Engineering Papers⌕ Search

SEARCH · Engineering Papers

Results for “process cooling”

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

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 1,351 records · Page 75
All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

Interplay of strain and phase evolution of laser powder bed fusion Ti–6Al–4V

While additive manufacturing (AM) provides a method of producing geometrically complex and highly detailed structures, the generation of residual strain in AM processes like laser powder bed fusion (L-PBF) can negatively impact performance-enabling properties. In applications such as orthopedic implants, specific performance windows require optimized microstructures in order to obtain desirable properties from multi-phase alloys like Ti–6Al–4V. This research aims to quantify the microscale origins of strain in L-PBF manufactured Ti–6Al–4V by understanding how strain is distributed at the grain and sub-grain scale, the interplay between phase evolution and strain, and examining post-processing strain relief strategies to control these features. Model spinal cage implants were manufactured from Ti–6Al–4V powder via L-PBF and then subjected to strain relieving heat treatment cycles above and below the Ti–6Al–4V β transus as a function of time and cooling rate. Residual strain was then studied via high resolution electron backscatter diffraction (HR-EBSD), and 2D strain maps with sub-micron resolution were generated for each post-processing state. It was found that macroscale thermal strains decreased with heat treatment time, but additional contributions from phase stabilizing residual strains retained primarily in the α' grains as lattice distortive strain remained. Additionally, the retention of β phase significantly changed the strain and dislocation distribution while reducing overall residual strain. In conclusion, these results were validated and reinforced with 3D mesoscopic micromechanical modeling of strain behavior across simulated microstructures, confirming that the local lattice dilation of α’ martensite is a primary contributor of microscale strain generation and retention in L-PBF Ti–6Al–4V.

36 MATERIALS SCIENCE↗
NASA NTRS2004

Turbulent Jet Flames Into a Vitiated Coflow

Examined is the vitiated coflow flame, an experimental condition that decouples the combustion processes of flows found in practical combustors from the associated recirculating fluid mechanics. The configuration consists of a 4.57 mm diameter fuel jet into a coaxial flow of hot combustion products from a lean premixed flame. The 210 mm diameter coflow isolates the jet flame from the cool ambient, providing a hot environment similar to the operating conditions of advanced combustors; this important high temperature element is lacking in the traditional laboratory experiments of jet flames into cool (room) air. A family of flows of increasing complexity is presented: 1) nonreacting flow, 2) all hydrogen flame (fuel jet and premixed coflow), and 3) set of methane flames. This sequence of experiments provides a convenient ordering of validation data for combustion models. Laser Raman-Rayleigh-LIF diagnostics at the Turbulent Diffusion Flame laboratory of Sandia National Laboratories produced instantaneous multiscalar point measurements. These results attest to the attractive features of the vitiated coflow burner and the well-defined boundary conditions provided by the coflow. The coflow is uniform and steady, isolating the jet flame from the laboratory air for a downstream distance ranging from z/d = 50-70. The statistical results show that differential diffusion effects in this highly turbulent flow are negligible. Complementing the comprehensive set of multiscalar measurements is a parametric study of lifted methane flames that was conducted to analyze flame sensitivity to jet and coflow velocity, as well as coflow temperature. The linear relationship found between the lift-off height and the jet velocity is consistent with previous experiments. New linear sensitivities were found correlating the lift-off height to coflow velocity and temperature. A blow-off study revealed that the methane flame blows off at a common coflow temperature (1260 K), regardless of coflow or jet velocity. An explanation for this phenomenon is that entrainment of ambient air at the high lift-off heights prevents autoignition. Analysis of the results suggests that flame stabilization occurs through a combination of flame propagation, autoignition, and localized extinction processes. Proposed is an expanded view of distributed reaction combustion based on analysis of the distributions of probe volume conditions at the stabilization region of the lifted hydrogen and methane flames. Turbulent eddies the size of the flame thickness mix fuel and hot coflow across the flame front, thereby enhancing the reaction zone with autoignition of reactants at elevated temperatures; this is the reverse effect of turbulent flames in ambient air, where intense turbulence in cool mixtures result in localized extinction. Each of the three processes (i.e., flame propagation, autoignition and localized extinction) contributes to flame stabilization in varying degrees, depending on flow conditions.

