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At least 1,225 records · Page 68

All sources NASA NTRS DOE OSTI

DOE OSTI2021

Surface Treatment Strategies for Mitigating Gas Hydrate & Asphaltene Formation, Growth, and Deposition in Flowloops

Abstract Numerous solids including gas hydrates, waxes, and asphaltenes have the potential to form in the production lines of gas and oil fields. This creates a highly non-ideal scenario as the accumulation of said species leads to flow assurance issues, especially with long-term processes like deposition. Since an ever-increasing amount of material is deposited in place at the pipe surface, production stoppage or active mitigation efforts become inevitable. The latter production issues result in increased safety risks and operational expenditures. Therefore, a cost-effective, passive deposition mitigation technology, such as a pipeline coating or surface treatment is especially appealing. The ability to address multiple pipeline flow assurance issues simultaneously without actively disrupting production would represent a dramatic step forward in this area. This study is part of a long-term ongoing effort that evaluates the performance and application of an omniphobic surface treatment for solids deposition prevention in industrially relevant systems. In particular, this specific work concentrates on the efficacy and robustness of the treatment under fully flowing conditions. The apparatuses utilized for this include two flowloops: a lab-scale, high-pressure flowloop for gas hydrate and surface treatment durability studies, and a bench-scale, atmospheric pressure loop for crude oil and asphaltene experiments. Film growth in high-pressure flowloop tests corroborated previous reports of delayed gas hydrate nucleation observed in rocking cells. Without the aid of the memory effect, treated oil-dominated experiments never experienced hydrate formation, spending upwards of a week in the hydrate stability zone (at the subcooled/fluid test conditions). Subsequent tests which utilized the memory effect then revealed that the hydrate formation rate reduced in the presence of the surface treatment compared to a bare stainless-steel surface. This testing was part of a larger set of trials conducted in the flowloop, which lasted about one year. The surface treatment durability under flowing conditions was evaluated during this time. Even after experiencing ∼4000 operating hours and 2 full pressure cycles, no evidence of delamination or damage was detected. Finally, as part of an extension to previous work, corroded surface asphaltene deposition experiments were performed in a bench-top flowloop. Treated experiments displayed an order of magnitude reduction in both total oil (all fractions of crude oil) and asphaltene fraction deposited.

03 NATURAL GAS↗

DOE OSTI2022

Evaluation of High-Temperature Martensitic Steels for Heavy-Duty Diesel Piston Applications

Five different commercially available high-temperature martensitic steels were evaluated for use in a heavy-duty diesel engine piston application and compared to existing piston alloys 4140 and microalloyed steel 38MnSiVS5 (MAS). Finite element analyses (FEA) were performed to predict the temperature and stress distributions for severe engine operating conditions of interest, and thus aid in the selection of the candidate steels. Complementary material testing was conducted to evaluate the properties relevant to the material performance in a piston. The elevated temperature strength, strength evolution during thermal aging, and thermal property data were used as inputs into the FEA piston models. Additionally, the long-term oxidation performance was assessed relative to the predicted maximum operating temperature for each material using coupon samples in a controlled-atmosphere cyclic-oxidation test rig. A current commercial steel piston alloy, quenched and tempered martensitic steel 4140, was tested in a single-cylinder research engine for a baseline oxidation and mechanical performance assessment using an abbreviated (50h) durability test plan. The predicted suitability of a candidate piston material in an engine is primarily based on its elevated temperature strength, oxidation resistance, and the complex influence of thermal conductivity, the latter of which is substantially lower for the candidate materials considered in this research relative to the traditional alloys. Although the lower thermal conductivity causes the candidate alloys to operate in higher temperature ranges under identical engine operating conditions and piston geometries, increasing the likelihood of partially or completely negating their strength and oxidation resistance advantages relative to 4140 and MAS steels, this evaluation indicates that several of the candidate piston alloys are predicted to enable improved oxidation resistance under more severe engine operating conditions relative to the current piston materials. However, further evaluation is required to determine if the elevated temperature fatigue strength and durability of these alloys are suitable for more severe engine conditions.

