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At least 1,225 records · Page 68

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DOE OSTI2024

UHT-CAMANCHE: Ultra-High Temperature Ceramic Additively Manufactured Compact Heat Exchangers

The conceptual basis for this project is the convergence of advanced ultra-high temperature ceramic materials and additive manufacturing technologies to produce compact ceramic heat exchangers with complex internal flow path geometries. Task areas were broadly divided into materials and manufacturing development, heat exchanger design, component testing, and techno-economic analysis. Technical challenges included the design and commissioning of new test facilities, improving feature resolution and deposition rate of ceramic additive manufacturing techniques, establishing process-structure-property relationships in additively manufactured ultra-high temperature ceramics, and assessing high temperature materials compatibility in CO 2 environments. The primary candidate material evaluated in this work is a composite comprising zirconium diboride (ZrB2) with 30 vol. % silicon carbide (SiC) which was selected based on its desirable combination of high temperature mechanical properties, high thermal and electrical conductivities, and oxidation resistance. High solids loaded ZrB2-SiC pastes suitable for extrusion-based additive manufacturing were developed for the first time as part of this work. Materials compatibility studies indicate this material oxidizes in CO 2 to form a protective borosilicate scale which transforms to pure silica above 1000°C. Parts made by additive manufacturing displayed enlarged grain sizes produced by pressureless sintering as compared to hot-press sintering. Increases in microstructural coarseness have outsized effect on oxidation performance up to 1400°C due to incomplete oxidation of coarse large diameter SiC particles resulting in lower amounts of silica that apparently inhibit protective scale formation. Additive manufacturing as a forming technique did not appear to significantly affect thermal conductivity, hardness, or elastic modulus, though flexural strength was reduced by half or more as compared to traditionally hot-pressed materials. This effect was attributed to the presence of strength-limiting flaws (ca. 40 microns in size) originating from extrudate inhomogeneities that could potentially be eliminated with further process improvements. Attempts to attain economies of scale for production of multi-kilowatt scale heat exchangers by ceramic additive manufacturing proved difficult. Lack of automation and a modest extrusion rate while retaining fine feature resolution made the overall process labor intensive and limited experimental throughput. A number of full-scale components were taken through post-process heat treatments including drying, binder burnout, and sintering; however, none survived without significant flaws or cracks. Therefore, no operational data from a newly installed heat exchanger test loop were able to be obtained during the performance period. Continued research and development is recommended to improve economic feasibility of ceramic additive manufacturing by standardizing the use of advanced sensors, artificial intelligence, and automation tools to reduce associated labor costs and accelerate production rates. The materials and manufacturing techniques demonstrated in this work are likely to find applications in defense and energy applications.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2024

Statistically Resolved Planetary Boundary Layer Height Diurnal Variability Using Spaceborne Lidar Data

The Planetary Boundary Layer Height (PBLH) significantly impacts weather, climate, and air quality. Understanding the global diurnal variation of the PBLH is particularly challenging due to the necessity of extensive observations and suitable retrieval algorithms that can adapt to diverse thermodynamic and dynamic conditions. This study utilized data from the Cloud-Aerosol Transport System (CATS) to analyze the diurnal variation of PBLH in both continental and marine regions. By leveraging CATS data and a modified version of the Different Thermo-Dynamics Stability (DTDS) algorithm, along with machine learning denoising, the study determined the diurnal variation of the PBLH in continental mid-latitude and marine regions. The CATS DTDS-PBLH closely matches ground-based lidar and radiosonde measurements at the continental sites, with correlation coefficients above 0.6 and well-aligned diurnal variability, although slightly overestimated at nighttime. In contrast, PBLH at the marine site was consistently overestimated due to the viewing geometry of CATS and complex cloud structures. The study emphasizes the importance of integrating meteorological data with lidar signals for accurate and robust PBLH estimations, which are essential for effective boundary layer assessment from satellite observations.