Holdeman, James D.↗
NASA NTRS2021

Physics and Chemistry of Te and HgTe-based Ternary Melts

Historically, the theoretical treatment of the liquid phases has always been more difficult and complicated than that for solid and gas phases. A liquid has no lattice structure as crystalline solids and the atoms/molecules in the liquid can migrate through it relatively rapidly. On the other hand, it is also interacting with many other atoms/molecules so that the simplifications of the kinetic theory of gases cannot be employed. For more complicated liquids, such as the liquids of high ionicity and those containing hydrogen bonds and electric dipoles, the understanding is far from complete. At the same time, accurate information on the physics and chemistry of semiconductor melts is needed for the quantitative descriptions of the process of crystal growth from melt. The pre-crystallization phenomena in the liquid phase are critical because the properties of the grown crystals depend on the state and structure of the melt as well as the thermal history of the melt during solidification process. However, the data on the liquid phase, such as thermophysical properties of semiconductor melts are scarce, especially for the HgTe-based II-VI ternary compound semiconductors because of their high vapor pressure and extreme toxicity. Analysis of the thermophysical properties of the melt can provide information about structural transitions of the melt during the solidification process. From a broader point of view, the structure of liquids is much more complicated than the crystalline solids, especially the relaxation behavior through different thermal histories. The theory of hetero-phase fluctuations of liquids is applicable to any many-body systems including condensed-matter physics, field theory, physics of nuclear-matter, cosmology, biology and even sociology. This book summarizes the physics and chemistry from the experimental measurements and theoretical analyses of phase diagram, thermodynamic properties, density, thermal conductivity, viscosity, and electrical conductivity on the binary, pseudo-binary and ternary melts of the most advanced IR-detector material systems of HgCdTe and HgZnTe as well as the analyses of these results. The main objectives of this study are: (1) to provide the phase diagrams and thermodynamic properties of Hg-Cd-Te and Hg-Zn-Te systems through quantitatively fitting the experimental data by assuming an associated solution model for the liquid phase, (2) to experimentally measure the thermophysical properties of the Hg-Cd-Te and Hg-Zn-Te melts, including density, viscosity, electrical conductivity and thermal conductivity as functions of temperature and composition and (3) to enhance the fundamental knowledge of hetero-phase fluctuations and relaxation phenomena in the melts and extend our understanding of the solidification process in order to interpret the experimental results of crystal growth so as to improve the melt growth processes of the compound semiconductor. The physics and chemistry of Te and HgTe-based ternary melts were explored through the studies of the structural transformation during melting, the supercooling during solidification, the relaxation phenomena after rapid cooling of the melts and the metal-semiconductor transition in the melts through the analyses of electrical conductivity and Lorenz number. An in-depth study on the thermophysical properties and their time-dependent structural dynamic processes taking place in the vicinity of the solid-liquid phase transition of the narrow homogeneity range HgTe-based ternary semiconductors as well as the analysis of the homogenization process in the melt will also be presented.

Thermophysical properties↗
DOE OSTI2024

High-order harmonics and the reverse of the squaring up process in the triangular-lattice magnet HoPdAl 4 ⁢Ge 2

We uncover high-order harmonics and the reverse of the squaring-up process, in terms of analyzing the evolution of magnetic orders in a centrosymmetric layered triangular-lattice magnet HoPdAl 4 ⁢Ge 2 , based on a detailed study of the crystal structure, magnetic susceptibility, magnetization, heat capacity, and magnetic structure. Temperature dependencies of magnetic susceptibility and heat capacity show two magnetic transitions at T N = 10.5 K and T t = 5.5 K. Below T N , Ho 3+ spins order antiferromagnetically as a transverse spin-density wave with the propagation vector k 1 = (001.5 – δ) with δ ≈ 0.18. Upon further cooling through T t , the high-order harmonics with k n = (001.5 – nδ), n = 3, 5, 7 develop, suggesting a squaring-up process. It is surprising that the squaring-up process does not continue down to 0 K but reverses the trend below 3 K. Magnetic-field-induced metastable transitions were observed in M⁡(H) curves with the fields applied both parallel and perpendicular to the triangular-lattice plane. Neutron-diffraction results suggest that the magnetization process in HoPdAl 4 ⁢Ge 2 involves the conversion of k n = (001.5 – n⁢δ) with n = 1, 3, 5, 7, to a ferromagnetic k F = (000) component. It is worth noting that the already weak seventh harmonic magnetic peak is enhanced by applying a small magnetic field in the ab plane at 1.5 K or warming up to 3 K, accompanied by a slight decrease of δ.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
NASA NTRSDate not supplied

In-Situ Detection of Process-Induced Porosity During Cure of Out-of-Autoclave Composites

