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At least 1,279 records · Page 71

Algorithm for Lossless Compression of Calibrated Hyperspectral Imagery

A two-stage predictive method was developed for lossless compression of calibrated hyperspectral imagery. The first prediction stage uses a conventional linear predictor intended to exploit spatial and/or spectral dependencies in the data. The compressor tabulates counts of the past values of the difference between this initial prediction and the actual sample value. To form the ultimate predicted value, in the second stage, these counts are combined with an adaptively updated weight function intended to capture information about data regularities introduced by the calibration process. Finally, prediction residuals are losslessly encoded using adaptive arithmetic coding. Algorithms of this type are commonly tested on a readily available collection of images from the Airborne Visible/Infrared Imaging Spectrometer (AVIRIS) hyperspectral imager. On the standard calibrated AVIRIS hyperspectral images that are most widely used for compression benchmarking, the new compressor provides more than 0.5 bits/sample improvement over the previous best compression results. The algorithm has been implemented in Mathematica. The compression algorithm was demonstrated as beneficial on 12-bit calibrated AVIRIS images.

Kiely, Aaron B.↗

Lightning Initiation Forecasting: An Operational Dual-Polarimetric Radar Technique

The objective of this NASA MSFC and NOAA CSTAR funded study is to develop and test operational forecast algorithms for the prediction of lightning initiation utilizing the C-band dual-polarimetric radar, UAHuntsville's Advanced Radar for Meteorological and Operational Research (ARMOR). Although there is a rich research history of radar signatures associated with lightning initiation, few studies have utilized dual-polarimetric radar signatures (e.g., Z(sub dr) columns) and capabilities (e.g., fuzzy-logic particle identification [PID] of precipitation ice) in an operational algorithm for first flash forecasting. The specific goal of this study is to develop and test polarimetric techniques that enhance the performance of current operational radar reflectivity based first flash algorithms. Improving lightning watch and warning performance will positively impact personnel safety in both work and leisure environments. Advanced warnings can provide space shuttle launch managers time to respond appropriately to secure equipment and personnel, while they can also provide appropriate warnings for spectators and players of leisure sporting events to seek safe shelter. Through the analysis of eight case dates, consisting of 35 pulse-type thunderstorms and 20 non-thunderstorm case studies, lightning initiation forecast techniques were developed and tested. The hypothesis is that the additional dual-polarimetric information could potentially reduce false alarms while maintaining high probability of detection and increasing lead-time for the prediction of the first lightning flash relative to reflectivity-only based techniques. To test the hypothesis, various physically-based techniques using polarimetric variables and/or PID categories, which are strongly correlated to initial storm electrification (e.g., large precipitation ice production via drop freezing), were benchmarked against the operational reflectivity-only based approaches to find the best compromise between forecast skill and lead-time. Forecast skill is determined by statistical analysis of probability of detection (POD), false alarm ratio (FAR), Operational Utility Index (OUI), and critical success index (CSI).

Woodard, Crystal J.↗

On the Calculation of Exact Cumulative Distribution Statistics for Burgers Equation

A mathematical procedure is presented for the calculation of exact cumulative distribution statistics for a viscosity-free variant of Burgers nonlinear partial differential equation (PDE) in one space dimension and time subject to sinusoidal initial data with uncertain (random variable) amplitude or phase shift. Analytical solutions of nonlinear PDEs with uncertain initial and/or boundary data are invaluable benchmarks in assessing approximate uncertainty quantification techniques. The Burgers equation solution with uncertain initial data results in nonsmooth solution behavior in both physical and random variable dimensions which provides a severe test for approximate uncertainty quantification techniques. Mathematical proofs are provided to verify that exact cumulative distribution statistics can be systematically and robustly obtained for all forward time.

Burgers↗

Irradiated Low-Enriched Uranium Fuel Measurements with a Gamma-Ray Scanning System

A gamma-ray scanning system was designed to perform post-irradiation measurements of nuclear fuel at Idaho National Laboratory (INL). The system is composed of a coaxial high-purity germanium (HPGe) detector, a collimator, and mechanical positioning stages that translate the fuel sample across the front of the collimator. A Monte Carlo N-Particle code simulation of the system and the fuel were created with vendor-supplied design specifications, dimensional measurements, and x-ray radiographs of the HPGe detector as well as all available fuel specifications. Benchmark measurements were performed by scanning an irradiated fuel rodlet containing eight pellets of 0.74% enriched UO2 in zirconium alloy. This fuel rodlet was part of the Static Environment Rodlet Transient Test Apparatus (SERTTA) testing campaign in the Transient Reactor Test Facility (TREAT). These results were compared to simulated spectra to help characterize the detector model and establish fidelity. A goal of the system is to determine the number of fissions per gram of UO2 in the fuel. This paper documents the modeling of the system and the calculation of the number of fissions per gram along the axial length of the SERTTA-C rodlet.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

