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At least 1,099 records · Page 61

A Comparative Study of Direct and Indirect Additive Manufacturing Approaches for the Production of a Wind Energy Component

Additive manufacturing (AM) was developed in the 1980s to create three-dimensional prototypes through layer-wise approaches to fabrication. Since then, these approaches have seen improvements in both materials and processing technologies. To date, there are now 7 types of additive manufacturing processes and hundreds of materials, which can be directly printed – going directly from digital design to fabricated components. In this project, Oak Ridge National Laboratory (ORNL), Vestas Wind Systems, and The National Renewable Energy Laboratory (NREL) collaborated to evaluate the effectiveness of state-of-the-art large-scale AM processes in the production of a structural component for use in a wind turbine nacelle, through both direct and indirect manufacturing approaches. Here, experienced AM design engineers detail techniques for AM design, including topology optimization (TO), support minimization, reverse engineering, and techniques for mitigating poor interlaminar performance. Fabrication of the components is presented, including printing parameters and postprocessing, and followed with full-scale component testing by a 3rd party testing laboratory. To evaluate the potential of the developed approaches, a complete techno-economic analysis is provided which evaluates the cost of these techniques given current and near to long-term projections of AM system capabilities.

17 WIND ENERGY↗

National Rotor Testbed Requirements. Draft

This document serves both as a guide and a record for requirements management associated with design of retrofit rotors for the Sandia SWiFT turbines. The rotors will support a long-term experimental campaign. Data gathered during the campaign will support formal verification and validation of complex flow numerical models for prediction of metrics deemed important for wind energy plant efficiency. These integrated projects involve multiple years of effort, dozens of engineers and collaborators, and dozens of stakeholders in the form of the research community, National Lab staff, and DOE staff. Creating of formal, written requirements will ensure flow-down of activities from high-level goals, aid communication, and enable clear verification of activities. A custom requirements schema is created and described. Commercial requirements management software —IBM Rational DOORS—is used to organize the information and ensure traceability. This document serves as a record of the process as well as a record of the exported, detailed contents of the DOORS database.

17 WIND ENERGY↗

It's Indisputable: Five Facts About Planning and Operating Modern Power Systems

An indisputable fact cannot be rebutted. It is supported by theory and experience. Over the past 25 years, wind and solar generation has undergone dramatic growth, resulting in a variety of experiences that model the integration of wind and solar into the planning and operation of modern electric power systems. In this article, we bring together examples from Europe, North America, and Australia to identify five indisputable facts about planning and operating modern power systems. Taken together, we hope these experiences can help build consensus among the engineering and public policy communities about the current state of wind and solar integration and also facilitate conversations about evolving future challenges.

24 POWER TRANSMISSION AND DISTRIBUTION↗

Wind-US Simulations of the NASA 1507 Inlet Test Case

Steady-state, Reynolds-Averaged Navier-Stokes (RANS) computational fluid dynamics (CFD) simulations were performed of the NASA 1507 Inlet Test Case from the 6th AIAA Propulsion Aerodynamics Workshop (PAW) held in January 2023 using the Wind-US CFD solver. The simulations were performed with bleed regions modeled as surface patches and the Slater bleed boundary condition models were applied within those regions. Both the constant-plenum-pressure and the fixed-plenum-exit bleed models where applied. The vortex generators were modeled using the Bender-Anderson-Yagle (BAY) vortex generator model. The CFD simulations were performed for inlet engine-face flow ratios varying from supercritical to subcritical inlet operation until inlet unstart. The results of the CFD simulations were compared to wind-tunnel data which included boundary layer profiles, axial static pressure distributions, bleed rates, total pressure recovery performance curves, and engine-face total pressure rake profiles. The CFD simulations were able to match most of the boundary layer rake data near the geometric throat, but the boundary layers on the centerbody were thinner than indicated by the wind-tunnel data. For the supercritical CFD simulations, the engine-face flow ratio was at least 2% to 2.5% lower than indicated by the wind-tunnel data, but still consistent with the level of supercritical bleed. The engine-face flow rates of the wind-tunnel tests had an uncertainty of ±2% which could explain the differences. The supercritical engine-face flow rates of the wind-tunnel data indicated a 5% supercritical bleed rate rather than the reported 7.18% bleed rate. The CFD simulations were able to calculate the maximum total pressure recovery of pt2/pt = 0.907 as observed for the wind-tunnel data. The CFD simulations with the constant-pressure bleed model were able to obtain a much lower engine-face total pressure ratio than indicated by both the wind-tunnel data and the CFD simulations using a fixed-plenum-exit bleed model. The CFD simulations indicated a sharp static pressure rise for the terminal shock rather than a more gradual rise indicated by the wind-tunnel data. The CFD simulations were not able to accurately compute the total pressure variation across the engine-face total pressure rake.