Composite materials offer unique benefits in aerospace applications and are becoming increasingly used by industry manufacturers. Current manufacturing and processing methods can lead to defects in the composites, which are identified after fabrication using inspection methods.This study utilized a high-temperature ultrasonic inspection system to detect process-induced porosity in an out-of-autoclave (OOA) composite panel. An ultrasonic scanner was enclosed in a nitrogen-cooled insulating box that prevented thermal damage from the industrial oven to the temperature-sensitive electronics. Inspection of the composite part was performed through the bottom of the enclosure, which served as the tool plate for the part. In this study, a porosity gradient was introduced through a misfit of the part and caul plate. Using the data obtained from B-scans and amplitude C-scans throughout the cure cycle, the high and low porosity regions within the composite laminate were detected and localized. OOA tests aided the transition of this system to an autoclave, which is the primary method of curing aerospace-grade thermoset composites.

In-process, Defect Detection, Cure Monitoring, Por↗
DOE OSTI2022

Zero Liquid Discharge and Water Reuse in Recirculating Cooling Towers at Power Facilities: Review and Case Study Analysis

Zero liquid discharge (ZLD) systems installed at power facilities with the primary purpose of meeting water discharge regulations have the added benefit of providing high quality effluent that can be reused in the facility. This paper provides a review of water use in power sector recirculating cooling towers and a baseline assessment of on-site water reuse at natural gas combined cycle (NGCC) power facilities. Two NGCC facilities with reverse-osmosis (RO) or brine-concentrator processes followed by evaporation ponds were selected as case studies; data from these facilities were used to quantify the water, energy, and cost implications of implementing conventional and emerging ZLD technologies. At one case study facility, model results show that implementation of ZLD would reduce water withdrawals by 18%, which is less than savings associated with implementation of dry cooling but comparable to current efforts to reduce water withdrawals by increasing cycles of concentration. Implementation of ZLD using high-recovery RO resulted in a doubling of the levelized cost of water (LCOW). LCOW increased more when a brine concentrator was used. For both case studies, the ZLD system using high-recovery RO required less than 0.1% of a facilitiy's annual electricity generation and the ZLD system using a brine concentrator process required less than 0.8%. Additionally, increasing the evaporation pond area to minimize required ZLD system recovery rates and reduce system electricity costs does not reduce the LCOW. Instead, the LCOW increases because less water is recovered and more water is lost to evaporation. Furthermore, if water availability decreases or water competition/cost increases, facilities may be incentivized to maximize water recovery from ZLD systems.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2025

Bi‐Continuous W‐Rich Refractory High Entropy Alloy‐Cu Composite: Toward Material Innovation of Nuclear Reactor Coolant System

Abstract Refractory high‐entropy alloys (RHEAs) are considered promising candidate materials for next‐generation nuclear reactors due to their superior mechanical strength, irradiation resistance, and thermal stability at high temperatures. However, the significant positive heat of mixing between refractory alloying elements and Cu, commonly used in cooling systems, poses challenges in forming composite structures. This study addresses the issue using a liquid metal dealloying (LMD) process. A precursor alloy (WTaVTi) with a directional dendrite‐interdendrite structure is fabricated and reacted with molten Cu at 1200 °C for 96 h. This approach produced a RHEA‐Cu composite with a stable interface between RHEA (W 31.5 Ta 30.9 V 21.4 Ti 14.3 ) and Cu, featuring a spontaneously formed W‐rich interlayer that enhances interfacial bonding. The composite showed excellent irradiation resistance, with 30% less swelling under α‐ion irradiation than pure W. It also exhibited low thermal conductivity at room temperature, but reached ≈120 W m −1 ·K −1 at ≈650 °C, surpassing pure W. This temperature‐dependent rise in κ, with a positive gradient of +0.075 W m −1 ·K − 2 , is attributed to decreasing diffuse mismatch at elevated temperatures. The large‐scale reaction and stable microstructure achieved through LMD process highlight its industrial potential. This work offers a strategy for developing high‐performance materials by combining RHEA's radiation resistance with Cu's thermal conductivity for extreme environments.