A Custom High-Throughput Optical Mapping Instrument for Accelerated Stress Testing of PV Module Materials

The performance and integrity of photovoltaic (PV) modules and materials may be assessed through optical characterizations. We have developed a custom optical mapping instrument (OMI) to improve measurement throughput time, facilitate automated measurements, allow for localized specimen examination, obtain spatial information relative to commercial benchtop spectrophotometer instruments, and provide automated data analysis. Both the key components and the methods used to improve the measurements are described. The measurement precision for the OMI is benchmarked for hemispherical transmittance relative to a previous round-robin study for commercial spectrophotometers. In addition to the unique instrument developed in this study, new insights have emerged from the examination of specimens from previous experiments, including: the depletion of the UV absorber is revealed for specimens beyond a certain size after artificial ultraviolet (UV) weathering; an optical degradation by internal haze formation is confirmed following Damp Heat (85 °C/85% relative humidity) testing; the better uniformity of the wear pattern for falling sand abrasion is used to select the DIN 52348 fixture over the ASTM D968 fixture; and the greater local (in the order of millimeters) heterogeneity of surface contamination in the soiling-prone location of Dubai relative to Kuwait. The results of the UV study have already been used to improve the standardized weathering of encapsulants. The example for Damp Heat testing is given to increase awareness of a degradation believed to be ubiquitously occurring in safety and design-type qualification testing of PV modules.

14 SOLAR ENERGY↗

Challenges for density functional theory: calculation of CO adsorption on electrocatalytically relevant metals

Density Functional Theory (DFT) is currently the most tractable choice of theoretical model used to understand the mechanistic pathways for electrocatalytic processes such as CO 2 or CO reduction. In this work, we assess the performance of two DFT functionals designed specifically to describe surface interactions, RTPSS and RPBE, as well as two popular meta-GGA functionals, SCAN and B97M-rV, that have not been a priori optimized for better interfacial properties. We assess all four functionals against available experimental data for prediction of bulk and bare surface properties on four electrocatalytically relevant metals, Au, Ag, Cu, and Pt, and for binding CO to surfaces of these metals. To partially mitigate issues such as thermal and anharmonic corrections associated with comparing computations with experiments, molecular benchmarks against high level quantum chemistry are reported for CO complexes with Au, Ag, Cu and Pt atoms, as well as the CO–water complex and the water dimer. Overall, we find that the surface modified RPBE functional performs reliably for many of the benchmarks examined here, and the meta-GGA functionals also show promising results. Specifically B97M-rV predicts the correct site preference for CO binding on Ag and Au (the only functional tested here to do so), while RTPSS performs well for surface relaxations and binding of CO on Pt and Cu.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

Solving the Hele–Shaw flow using the Harrow–Hassidim–Lloyd algorithm on superconducting devices: A study of efficiency and challenges

The development of quantum processors for practical fluid flow problems is a promising yet distant goal. Recent advances in quantum linear solvers have highlighted their potential for classical fluid dynamics. In this study, we evaluate the Harrow–Hassidim–Lloyd (HHL) quantum linear systems algorithm (QLSA) for solving the idealized Hele–Shaw flow. Our focus is on the accuracy and computational cost of the HHL solver, which we find to be sensitive to the condition number, scaling exponentially with problem size. This emphasizes the need for preconditioning to enhance the practical use of QLSAs in fluid flow applications. Moreover, we perform shots-based simulations on quantum simulators and test the HHL solver on superconducting quantum devices, where noise, large circuit depths, and gate errors limit performance. Error suppression and mitigation techniques improve accuracy, suggesting that such fluid flow problems can benchmark noise mitigation efforts. Finally, our findings provide a foundation for future, more complex application of QLSAs in fluid flow simulations.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗

The accuracy of multi-group models for nonlocal electron transport in magnetized plasmas