Supersonics↗

Preliminary Evaluation of Turbine Performance with Variable-Area Turbine Nozzles in a Turbojet Engine

The performance of a two-stage turbine with variable-area first-stage turbine nozzles was determined in the NACA Lewis altitude wind tunnel over a range of simulated altitudes from 15,000 to 44,000 feet and engine speeds from 50 to 100 percent of rated speed. The variable-area turbine nozzles used in this investigation were primarily a test device for compressor research purposes and were not necessarily of optimum aerodynamic design. The results of this investigation are indicative of effects of turbine-nozzle-area variation on turbine performance within the operating range allowed by the engine. The variable-area turbine nozzles were found to be mechanically reliable and to have negligible leakage losses. Increasing the turbine-nozzle-throat area from 1.15 to 1.67 square feet increased the corrected turbine gas flow or effective turbine nozzle area about 10 percent. At a given corrected turbine speed and turbine pressure ratio, changing the turbine nozzle area from 1.30 to 1. 67 square feet lowered the turbine efficiency 3 or 4 percent. The effect of increasing the turbine nozzle area from 1.15 to 1.67 square feet (decreasing the turning angle about 7 1/2 degrees) would be to lower the turbine efficiency about 5 or 6 percent.

Campbell, Carl E.↗

Experimental Investigation of Concrete Fatigue in Axial Compression

The use of concrete in fatigue critical structures, such as wind turbine towers, has necessitated the replacement of simplistic (and therefore insufficient) fatigue design recommendations with more accurate and advanced fatigue models that can consider a greater complexity of stress states and materials. As the first part of a multistage test series, an experimental investigation was conducted to determine the fatigue life of concrete subjected to axial compressive fatigue loading, focusing on the relatively high-cycle fatigue domain. Here, a wide range of values for maximum stress levels and stress ratios were considered. The experimental results were compared against existing predictive models, and the most applicable model was identified. Concrete strain and stiffness behavior during fatigue loading were also investigated and reported. Based on the observed behavior, a hypothesis for identifying the impending occurrence of fatigue failure, based on the monotonic stress-strain curve, is examined.

17 WIND ENERGY↗

Differential elevon effectiveness lateral control optimization and elevon hinge moment investigation on a 0.015 scale space shuttle orbiter model 49-0 (140A/B/C modified) in the AECD VKF wind tunnel A (0A115)

Experimental aerodynamic investigations were conducted in the Arnold Engineering Development Center (AEDC) Von Karman Facility Tunnel A on a scale model of the space shuttle orbiter. The objectives of this test were: (1) determine supersonic differential elevon/aileron lateral control optimization, (2) determine supersonic elevon hinge moments, (3) determine the supersonic effects of the new baseline 6-inch elevon/elevon and elevon/fuselage gaps, and 4) determine the supersonic effects of the new short (VL70-008410) OMS pods. Six-component aerodynamic force, moment, and elevon hinge moment data were recorded.

Esparza, V.↗

Some considerations on the integration of engine nacelles into low-boom aircraft concepts

A study of wind-tunnel data has shown why unexpected strong shock waves appeared in wind tunnel pressure signatures of two low-boom models, and has indicated that changes to the current methods for analyzing and designing low-boom aircraft are needed. The discussion provided corrections for the interface lift code, and suggested methods of treatment for the equivalent areas of the aircraft, especially the nacelles and the interference lift, which were to be used in the aircraft design and the sonic boom analysis.

Mack, Robert J.↗

Design and Development of a Deep Acoustic Lining for the 40-by 80-Foot Wind Tunnel Test Section

The work described in this report has made effective use of design teams to build a state-of-the-art anechoic wind-tunnel facility. Many potential design solutions were evaluated using engineering analysis, and computational tools. Design alternatives were then evaluated using specially developed testing techniques, Large-scale coupon testing was then performed to develop confidence that the preferred design would meet the acoustic, aerodynamic, and structural objectives of the project. Finally, designs were frozen and the final product was installed in the wind tunnel. The result of this technically ambitious project has been the creation of a unique acoustic wind tunnel. Its large test section (39 ft x 79 ft x SO ft), potentially near-anechoic environment, and medium subsonic speed capability (M = 0.45) will support a full range of aeroacoustic testing-from rotorcraft and other vertical takeoff and landing aircraft to the take-off/landing configurations of both subsonic and supersonic transports.

Soderman, Paul T.↗

Space Launch System Booster Separation Aerodynamic Database Development and Uncertainty Quantification

The development of the aerodynamic database for the Space Launch System (SLS) booster separation environment has presented many challenges because of the complex physics of the ow around three independent bodies due to proximity e ects and jet inter- actions from the booster separation motors and the core stage engines. This aerodynamic environment is dicult to simulate in a wind tunnel experiment and also dicult to simu- late with computational uid dynamics. The database is further complicated by the high dimensionality of the independent variable space, which includes the orientation of the core stage, the relative positions and orientations of the solid rocket boosters, and the thrust lev- els of the various engines. Moreover, the clearance between the core stage and the boosters during the separation event is sensitive to the aerodynamic uncertainties of the database. This paper will present the development process for Version 3 of the SLS booster separa- tion aerodynamic database and the statistics-based uncertainty quanti cation process for the database.