54 ENVIRONMENTAL SCIENCES↗

NASA NTRS1973

Microfog lubricant application system for advanced turbine engine components, phase 3

The wetting characteristics and deposit forming tendencies of a series of lubricants were evaluated using a microfog jet delivery system to wet a flat heated rotating disc. The performances of the nine lubricants are discussed in terms of the various testing parameters which include temperature, disc speed and lubricant gas flow rates. Also discussed are the heat transfer characteristics of two of the lubricants on that same plane disc specimen. The wetting characteristics and heat transfer characteristics of one of the lubricants on a complex disc simulating bearing geometry are also discussed.

Petrucco, R. J.↗

NASA NTRS1975

Numerical solutions for inviscid supersonic corner flows

Analytical solutions for inviscid supersonic corner flows are virtually nonexistent due to the complexity of the interference geometry. In view of this, numerical solutions for compressive-compressive and expansive-compressive corner flows are obtained. The governing equations are written in strong conservation-law form and are solved iteratively in nonorthogonal conical coordinates by use of a second-order, shock-capturing, finite-difference technique. The computed wave structure and surface pressure distributions are compared with high Reynolds number (Re greater than 2,500,000 ft) experimental data. The results clearly show that the wave structure in the corner is dominated by the inviscid field.

Shankar, V. S. V.↗

NASA NTRS1975

Numerical solutions for supersonic corner flow

Analytical solutions for inviscid supersonic corner flows are virtually nonexistent due to the complexity of the interference geometry. In view of this, numerical solutions for swept-compressive and swept-expansive corner flows are obtained. The governing equations are written in strong conservation-law form and are solved iteratively in nonorthogonal conical coordinates by use of a second-order, shock-capturing, finite-difference technique. The computed wave structure and surface pressure distributions are compared with high Reynolds number experimental data and show very good agreement. The results clearly show that supersonic corner flow at reasonably high Reynolds numbers including the effect of sweep is dominated by the inviscid field.

Shankar, V.↗

NASA NTRS1977

Space Shuttle Plume and Plume Impingement Study

The extent of the influence of the propulsion system exhaust plumes on the vehicle performance and control characteristics is a complex function of vehicle geometry, propulsion system geometry, engine operating conditions and vehicle flight trajectory were investigated. Analytical support of the plume technology test program was directed at the two latter problem areas: (1) definition of the full-scale exhaust plume characteristics, (2) application of appropriate similarity parameters; and (3) analysis of wind tunnel test data. Verification of the two-phase plume and plume impingement models was directed toward the definition of the full-scale exhaust plume characteristics and the separation motor impingement problem.

Tevepaugh, J. A.↗

NASA NTRS1979

Recent developments in finite element analysis for transonic airfoils

The prediction of aerodynamic forces in the transonic regime generally requires a flow field calculation to solve the governing non-linear mixed elliptic-hyperbolic partial differential equations. Finite difference techniques were developed to the point that design and analysis application are routine, and continual improvements are being made by various research groups. The principal limitation in extending finite difference methods to complex three-dimensional geometries is the construction of a suitable mesh system. Finite element techniques are attractive since their application to other problems have permitted irregular mesh elements to be employed. The purpose of this paper is to review the recent developments in the application of finite element methods to transonic flow problems and to report some recent results.

Hafez, M. M.↗

NASA NTRS1980

Impact of new instrumentation on advanced turbine research

A description is presented of an orderly test program that progresses from the simplest stationary geometry to the more complex, three dimensional, rotating turbine stage. The instrumentation requirements for this evolution of testing are described. The heat transfer instrumentation is emphasized. Recent progress made in devising new measurement techniques has greatly improved the development and confirmation of more accurate analytical methods for the prediction of turbine performance and heat transfer. However, there remain challenging requirements for novel measurement techniques that could advance the future research to be done in rotating blade rows of turbomachines.

