads from sudden, abrupt events like gusts rather than fatigue. Finally, an analysis of carbon fiber spar caps for downwind machines finds that, compared to typical carbon fibers, the use of a new heavy-tow carbon fiber in the spar caps is found to yield between 9 % and 13 % cost savings.

17 WIND ENERGY↗
DOE OSTI2022

Physics-informed Bayesian machine learning case study: Integral blade rotors

This paper provides a physics-informed Bayesian machine learning (PIBML) description and case study. The PIBML approach applies three physics-based models to establish the initial beliefs before testing to determine the probability of milling stability (or prior). These include: receptance coupling substructure analysis (RCSA) prediction for the tool tip frequency response functions; finite element software prediction of the mechanistic force model coefficients; and a spindle speed-dependent power law model for process damping. Testing was then performed to identify optimal stable machining conditions using an expected improvement in material removal rate criterion. The prior probability of stability was updated using the test results to determine the posterior probability of stability. The test results were compared to the parameter recommendations provided by the endmill manufacturer. A demonstration integral blade rotor was machined at the optimal stable machining conditions for 304 stainless steel and 6061-T6 aluminum. Finally, the disagreement between manufacturer recommendations and milling performance in both materials tested emphasizes the need for broad implementation of PIBML approaches to increase machining productivity and efficiency.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
DOE OSTI2024

Tribological behavior of hybrid Aluminum-TiB 2 metal matrix composites for brake rotor applications

Here, this research investigates the feasibility of hybrid aluminum metal matrix composites (MMC) incorporating TiB 2 particles for brake rotor applications. The composites were produced by incorporating both in-situ, submicron-sized TiB 2 particles and regular micron-sized TiB 2 powders via stir and squeeze casting techniques into A206 aluminum alloy matrix. Systematic adjustments in the fractions of in-situ and ex-situ TiB 2 particles were conducted to evaluate their impact on wear behavior and mechanisms. Combination of both particle types allowed composites with up to 10 vol% of reinforcements. Composites with higher proportions of ex-situ particles demonstrated increased wear resistance compared to those solely composed of in-situ particles, control specimens without TiB 2 , and conventional cast iron counterparts. The lowest wear rate for the hybrid composites sliding against phenolic brake pads was 1.1 × 10 -5 mm 3 /Nm, signifying a 3-fold reduction relative to cast iron sliding against the same pads. Wear analysis elucidated distinctive mechanisms within the hybrid composites, characterized by mild fragmented abrasive wear, adhesive wear, and plastic deformation, accompanied by the formation of an intermixed tribo-oxide layer.

42 ENGINEERING↗
DOE OSTI2021

Active Thermochemical Tables: the thermophysical and thermochemical properties of methyl, CH 3 , and methylene, CH 2 , corrected for nonrigid rotor and anharmonic oscillator effects

The thermophysical properties (isobaric heat capacity, entropy, enthalpy increment) of two prominent radicals, methyl, CH 3 , and methylene, CH 2 , were computed using the Nonrigid Rotor Anharmonic Oscillator (NRRAO) approach and compared to their RRHO counterparts, demonstrating significant differences between the results from the two approaches. Methylene presents a typical case in which the NRRAO thermophysical properties have significantly higher values than their RRHO counterparts at higher temperatures. In the case of methyl, the positive anharmonicity of the umbrella motion causes an opposite effect, and the NRRAO corrected thermophysical properties have lower values than their RRHO counterparts. The NRRAO corrected thermophysical properties, in turn, affect the resulting thermochemical properties. Here, two reactions important in combustion modelling were tested: the recombination of methyl radical with hydrogen atoms to form methane, and the recombination of two methyl radicals to form ethane. The related NRRAO equilibrium constants differ significantly from their RRHO analogs, and the consequences for chemical modelling are discussed. Also reported are the most current ATcT enthalpies of formation for CH n (n = 4-0) species and for C 2 H 6 , together with the tightly related sequential bond dissociation enthalpies along with the CHn series.