36 MATERIALS SCIENCE↗

DOE OSTI2026

Total Cost of Ownership Reduction Using Passive Pre-Chamber Ignition in Natural Gas Engines

Spark plug durability is a factor affecting the total cost of ownership (TCO) of spark-ignited natural gas engines, with some heavy-duty platforms requiring plug replacement after only 750 hours of operation. The high ignition energy demand under lean or diluted conditions accelerates electrode wear, shortening plug life and increasing maintenance frequency. This work evaluates passive pre-chamber (PC) ignition operating at lowered spark energies as a strategy to reduce spark energy requirements and extend plug durability, thereby lowering TCO. Experiments were conducted on a medium-duty Cummins 6.7L ISB engine at 1600 RPM and 50% load under varying exhaust gas recirculation (EGR) dilution levels (0–40%). Two passive pre-chambers with 1.1 mm and 1.6 mm nozzle diameters were compared with conventional spark ignition (SI). SI was operated with a fixed coil dwell of 4 ms (~90 mJ), while the PC configuration was tested across 2–4 ms dwell times (~30–90 mJ). Cylinder pressure analysis revealed that PC ignition sustained stable combustion at significantly lower spark energies than SI, with improved combustion stability at ~30 mJ compared with SI at ~90 mJ. The PC system also extended the dilution tolerance beyond that achievable with SI, while delivering up to ~2% higher indicated thermal efficiency and reducing the COV by nearly 90% at 30% EGR. A TCO analysis was conducted to assess the economic benefit of adopting a passive PC system operating at reduced spark energies compared to SI. It was found that adopting a passive PC system could reduce TCO by approximately $11,000 per engine over a five-year operational period, primarily due to fuel savings, extended spark plug life, and reduced maintenance frequency. These projections were weighed against the additional hardware cost of the pre-chamber, yielding a rapid estimated return on investment of ~300 operating hours. Therefore, this work motivates continued research and development of passive PC technology and its commercial adoption in natural gas engines used in transportation applications.

Dhotre, Akash [University of Minnesota]↗

DOE OSTI2020

More science with less: evaluation of a 3D-printed weather station

Abstract. A weather station built using 3D-printed parts and low-cost sensors, based on plans and guidance provided by the University Corporation for Atmospheric Research 3D-Printed Automatic Weather Station Initiative, was deployed alongside an Oklahoma Mesonet station to compare its performance against standard commercial sensors and determine the longevity and durability of the system. Temperature, relative humidity, atmospheric pressure, wind speed and direction, solar radiation, and precipitation measurements were collected over an 8-month field deployment in Norman, Oklahoma. Measurements were comparable to the commercial sensors except for wind direction, which proved to be problematic. Longevity and durability of the system varied, as some sensors and 3D-printed components failed during the deployment. Overall, results show that these low-cost sensors are comparable to the more expensive commercial counterparts and could serve as viable alternatives for researchers and educators with limited resources for short-term deployments. Long-term deployments are feasible with proper maintenance and regular replacement of sensors and 3D-printed components.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2026

Hygrothermal Performance of Bio-Based Materials in Residential Building Wall Envelope Systems

In the United States, building envelope systems contribute approximately 28% of building energy consumption, with walls being a primary factor. As the construction industry explores new approaches to lower the energy intensity needed to manufacture materials and, in turn, reduce energy consumption, bio-based materials are gaining attention as a promising alternative. While prior studies have demonstrated that bio-based materials can decrease material energy intensity, their long-term hygrothermal behavior within a whole residential wall system is not yet fully understood. This study aims to evaluate the potential of replacing Oriented Strand Board (OSB) and drywall in residential wall systems with bio-based alternatives. The research focuses on two bio-based materials, assessing their hygrothermal performance under Chicago climate condition (Climate Zone 5). To achieve that, a series of laboratory experiments were conducted to measure key properties of the bio-based materials such as thickness, dimensions, density, thermal conductivity (as a function of temperature and humidity), moisture-dependent permeance and water vapor permeability (WVP), and sorption isotherms. These properties were then used in WUFI® simulations to predict the moisture durability of a standard residential wall system in Climate Zone 5. Results show that substituting OSB and drywall with bio-based materials can achieve acceptable moisture durability, effectively mitigating risks of mold growth and structural damage over time.