Graham, R. W.↗

NASA NTRS1980

Impact of new instrumentation on advanced turbine research

The progression of experimental programs is discussed from the simplest two-dimensional stationary geometry to the highly complex three-dimensional flow in a rotating blade row. Experimental methods and instrumentation techniques are described. Emphasis is placed on rotating blade row measurements.

Graham, R. W.↗

NASA NTRS1982

Thermal radiation view factor: Methods, accuracy and computer-aided procedures

The computer aided thermal analysis programs which predicts the result of predetermined acceptable temperature range prior to stationing of these orbiting equipment in various attitudes with respect to the Sun and the Earth was examined. Complexity of the surface geometries suggests the use of numerical schemes for the determination of these viewfactors. Basic definitions and standard methods which form the basis for various digital computer methods and various numerical methods are presented. The physical model and the mathematical methods on which a number of available programs are built are summarized. The strength and the weaknesses of the methods employed, the accuracy of the calculations and the time required for computations are evaluated. The situations where accuracies are important for energy calculations are identified and methods to save computational times are proposed. Guide to best use of the available programs at several centers and the future choices for efficient use of digital computers are included in the recommendations.

Kadaba, P. V.↗

NASA NTRS1985

Liquid rocket combustor computer code development

The Advanced Rocket Injector/Combustor Code (ARICC) that has been developed to model the complete chemical/fluid/thermal processes occurring inside rocket combustion chambers are highlighted. The code, derived from the CONCHAS-SPRAY code originally developed at Los Alamos National Laboratory incorporates powerful features such as the ability to model complex injector combustion chamber geometries, Lagrangian tracking of droplets, full chemical equilibrium and kinetic reactions for multiple species, a fractional volume of fluid (VOF) description of liquid jet injection in addition to the gaseous phase fluid dynamics, and turbulent mass, energy, and momentum transport. Atomization and droplet dynamic models from earlier generation codes are transplated into the present code. Currently, ARICC is specialized for liquid oxygen/hydrogen propellants, although other fuel/oxidizer pairs can be easily substituted.

Liang, P. Y.↗

NASA NTRS1985

A three-dimensional incompressible flow simulation method and its application to the Space Shuttle main engine. II Turbulent flow

An implicit finite difference code cast in general curvilinear coordinates is further developed for three-dimensional incompressible turbulent flows. The code is based on the method of pseudocompressibility and utilizes the Beam and Warming implicit approximate factorization algorithm to achieve computational efficiency. A multiple-zone method is further extended to include composite-grids to overcome the excessive computer memory required for solving turbulent flows in complex three-dimensional geometries. A simple turbulence model is proposed for internal flows. The code is being used for the Space Shuttle Main Engine (SSME) internal flow analyses.

Chang, J. L. C.↗

NASA NTRS1985

Reflectance Modeling

The overall goal of this work has been to develop a set of computational tools and media abstractions for the terrain bidirectional reflectance problem. The modeling of soil and vegetation surfaces has been emphasized with a gradual increase in the complexity of the media geometries treated. Pragmatic problems involved in the combined modeling of soil, vegetation, and atmospheric effects have been of interest and one of the objectives has been to describe the canopy reflectance problem in a classical radiative transfer sense permitting easier inclusion of our work by other workers in the radiative transfer field.

Smith, J. A.↗

NASA NTRS1985

Structural and aeroelastic analysis of the SR-7L propfan

A structural and aeroelastic analysis of a large scale advanced turboprop rotor blade is presented. This 8-blade rotor is designed to operate at Mach 0.8 at an altitude of 35,000 ft. The blades are highly swept and twisted and of spar/shell construction. Due to the complexity of the blade geometry and its high performance, it is subjected to much higher loads and tends to be much less stable than conventional blades. Four specific analyses were conducted: (1) steady deflection; (2) natural frequencies and mode shapes; (3) steady stresses; and (4) aeroelastic stability. State-of-the-art methods were used to analyze the blades including a large deflection, finite element structural analysis, and an aeroelastic analysis including interblade aerodynamic coupling (cascade effects). The study found the blade to be structurally sound and aeroelastically stable. However, it clearly indicated that advanced turboprop blades are much less robust than conventional blades and must be analyzed and fabricated much more carefully in order to assure that they are structurally sound and aeroelastically stable.