Chan, David T.↗

An Obscured, Seyfert 2-like State of the Stellar-mass Black Hole GRS 1915+105 Caused by Failed Disk Winds

We report on Chandra grating spectra of the stellar-mass black hole GRS 1915+105 obtained during a novel, highly obscured state. As the source entered this state, a dense, massive accretion disk wind was detected through strong absorption lines. Photoionization modeling indicates that it must originate close to the central engine, orders of magnitude from the outer accretion disk. Strong, nearly sinusoidal flux variability in this phase yielded a key insight: the wind is blueshifted when its column density is relatively low, but redshifted as it approaches the Compton-thick threshold. At no point does the wind appear to achieve the local escape velocity; in this sense, it is a “failed wind.” Later observations suggest that the disk ultimately fails to keep even the central engine clear of gas, leading to heavily obscured and Compton-thick states characterized by very strong Fe K emission lines. Indeed, these later spectra are successfully described using models developed for obscured active galactic nuclei (AGNs). We discuss our results in terms of the remarkable similarity of GRS 1915+105 deep in its “obscured state” to Seyfert 2 and Compton-thick AGNs, and we explore how our understanding of accretion and obscuration in massive black holes is impacted by our observations.

Black holes↗

Increased power gains from wake steering control using preview wind direction information

Abstract. Yaw controllers typically rely on measurements taken at the wind turbine, resulting in a slow reaction to wind direction changes and subsequent power losses due to misalignments. Delayed yaw action is especially problematic in wake steering operation because it can result in power losses when the yaw misalignment angle deviates from the intended one due to a changing wind direction. This study explores the use of preview wind direction information for wake steering control in a two-turbine setup with a wind speed in the partial load range. For these conditions and a simple yaw controller, results from an engineering model identify an optimum preview time of 90 s. These results are validated by forcing wind direction changes in a large-eddy simulation model. For a set of six simulations with large wind direction changes, the average power gain from wake steering increases from only 0.44 % to 1.32 %. For a second set of six simulations with smaller wind direction changes, the average power gain from wake steering increases from 1.24 % to 1.85 %. Low-frequency fluctuations are shown to have a larger impact on the performance of wake steering and the effectiveness of preview control, in particular, than high-frequency fluctuations. From these results, it is concluded that the benefit of preview wind direction control for wake steering is substantial, making it a topic worth pursuing in future work.

17 WIND ENERGY↗

Charactarization of Thermal Protection Systems

In 2012, NASA's mission of landing the Mars Science Laboratory (MSL) on Mars was successful. MSL was protected by an ablative heatshield of tiled low density material known as PICA (phenolic impregnated carbon ablator). The heatshield was instrumented with MEDLI (MSL Entry Descent Landing Instrument) a suite of sensors & thermocouples at discrete locations in order to monitor the in-depth ablator temperature response and surface pressure. MEDLI was designed and developed by NASA Langley, in partnership with NASA Ames Research Center for the purposes of probing Mars and evaluating the performance of the spacecraft upon entry into the Martian atmosphere. The flight data reduces the uncertainty in engineer models for predicting the response of a spacecraft towards the extreme heating environment of an entry into the Martian atmosphere. MEDLI2 is a part of the Mars 2020 mission and is the next-generation sensor suite for entry, descent, and landing. This data will again help engineers validate their flight models. Additionally, the atmospheric data, can help us understand atmospheric density and winds. This is a critical study for reducing risks to both robotic and future human missions to Mars. Engineered models for Mars 2020 are dependent upon parameters related to the materials response to heating and radiation. In this work, the thermal properties and other measurements of various ablative materials are analyzed to achieve greater utility of the 2012 MEDLI flight data and more accurately determine the parameters being used in Mars 2020. The purpose of this study was to measure specific heat, thermal conductivity, char yield, reflectance as a function of wavelength, and other thermal parameters and optical properties of various ablative materials. CO2(g) at extreme temperatures emits radiation impacting MEDLI2 flight predictions. Emissivity & absorptivity as a function of temperature were calculated from FTIR and UV-Vis data as a means of investigating whether these materials might absorb CO2 radiation upon entry into the Mars atmosphere.

HEEET↗

The Mod-2 wind turbine development project

A major phase of the Federal Wind Energy Program, the Mod-2 wind turbine, a second-generation machine developed by the Boeing Engineering and Construction Co. for the U.S. Department of Energy and the Lewis Research Center of the National Aeronautics and Space Administration, is described. The Mod-2 is a large (2.5-MW power rating) horizontal-axis wind turbine designed for the generation of electrical power on utility networks. Three machines were built and are located in a cluster at Goodnoe Hills, Washington. All technical aspects of the project are described: design approach, significant innovation features, the mechanical system, the electrical power system, the control system, and the safety system.

Linscott, B. S.↗