Palani, Hevar [ORNL] (ORCID:0000000220211994)↗

NASA NTRS1972

Evaluation of tantalum 316 stainless steel transition joints

Tubular transition joints providing a metallurgically bonded connection between tantalum and 316 stainless steel pipe sections were comparatively evaluated for durability under thermal cycling conditions approximating the operation of a SNAP-8 mercury boiler. Both coextruded and vacuum brazed transition joints of 50mm (2 inch) diameter were tested by thermal cycling 100 times between 730 C and 120 C(1350 F and 250 F) in a high vacuum environment. The twelve evaluated transition joints survived the full test sequence without developing leaks, although liquid penetrant bond line indications eventually developed in all specimens. The brazed transition joints exhibited the best dimensional stability and bond line durability.

Stoner, D. R.↗

NASA NTRS1975

Research, development and application of noncombustible Beta fiber structures

Beta fiber was selected as the primary material for flexible fibrous structures used in spacecraft and crew systems applications in the Apollo program because it was noncombustible in a 100 percent oxygen atmosphere up to 16.5 psia. It met NASA criteria for outgassing, toxicity, odor, and crew comfort, and possessed sufficient durability to last through the mission. Topics discussed include: study of spacecraft applications; design of Beta fiber textile structures to meet the requirements; selection of surface treatments (finishes, coatings, and printing systems) to impart the required durability and special functional use to the textile structures; development of sewing and fabrication techniques; and testing and evaluation programs, and development of production sources.

Dillon, J. J.↗

NASA NTRS1975

Monopropellant engine investigation for space shuttle reaction control system. Volume 3: Improvement of metal foam for catalyst retention

The retention of granular catalyst in a metal foam matrix was demonstrated to greatly increase the life capability of hydrazine monopropellant reactors. Since nickel foam used in previous tests was found to become degraded after long-term exposure the cause of degradation was examined and metal foams of improved durability were developed. The most durable foam developed was a rhodium-coated nickel foam. An all-platinum foam was found to be incompatible in a hot ammonia (hydrazine) environment. It is recommended to scale up the manufacturing process for the improved foam to produce samples sufficiently large for space shuttle APU gas generator testing.

Source record↗

NASA NTRS1976

Ceramic thermal-barrier coatings for cooled turbines

Coating systems consisting of a plasma sprayed layer of zirconia stabilized with either yttria, magnesia or calcia over a thin alloy bond coat have been developed, their potential was analyzed and their durability and benefits evaluated in a turbojet engine. The coatings on air cooled rotating blades were in good condition after completing as many as 500 two-minute cycles of engine operation between full power at a gas temperature of 1644 K and flameout, or as much as 150 hours of steady state operation on cooled vanes and blades at gas temperatures as high as 1644 K with 35 start and stop cycles. On the basis of durability and processing cost, the yttria stabilized zirconia was considered the best of the three coatings investigated.

Liebert, C. H.↗

NASA NTRS1976

Ceramic thermal-barrier coatings for cooled turbines

Ceramic thermal-barrier coatings on hot engine parts have the potential to reduce metal temperatures, coolant requirements, cost, and complexity of the cooling configuration, and to increase life, turbine efficiency and gas temperature. Coating systems consisting of a plasma-sprayed layer of zirconia stabilized with either yttria, magnesia or calcia over a thin alloy bond coat have been developed, their potential analyzed and their durability and benefits evaluated in a turbojet engine. The coatings on air-cooled rotating blades were in good condition after completing as many as 500 two-minute cycles of engine operation between full power at a gas temperature of 1644 K and flameout, or as much as 150 hours of steady-state operation on cooled vanes and blades at gas temperatures as high as 1644 K witn 35 start and stop cycles. On the basis of durability and processing cost, the yttria-stabilized zirconia was considered the best of the three coatings investigated.