Hirschbein, Murray↗

NASA NTRS1988

Advanced composite turboprops - Modeling, structural, and dynamic analyses

This paper presents a structural and dynamic analysis of a scaled-down wind tunnel model propfan blade made from fiber composites. This blade is one of a series of propfan blades that have been tested at the NASA Lewis Research Center wind tunnel facilities. The blade is highly swept and twisted and of the spar/shell construction. Due to the complexity of the blade geometry and its high performance, it is subjected to much higher loads and tends to be much less stable than conventional blades. The structural and dynamic analyses of the blade were performed using the NASA-Lewis COBSTRAN computer code. COBSTRAN is designed to generate the mesh and calculate the anisotropic material properties for composite blade analysis. Comparison of analytical and experimental mode shapes and frequencies are shown, verifying the model development and analysis techniques used. The methodologies and programs developed for this analysis are directly applicable to other propfan blades.

Aiello, R. A.↗

NASA NTRS1988

Development and validation of an advanced low-order panel method

A low-order potential-flow panel code, PMARC, for modeling complex three-dimensional geometries, is currently being developed at NASA Ames Research Center. The PMARC code was derived from a code named VSAERO that was developed for Ames Research Center by Analytical Methods, Inc. In addition to modeling potential flow over three-dimensional geometries, the present version of PMARC includes several advanced features such as an internal flow model, a simple jet wake model, and a time-stepping wake model. Data management within the code was optimized by the use of adjustable size arrays for rapidly changing the size capability of the code, reorganization of the output file and adopting a new plot file format. Preliminary versions of a geometry preprocessor and a geometry/aerodynamic data postprocessor are also available for use with PMARC. Several test cases are discussed to highlight the capabilities of the internal flow model, the jet wake model, and the time-stepping wake model.

Ashby, Dale L.↗

NASA NTRS1989

Reflector surface distortion analysis techniques (thermal distortion analysis of antennas in space)

A group of large computer programs are used to predict the farfield antenna pattern of reflector antennas in the thermal environment of space. Thermal Radiation Analysis Systems (TRASYS) is a thermal radiation analyzer that interfaces with Systems Improved Numerical Differencing Analyzer (SINDA), a finite difference thermal analysis program. The programs linked together for this analysis can now be used to predict antenna performance in the constantly changing space environment. They can be used for very complex spacecraft and antenna geometries. Performance degradation caused by methods of antenna reflector construction and materials selection are also taken into consideration. However, the principal advantage of using this program linkage is to account for distortions caused by the thermal environment of space and the hygroscopic effects of the dry-out of graphite/epoxy materials after the antenna is placed into orbit. The results of this type of analysis could ultimately be used to predict antenna reflector shape versus orbital position. A phased array antenna distortion compensation system could then use this data to make RF phase front corrections. That is, the phase front could be adjusted to account for the distortions in the antenna feed and reflector geometry for a particular orbital position.

Sharp, R.↗

NASA NTRS1989

Acoustic radiation from a shell with internal structures

A method is developed to compute frequency response and acoustic radiation of a complex shell. The axisymmetric geometry of the shell includes cylindrical, conical, and spherical segments stiffened by discrete rings and bulkheads. The shell is coupled to internal masses and elastic frames. Shell segments are treated by transfer matrices. Rings, bulkheads, frames, and concentrated masses are treated by impedances at junctions of segments. The shell is coupled to an external acoustic fluid treated by Green's function and curved surface elements. A major issue facing the method's treatment of the fluid would be lack of existence or uniqueness encountered in the uncoupled, external acoustic problem at characteristic wavenumbers. By using a simple spherical shell, without internal structures, this potential hindrance is shown not to arise. A fuller application of the method awaits subsequent results.

El-Raheb, M.↗