In the extreme conditions of inertial confinement fusion experiments, heat flow plays a vital role, but local diffusive models frequently break down and overestimate the heat flow. The situation becomes more complicated again in the significant magnetic fields generated during laser–plasma interactions or in magnetized fusion schemes. Accurate non-local and magnetized heat flow computations can be carried out using Vlasov–Fokker–Planck (VFP) simulations, but these are computationally expensive. There is, therefore, significant interest in using faster multi-group models to accurately calculate the non-local heat flow in magnetized plasmas. We benchmark two such multi-group models for calculating the heat flow, M1 and hybrid-AWBS-BGK, against diffusive models and full VFP simulations, before applying the models to realistic example test cases, both magnetized and unmagnetized. We find that the multi-group models generally perform very well for moderate non-localities up to kλmfp∼0.01, but the computational cost increases dramatically. hybrid-AWBS-BGK performs more effectively than M1 at high non-localities, up to kλmfp∼1, due to its adaptive solver and robust P1 closure, but tends to fail in very strong magnetic fields. Both codes are much faster than VFP simulations but are still slow in steep temperature gradients.

Arran, C. (ORCID:0000000286448118)↗

HipBone: A performance-portable graphics processing unit-accelerated C++ version of the NekBone benchmark

We present hipBone, an open-source performance-portable proxy application for the Nek5000 (and NekRS) computational fluid dynamics applications. HipBone is a fully GPU-accelerated C++ implementation of the original NekBone CPU proxy application with several novel algorithmic and implementation improvements which optimize its performance on modern fine-grain parallel GPU accelerators. Our optimizations include a conversion to store the degrees of freedom of the problem in assembled form in order to reduce the amount of data moved during the main iteration and a portable implementation of the main Poisson operator kernel. We demonstrate near-roofline performance of the operator kernel on three different modern GPU accelerators from two different vendors. We present a novel algorithm for splitting the application of the Poisson operator on GPUs which aggressively hides MPI communication required for both halo exchange and assembly. Our implementation of nearest-neighbor MPI communication then leverages several different routing algorithms and GPU-Direct RDMA capabilities, when available, which improves scalability of the benchmark. We demonstrate the performance of hipBone on three different clusters housed at Oak Ridge National Laboratory, namely, the Summit supercomputer and the Frontier early-access clusters, Spock and Crusher. Our tests demonstrate both portability across different clusters and very good scaling efficiency, especially on large problems.

Computer Science↗

Robotic automation of maintenance work in nuclear power plants a cross-sector survey and roadmap

Nuclear power plants face increasing cost pressures, workforce constraints (aging workforce and skilled labor shortages), and safety requirements that are accelerating interest in robotic systems for inspection and maintenance. We conducted semi-structured interviews with personnel from seven U.S. nuclear utilities and compared deployment models, operational use cases, and integration practices with those reported by participants in the oil, gas, and petrochemical sector. In nuclear plants, robotic use remains concentrated in inspection—particularly indoor unmanned aerial vehicles and submersible remotely operated vehicles—with limited application to physical maintenance tasks. Reported near-term value includes reduced radiological and industrial risk, reduced outage labor, and improved data for planning and condition assessment. Key barriers include integration and data-interoperability constraints, operator qualification requirements, cybersecurity review burden, and difficulty demonstrating reliability in plant-representative environments. Cross-sector benchmarking highlights organizational and deployment practices that may help nuclear plants scale from pilots to routine use. We propose a deployment-oriented roadmap emphasizing modular payload strategies, representative qualification pathways and testing environments, and improved data governance to support safe and economically justified expansion of robotics in operating nuclear power plants.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

MIP dQ/dx Calibration in DUNE ND-LAr Prototypes with Pixelated Charge Readout

The Deep Underground Neutrino Experiment (DUNE) will be a next-generation long baseline neutrino oscillation experiment that will employ LArTPC technology in a near detector placed at Fermilab and a far detector at the Sanford Underground Research Facility, at a baseline of 1300 km. The DUNE Liquid Argon Near Detector (ND-LAr) design takes into account the high neutrino intensity expected from the beam at the Long-Baseline Neutrino Facility (LBNF): 35 modules, each containing two optically separated time projection chambers, are instrumented with a pixel-based, true 3D charge readout alongside scintillation light traps to disentangle the O(100) interactions expected per 10us beam spill. A robust prototyping program supports ND-LAr’s design: the 2x2 Demonstrator consists of four scaled-down ND-LAr modules exposed to the NuMI beam at Fermilab, and the Full Scale Demonstrator (FSD) is a single ND-LAr module tested with cosmic rays at the University of Bern. We present here an analysis of minimum ionizing particle (MIP) tracks selected from 2x2 beam data and FSD cosmic ray data used to benchmark the pixel-based charge readout simulation and calibration in both detectors, with the ultimate goal of validating the design of DUNE ND-LAr as well as informing future calibration methods. This poster will showcase the dependence of the charge response on track inclination as well as a per-pixel dQ/dX extraction.