Liebert, C. H.↗

NASA NTRS1977

Summary of NASA research on thermal-barrier coatings

A durable, two-layer, plasma-sprayed coating consisting of a ceramic layer over a metallic layer was developed that has the potential of insulating hot engine parts and thereby reducing metal temperatures and coolant flow requirements and/or permitting use of less costly and complex cooling configurations and materials. The investigations evaluated the reflective and insulative capability, microstructure, and durability of several coating materials on flat metal specimens, a combustor liner, and turbine vanes and blades. In addition, the effect on the aerodynamic performance of a coated turbine vane was measured. The tests were conducted in furnaces, cascades, hot-gas rigs, an engine combustor, and a research turbojet engine. Summaries of current research related to the coating and potential applications for the coating are included.

Stepka, F. S.↗

NASA NTRS1977

Summary of NASA research on thermal-barrier coatings

This paper summarizes the work conducted at the NASA Lewis Research Center to evolve and evaluate a two-layer, thermal-barrier coating system. A durable, two-layer, plasma-sprayed coating consisting of a ceramic layer over a metallic layer was developed that has the potential of insulating hot engine parts and thereby reducing metal temperatures and coolant flow requirements and/or permitting use of less costly and complex cooling configurations and materials. The investigations evaluated the reflective and insulative capability, microstructure, and durability of several coating materials on flat metal specimens, a combustor liner, and turbine vanes and blades. In addition, the effect on the aerodynamic performance of a coated turbine vane was measured. The tests were conducted in furnaces, cascades, hot-gas rigs, an engine combustor, and a research turbojet engine. Included also are summaries of current research related to the coating and potential applications for the coating.

Stepka, F. S.↗

NASA NTRS1977

Experimental performance of an ablative material as an external insulator for a hypersonic research aircraft

An ablative material composed of silica-filled elastomeric silicone was tested to evaluate its thermal and structural performance as an external insulator, or heat shield, for a hypersonic research aircraft. The material was also tested to determine whether it would form a durable char layer when initially heated and thereafter function primarily as an insulator with little further pyrolysis or char removal. Aerothermal tests were representative of nominal Mach 6 cruise conditions of the aircraft, and additional tests were representative of Mach 8 cruise and interference heating conditions. Radiant heating tests were used to simulate the complete nominal Mach 6 surface-temperature history. The silica char that formed during aerothermal tests was not durable. The char experienced a general and preferential surface recession, with the primary mechanism for char removal being erosion. Tests revealed that radiant heating is not a valid technique for simulating aerodynamic heating of the material.

Puster, R. L.↗

NASA NTRS1978

Analytical evaluation of the impact of broad specification fuels on high bypass turbofan engine combustors

The impact of the use of broad specification fuels on the design, performance durability, emissions and operational characteristics of combustors for commercial aircraft gas turbine engines was assessed. Single stage, vorbix and lean premixed prevaporized combustors, in the JT9D and an advanced energy efficient engine cycle were evaluated when operating on Jet A and ERBS (Experimental Referee Broad Specification) fuels. Design modifications, based on criteria evolved from a literature survey, were introduced and their effectiveness at offsetting projected deficiencies resulting from the use of ERBS was estimated. The results indicate that the use of a broad specification fuel such as ERBS, will necessitate significant technology improvements and redesign if deteriorated performance, durability and emissions are to be avoided. Higher radiant heat loads are projected to seriously compromise liner life while the reduced thermal stability of ERBS will require revisions to the engine-airframe fuel system to reduce the thermal stress on the fuel. Smoke and emissions output are projected to increase with the use of broad specification fuels. While the basic geometry of the single stage and vorbix combustors are compatible with the use of ERBS, extensive redesign of the front end of the lean premixed prevaporized burner will be required to achieve satisfactory operation and optimum emissions.