74 ATOMIC AND MOLECULAR PHYSICS↗
DOE OSTI2023

Mott insulators in moiré transition metal dichalcogenides at fractional fillings: Slave-rotor mean-field theory

In this study, we study a slave-rotor mean-field theory of an extended Hubbard model, applicable to transition metal dichalcogenide moiré systems, that captures both the formation of Wigner crystals as well as exotic spin states on top of these charge backgrounds. Phase diagrams are mapped out for different choices of long-range Coulomb repulsion strength, reproducing several experimentally found Wigner crystal states. Assuming unbroken time-reversal symmetry, we find several spin-liquid states as well as dimer states at fractional fillings. While spin dimer states are always found to have the lowest mean-field energy, several spin-liquid states are energetically competitive and may be stabilized by including gauge fluctuations or further interaction terms. We further discuss possible experimental signatures of these states pertinent to two-dimensional moiré heterostructures.

Charge order↗
DOE OSTI2024

Bulk viscosity of the rigid rotor one-component plasma

Bulk viscosity of a plasma consisting of strongly coupled diatomic ions is computed using molecular dynamics simulations. The simulations are based on the rigid rotor one-component plasma, which is introduced as a model system that adds two degrees of molecular rotation to the traditional one-component plasma. It is characterized by two parameters: the Coulomb coupling parameter, Γ, and the bond length parameter, Ω. Results show that the long-range nature of the Coulomb potential can lead to long rotational relaxation times, which in turn yield large values for bulk viscosity. Here, the bulk-to-shear viscosity ratio is found to span from small to large values depending on the values of Γ and Ω. Although bulk viscosity is often neglected in plasma modeling, these results motivate that it can be large in molecular plasmas with rotational degrees of freedom.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2021

Evaluating the Effects of Transient Purge Flow on Stator-Rotor Seal Performance

Abstract As modern engine designs target higher efficiencies through increased turbine inlet temperatures, critical turbine components are at increased risk of damage from conditions exceeding material melting temperatures. In particular, improperly designed underplatform hardware components are susceptible to damage when hot main gas path flow is ingested into the stator-rotor cavity. While all turbines inherently experience transients during operation, a majority of publicly available turbine studies have been executed using steady operating conditions or inherently transient “blowdown” rigs. For this reason, routine transient events are not well understood. To address this need, the present study utilized a combined experimental and computational approach. The test article is a continuous-duration, one-stage test turbine operating with true-scale engine hardware and seal geometries at engine-representative flow conditions. The nature of the continuous-duration facility uniquely supports the direct assessment of transient events through its ability to transition between steady-state operating conditions. The effects of a transient purge flow were investigated in this study to identify general trends for transient events in a full-scale engine. Results from multiple measurement techniques in the wheelspace region show an interdependence of transient purge flow with a thermal lag of the underplatform hardware. Through experiments conducted at different coolant-to-main gas path temperature ratios, the use of pressure measurements as an indicator of fully purged behavior was introduced, and a thermally driven influence on rim seal performance was quantified. The computational results show good agreement with experimental pressure measurements and provide insight into the physical mechanisms that drive the relationship between pressure and sealing effectiveness measurements observed for the tested geometry.

Engineering↗
DOE OSTI2021

Big Adaptive Rotor Phase I Final Report

The Big Adaptive Rotor (BAR) project was initiated by the U.S. Department of Energy (DOE) in 2018 with the goal of identifying novel technologies that can enable large (>100 meter [m]) blades for low-specific-power wind turbines. Five distinct tasks were completed to achieve this goal: 1. Assessed the trends, impacts, and value of low-specific-power wind turbines; 2. Developed a wind turbine blade cost-reduction road map study; 3. Completed research-and-development opportunity screening; 4. Performed detailed design and analysis; and, 5. Assessed low-cost carbon fiber. These tasks were completed by the national laboratory team consisting of Sandia National Laboratories (Sandia), the National Renewable Energy Laboratory (NREL), and Lawrence Berkeley National Laboratory.