Mandujano, Roberto [UC, Irvine]↗

A Centralized AI Lakehouse Framework for Brain Tumor MRI Classification and Segmentation, University KPI Forecasting, and Water Potability Prediction

In many university and healthcare projects, models are built for very different data types such as tables, institutional time series, and medical images, but they are deployed as separate applications. In this work, that separation made testing and maintenance difficult because each module had its own pipeline and runtime requirements. This paper presents an integrated AI lakehouse-style implementation that runs three model pipelines inside one containerized backend. For medical imaging, we used MRI datasets from IEEE DataPort: a four-class classification set with 7012 images (5708 train/1304 test) and a segmentation set with 3063 image–mask pairs. The classification model (ResNet50 transfer learning) is evaluated using a proper train–validation–test protocol across multiple splits (80/10/10, 70/10/20, 60/10/30, and 10/30/60), achieving a test accuracy of 99.00% under the standard 80/10/10 split. Additionally, a patient-level evaluation is conducted using an external glioma dataset to provide a more realistic assessment without data leakage. The segmentation model (DeepLabV3-ResNet50) achieved 83.09% validation mIoU and 88.79% Dice score. For university KPI forecasting, we used annual IPEDS and NSF HERD data from 2010 to 2023 for three universities (BSU, EOU, and UAB). To examine the effect of preprocessing on forecasting performance, two case studies are conducted. In the first case, linear interpolation is applied to generate semester-level data. In the second case, the original annual data is used directly without interpolation. Random Forest regression and ARIMA models are evaluated using MAE, RMSE, MAPE, and R 2 . The results showed that interpolation improved apparent forecasting performance due to smoothing, while evaluation on the original annual data provided a more realistic assessment of model behavior. To further validate the framework on a larger dataset, an additional case study is conducted using a student dropout dataset. For water potability, we trained and compared multiple tabular classifiers on a large dataset (1,048,575 samples). A Random Forest model (100 trees, max depth 10) achieved 85.86% test accuracy and high recall for unsafe samples (0.8447). All modules are served via FastAPI and deployed together using Docker, with workflow automation routing requests to the correct endpoint. System-level benchmarking indicates that the backend maintains stable throughput and latency under concurrent requests.

97 MATHEMATICS AND COMPUTING↗

A Return to Innovative Engineering Design, Critical Thinking and Systems Engineering

I believe we are facing a critical time where innovative engineering design is of paramount importance to the success of our aerospace industry. However, the very qualities and attributes necessary for enhancing, educating, and mentoring a creative spirit are in decline in important areas. The importance of creativity and innovation in this country was emphasized by a special edition of the Harvard Business Review OnPoint entitled: "The Creative Company" which compiled a series of past and present articles on the subject of creativity and innovation and stressed its importance to our national economy. There is also a recognition of a lack of engineering, critical thinking and problem-solving skills in our education systems and a trend toward trying to enhance those skills by developing K-12 educational programs such as Project Lead the Way, "Science for All Americans", Benchmarks 2061 , etc. In addition, with respect to spacecraft development, we have a growing need for young to mid-level engineers with appropriate experience and skills in spacecraft design, development, analysis, testing, and systems engineering. As the Director of Engineering at NASA's Johnson Space Center, I realized that sustaining engineering support of an operational human spacecraft such as the Space Shuttle is decidedly different than engineering design and development skills necessary for designing a new spacecraft such as the Crew Exploration Vehicle of the Constellation Program. We learned a very important lesson post Columbia in that the Space Shuttle is truly an experimental and not an operational vehicle and the strict adherence to developed rules and processes and chains of command of an inherently bureaucratic organizational structure will not protect us from a host of known unknowns let alone unknown unknowns. There are no strict rules, processes, or procedures for understanding anomalous results of an experiment, anomalies with an experimental spacecraft like Shuttle, or in the conceptual design of a spacecraft. Engineering design is as much an art as it is a science. The critical thinking skills necessary to uncover lurking problems in an experimental design and creatively develop solutions are some of the same skills necessary to design a new spacecraft. Thus, I believe engineers unfamiliar with or removed from design and development need time to transition and develop the required skill set to be effective spacecraft designers. I believe the creative process necessary in design can be enhanced and even taught as early as grades K-12 and should continue to be nurtured and developed at the university level and beyond. I am going to present a strategy for developing learning teams to address complex multidisciplinary problems and to creatively develop solutions to those problems rapidly at minimal cost. I will frame a real problem, the development of on-orbit thermal protection system repair of the Space Shuttle, and step through the series of skills necessary to enhance the creative process. The case study I will illustrate is based on a real project, the R&D Reinforced Carbon-Carbon (RCC) Repair Team's development of on-orbit repair concepts for damaged Space Shuttle RCC nose cap and/or leading edges.