Lohmann, R. P.↗

NASA NTRS1978

NASA thermal barrier coatings: Summary and update

A durable, two-layer, plasma-sprayed coating consisting of a ceramic layer over a metallic layer was developed that has the potential of insulating hot engine parts and thereby reducing metal temperatures and coolant flow requirements and/or permitting use of less costly and complex cooling configurations and materials. The results are summarized of analytical and experimental investigations of the coatings on flat metal specimens, turbine vanes and blades, and combustor liners. Discussed are results of investigations to determine coating adherence and durability, coating thermal, strength and fatigue properties, and chemical reactions of the coating with oxides and sulfates. Also presented are the effect of the coating on aerodynamic performance of a turbine vane, measured vane and combustor liner temperatures with and without the coating, and predicted turbine metal temperatures and coolant flow reductions potentially possible with the coating. Included also are summaries of some current research related to the coating and potential applications for the coating.

Stepka, F. S.↗

NASA NTRS1979

Analytical evaluation of the impact of broad specification fuels on high bypass turbofan engine combustors

Six conceptual combustor designs for the CF6-50 high bypass turbofan engine and six conceptual combustor designs for the NASA/GE E3 high bypass turbofan engine were analyzed to provide an assessment of the major problems anticipated in using broad specification fuels in these aircraft engine combustion systems. Each of the conceptual combustor designs, which are representative of both state-of-the-art and advanced state-of-the-art combustion systems, was analyzed to estimate combustor performance, durability, and pollutant emissions when using commercial Jet A aviation fuel and when using experimental referee board specification fuel. Results indicate that lean burning, low emissions double annular combustor concepts can accommodate a wide range of fuel properties without a serious deterioration of performance or durability. However, rich burning, single annular concepts would be less tolerant to a relaxation of fuel properties. As the fuel specifications are relaxed, autoignition delay time becomes much smaller which presents a serious design and development problem for premixing-prevaporizing combustion system concepts.

Taylor, J. R.↗

NASA NTRS1978

Impact of future fuel properties on aircraft engines and fuel systems

From current projections of the availability of high-quality petroleum crude oils, it is becoming increasingly apparent that the specifications for hydrocarbon jet fuels may have to be modified. The problems that are most likely to be encountered as a result of these modifications relate to engine performance, component durability and maintenance, and aircraft fuel-system performance. The effect on engine performance will be associated with changes in specific fuel consumption, ignition at relight limits, at exhaust emissions. Durability and maintenance will be affected by increases in combustor liner temperatures, carbon deposition, gum formation in fuel nozzles, and erosion and corrosion of turbine blades and vanes. Aircraft fuel-system performance will be affected by increased deposits in fuel-system heat exchangers and changes in the pumpability and flowability of the fuel. The severity of the potential problems is described in terms of the fuel characteristics most likely to change in the future. Recent data that evaluate the ability of current-technology aircraft to accept fuel specification changes are presented, and selected technological advances that can reduce the severity of the problems are described and discussed.

Rudey, R. A.↗

NASA NTRS1978

NASA thermal barrier coatings - Summary and update

The work conducted at the NASA Lewis Research Center to evolve and evaluate a thermal-barrier coating system will be discussed. A durable, two-layer, plasma-sprayed coating consisting of a ceramic layer over a metallic layer was developed that has the potential of insulating hot engine parts and thereby reducing metal temperatures and coolant flow requirements and/or permitting use of less costly and complex cooling configurations and materials. The paper summarizes the results of analytical and experimental investigations of the coatings on flat metal specimens, turbine vanes and blades, and combustor liners. Discussed are results of investigations to determine coating adherence and durability, coating thermal, strength and fatigue properties, and chemical reactions of the coating with oxides and sulfates. Also presented are the effect of the coating on aerodynamic performance of a turbine vane, measured vane and combustor liner temperatures with and without the coating, and predicted turbine metal temperatures and coolant flow reductions potentially possible with the coating. Included also are summaries of some current research related to the coating and potential applications for the coating.

Stepka, F. S.↗