17 WIND ENERGY↗
DOE OSTI2020

Manufacturing Hybrid Copper-Aluminum Rotors for High Power Induction and Permanent Magnet Electric Motors: CRADA 475 [Abstract only]

General Motors Research & Development (GM R&D) and Pacific Northwest National Laboratory (PNNL) will develop an electric rotor manufacturing technology with the potential of making electric motors lighters and more efficient. This will be achieved by developing a solid phase joining method to effectively join the Copper shorting bars to Aluminum end cap.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2020

Wind Turbine Rotor Design Optimization Using Importance Sampling: Preprint

Probabilistic methods are commonly adopted to estimate both ultimate and fatigue loads in wind turbines, and multiple papers have presented a variety of approaches. In contrast, system-level, integrated design optimization methods for wind turbines have so far relied on deterministic methods to estimate loads and deflections. This work aims at addressing this gap by adopting importance sampling to estimate ultimate blade deflection for use within a rotor design optimization. A comparison between the results of this approach against traditional approaches using deterministic load evaluations show that the probabilistic approach is more conservative and that the solutions found with deterministic approaches violate the probabilistic constraint on tip deflection between 13% and 17%. This highlights the importance of accurate load and deflection estimates and demonstrates that probabilistic approaches can be successfully integrated within a wind turbine design process despite the higher computational costs.

17 WIND ENERGY↗
DOE OSTI2024

Wind Turbine Water Setbacks: Ordinances (2022) and Extrapolated Trends, 115 Hub Height 170 Rotor Diameter

This dataset represents wind energy setback requirements from water based on existing county ordinances as of April 2022. A setback requirement is a minimum distance from water that an energy project may be developed, and these varied widely across the counties in which they existed. Two versions are provided: one reflecting only the county ordinances and another incorporating extrapolated trends. In the extrapolated version, a median setback equivalent to 1.1 times the turbine tip-height was applied in counties that lacked specific water setback regulations. A TIF data file and a PNG map of the data are provided for both versions, showing areas where wind energy is prohibited or permitted across the contiguous United States. The turbine parameters used were a hub-height of 115 meters and a rotor diameter of 170 meters, as obtained from the Annual Technology Baseline (ATB) 2022. For further details and citation, please refer to the publication linked below: Lopez, Anthony, Pavlo Pinchuk, Michael Gleason, Wesley Cole, Trieu Mai, Travis Williams, Owen Roberts, Marie Rivers, Mike Bannister, Sophie-Min Thomson, Gabe Zuckerman, and Brian Sergi. 2024. Solar Photovoltaics and Land-Based Wind Technical Potential and Supply Curves for the Contiguous United States: 2023 Edition. Golden, CO: National Renewable Energy Laboratory. NREL/TP-6A20-87843.

Array↗
DOE OSTI2024

Wind Turbine Transmission Setbacks: Ordinances (2022) and Extrapolated Trends, 115 Hub Height 170 Rotor Diameter

This dataset represents wind energy setback requirements from transmission based on existing county ordinances as of April 2022. A setback requirement is a minimum distance from transmission infrastructure that an energy project may be developed, and these varied widely across the counties in which they existed. Two versions are provided: one reflecting only the county ordinances and another incorporating extrapolated trends. In the extrapolated version, a median setback equivalent to 1.1 times the turbine tip-height was applied in counties that lacked specific transmission setback regulations. A TIF data file and a PNG map of the data are provided for both versions, showing areas where wind energy is prohibited or permitted across the contiguous United States. The turbine parameters used were a hub-height of 115 meters and a rotor diameter of 170 meters, as obtained from the Annual Technology Baseline (ATB) 2022. For further details and citation, please refer to the publication linked below: Lopez, Anthony, Pavlo Pinchuk, Michael Gleason, Wesley Cole, Trieu Mai, Travis Williams, Owen Roberts, Marie Rivers, Mike Bannister, Sophie-Min Thomson, Gabe Zuckerman, and Brian Sergi. 2024. Solar Photovoltaics and Land-Based Wind Technical Potential and Supply Curves for the Contiguous United States: 2023 Edition. Golden, CO: National Renewable Energy Laboratory. NREL/TP-6A20-87843.

Array↗