Camarda, Charles J.↗

Use of Traditional and Novel Methods to Evaluate the Influence of an EVA Glove on Hand Performance

The gloved hand is one of an astronaut s primary means of interacting with the environment, and any restrictions imposed by the glove can strongly affect performance during extravehicular activity (EVA). Glove restrictions have been the subject of study for decades, yet previous studies have generally been unsuccessful in quantifying glove mobility and tactility. Past studies have tended to focus on the dexterity, strength, and functional performance of the gloved hand; this provides only a circumspect analysis of the impact of each type of restriction on the glove s overall capability. The aim of this study was to develop novel capabilities to provide metrics for mobility and tactility that can be used to assess the performance of a glove in a way that could enable designers and engineers to improve their current designs. A series of evaluations were performed to compare unpressurized and pressurized (4.3 psi) gloved conditions with the ungloved condition. A second series of evaluations were performed with the Thermal Micrometeoroid Garment (TMG) removed. This series of tests provided interesting insight into how much of an effect the TMG has on gloved mobility - in some cases, the presence of the TMG restricted glove mobility as much as pressurization did. Previous hypotheses had assumed that the TMG would have a much lower impact on mobility, but these results suggest that an improvement in the design of the TMG could have a significant impact on glove performance. Tactility testing illustrated the effect of glove pressurization, provided insight into the design of hardware that interfaces with the glove, and highlighted areas of concern. The metrics developed in this study served to benchmark the Phase VI EVA glove and to develop requirements for the next-generation glove for the Constellation program.

Benson, Elizabeth A.↗

Development of an Improved RELAP5-3D Model for the High Temperature Test Facility

High-temperature gas-cooled reactors (HTGRs) are rapidly approaching deployment. Confidence in transient analysis of these systems for design, optimization, and licensing calculations requires modeling and simulation tools that have been validated against data relevant to HTGR conditions. The High Temperature Test Facility (HTTF) is an integral effects thermal hydraulics test facility for prismatic HTGRs. In spring and summer of 2019, HTTF was used for a series of experiments that now serve as the basis for the OECD/NEA Thermal Hydraulic Code Validation Benchmark for High Temperature Gas-Cooled Reactors using HTTF Data (HTGR T/H Benchmark). This benchmark contains problems for systems code, computational fluid dynamics (CFD), and coupled systems code/CFD modeling representing lower plenum mixing and both the depressurized and pressurized conduction cooldown (DCC and PCC respectively) transients. Benchmark problems include exercises for code-to-code and code-to-data comparisons as well as an exercise for error scaling between HTTF and the Modular High Temperature Gas-Cooled Reactor, which serves as the basis for the HTTF design. Previous analysis as part of the HTGR T/H benchmark used a RELAP5-3D model developed at Idaho National Laboratory (INL) and demonstrated an ability to reproduce trends in the measured data but difficulties reproducing experimental values within their uncertainty. These difficulties were largely attributed to assumptions made during the development of the initial RELAP5-3D model, which predated the HTTF experiments. A significant cause of difficulty reproducing the measured temperatures may be the radial nodalization of the previous RELAP5-3D model. The new model provides a finer nodalization to assess the impact of radial nodalization and allows for asymmetric heating within the core, which was a feature of multiple HTTF experiments. In this paper, we present the new RELAP5-3D model of HTTF. In addition to describing the new model, this paper compares the new and old models and provides results for a full-power steady state, a DCC, and a PCC in HTTF. These analyses are based on the code-to-code comparison exercises for the DCC and PCC problems of the HTGR T/H benchmark. We present the results of these exercises from the new model and compare them to the results of the old model.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

Validation of Numerical Tools for Calculating Reactivity Feedback in Sodium Fast Reactors Using SEFOR Experimental Data

The Southwest Experimental Fast Oxide Reactor (SEFOR) was an experimental sodium-cooled fast breeder reactor operated from 1969 to 1972 with experiments designed to measure Doppler reactivity feedback in a wide temperature range from around 350 °F to temperatures approaching the melting point of mixed oxide fuel of around 5000 °F, providing valuable data for code validations. Co-supported by the Department of Energy (DOE) Fast Reactor Program (FRP) and the DOE Nuclear Energy Advanced Modeling and Simulation (NEAMS) program, the SEFOR benchmark project focused on using the experimental data to validate numerical tools that are used in industry and academia to design and license sodium-cooled fast reactors (SFRs). By the end of FY-25, substantial progress was achieved in the SEFOR benchmark study. A variety of numerical tools commonly used for modeling SFRs were applied to develop models for SEFOR core configurations I-D, I-E, I-I, and I-J. These included Monte Carlo codes such as MCNP, Serpent, and Shift; deterministic codes such as the legacy Argonne Reactor Computation (ARC) suite and the high-fidelity NEAMS code Griffin; and the system analysis code SAS4A/SASSYS-1 (SAS). Using these models, both SEFOR zero-power experiments and power-ascending tests were successfully simulated. Comparisons were performed against experimental measurements of core criticalities, reflector worth, kinetics parameters (Λ/βeff), isothermal reactivity feedback (from 350 °F to 760 °F at zero power), and power-ascending reactivity feedback (as power increased from 0.4 MW to 17 MW). In general, these comparisons demonstrated very good agreement between numerical results and experimental data. In Fiscal Year 26 (FY-26), the SEFOR benchmark project will continue to address the modeling issues identified in FY-25. Effort will focus on the simulation of reactivity insertion transients in SEFOR core II using the ARC/SAS model. Future work will also focus on incorporating BISON into the SEFOR core modeling process to enable the first Multiphysics simulations of the isothermal tests based on the MOOSE framework.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

Julia Programming Language Benchmark Using a Flight Simulation

Julia’s goal to provide scripting language ease-of-coding with compiled language speed is explored. The runtime speed of the relatively new Julia programming language is assessed against other commonly used languages including Python, Java, and C++. An industry-standard missile and rocket simulation, coded in multiple languages, was used as a test bench for runtime speed. All language versions of the simulation, including Julia, were coded to a highly-developed object-oriented simulation architecture tailored specifically for time-domain flight simulation. A “speed-of-coding” second-dimension is plotted against runtime for each language to portray a space that characterizes Julia’s scripting language efficiencies in the context of the other languages. With caveats, Julia runtime speed was found to be in the class of compiled or semi-compiled languages. However, some factors that affect runtime speed at the cost of ease-of-coding are shown. Julia’s built-in functionality for multi-core processing is briefly examined as a means for obtaining even faster runtime speed. The major contribution of this research to the extensive language benchmarking body-of-work is comparing Julia to other mainstream languages using a complex flight simulation as opposed to benchmarking with single algorithms.

Sells, Ray↗

Labyrinth Seal Flutter Analysis and Test Validation in Support of Robust Rocket Engine Design

High energy-density turbomachines, like the SSME turbopumps, utilize labyrinth seals, also referred to as knife-edge seals, to control leakage flow. The pressure drop for such seals is order of magnitude higher than comparable jet engine seals. This is aggravated by the requirement of tight clearances resulting in possible unfavorable fluid-structure interaction of the seal system (seal flutter). To demonstrate these characteristics, a benchmark case of a High Pressure Oxygen Turbopump (HPOTP) outlet Labyrinth seal was studied in detail. First, an analytical assessment of the seal stability was conducted using a Pratt & Whitney legacy seal flutter code. Sensitivity parameters including pressure drop, rotor-to-stator running clearances and cavity volumes were examined and modeling strategies established. Second, a concurrent experimental investigation was undertaken to validate the stability of the seal at the equivalent operating conditions of the pump. Actual pump hardware was used to construct the test rig, also referred to as the (Flutter Rig). The flutter rig did not include rotational effects or temperature. However, the use of Hydrogen gas at high inlet pressure provided good representation of the critical parameters affecting flutter especially the speed of sound. The flutter code predictions showed consistent trends in good agreement with the experimental data. The rig test program produced a stability threshold empirical parameter that separated operation with and without flutter. This empirical parameter was used to establish the seal build clearances to avoid flutter while providing the required cooling flow metering. The calibrated flutter code along with the empirical flutter parameter was used to redesign the baseline seal resulting in a flutter-free robust configuration. Provisions for incorporation of mechanical damping devices were introduced in the redesigned seal to ensure added robustness

El-Aini, Yehia↗