Chemistry↗
DOE OSTI2022

Texture analysis of AGR program matrix materials

We report the fuel form for high-temperature gas-cooled reactors consists of tristructural isotropic (TRISO) particles embedded in a matrix of graphite flake and carbonized resin. The process of overcoating particles prior to compacting yields a circumferential orientation of the graphite flake surrounding the TRISO particles, which is modified to varied extents when overcoated particles are pressed into the final fuel form. As graphite is highly anisotropic, the texture may impact the properties and performance of the fuel. Ellipsometry was used to measure the texture of the matrix for fueled compacts and unfueled “matrix-only” samples. Results indicated local texture related to the spherical particles in compacts associated with overcoating versus a more linear layered structure in “matrix-only” samples.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2026

A MINi Powder INjector (MINPIN) for the SMART tokamak

Here, this article presents the design and performance characterization of a MINi Powder INjector (MINPIN) developed for boron wall conditioning (boronization) in the SMall Aspect Ratio Tokamak (SMART) at the University of Seville, Spain. SMART studies positive and negative triangularity plasmas within the low aspect ratio range of 1.4 < R/a < 3, with a major radius (R) of 0.40–0.60 m and a minor radius (a) of 0.20–0.33 m. MINPIN, in design, will gravitationally deliver boron (B) powder into the plasma, which ablates and transports the injected material. Mounted on the top of the vessel, the MINPIN will drop controlled amounts of powder using a piezoelectric blade driven by a signal generator that vibrates at a set frequency. The B will then be deposited in a layer on SMART’s stainless steel vacuum vessel walls, and this boronization process reduces the influx of intrinsic wall impurities, such as oxygen, carbon, nitrogen, and iron, which radiate power and cool the plasma. In the laboratory, we calibrated the drop rate for 1–10 mg/s, which will enable controlled boronization coating while achieving efficient powder ablation. We propose MINPIN’s operational scenarios based on the calibrated drop rate and estimated drop duration, assuming the distance from MINPIN to SMART’s plasmas.

Boron powder↗
DOE OSTI2024

Novel Hot Gas Components for Gas Turbine Engines Enabled by Materials and Additive Manufacturing Process Development

Additive Manufacturing (AM), also known as 3D printing, has emerged as a manufacturing method that enables new design freedom for gas turbine engine manufacturers. However, the material selection for AM processable high-temperature super alloys is currently limited. Additionally, the heat transfer performance of AM enabled micro-cooling architectures is not yet well understood. Accordingly, in support of advanced manufacturing and engine performance development, Oak Ridge National Laboratory (ORNL)and Solar Turbines (Solar) conducted a multidisciplinary project to generate both AM super alloy material properties data and micro-channel performance data for two AM super alloys. The data supported the design and analysis of an internally cooled turbine hot section AM tip shoe component. This data was used to analytically predict the reduction in operating temperature of a gas turbine tip shoe. The work concluded that the cooling flow required to cool the tip shoe can be tuned to suit the efficiency improvements desired in an industrial gas turbine.

36 MATERIALS SCIENCE↗
NASA NTRS1972

A microwave-biased millimeter- and submillimeter-wave detector using InSb.

Description of a high-purity n-type indium antimonide sample mounted in a reentrant cavity, cooled to 4.2 K, and operated as a millimeter-wave detector. The scheme utilizes a down-conversion process, and free-carrier absorption is the mechanism responsible for the detection process. Power applied at the millimeter-wave frequency causes a change in the material conductivity, which in turn causes a change in the X-band power absorption. Cavity perturbation techniques are used to analyze the scheme. The detector was operated successfully at frequencies between 35 and 150 GHz with no long-wavelength or short-wavelength cutoff observed. The scheme offers a fast, highly sensitive, and rugged detector with low conversion loss.

Eldumiati, I. I.↗
NASA NTRS1974

Shuttle active thermal control system development testing. Volume 1: Overall summary

A summary is given of a series of thermal vacuum tests designed to support the development of the orbiter active thermal control system (ATCS) and included testing of a wide heat load range modular radiator system (MRS) configured to the March 1973 orbiter baseline system, a candidate weight reducing radiator/water cooling system, and a smaller radiator system with a high performance radiator coating. The tests verified the performance of the baseline system and obtained detailed design information for application of a wide heat load range modular radiator system to the orbiter. The two candidate ATCS weight reducing designs have undergone extensive concept verification testing and their system operating characteristics have been determined in sufficient detail for application to the orbiter. Design information has been obtained for an integrated radiator/water cooling system that provides for vehicle heat rejection as well as water management of the excess fuel cell water. Processing techniques have been developed and verified for the application of a high performance thermal control coating to large radiator areas subjected to a temperature range of -280 F to +160 F.

Howell, H. R.↗
NASA NTRS1976

Heat transfer to a full-coverage film-cooled surface with 30 degree slant-hole injection

Heat transfer behavior was studied in a turbulent boundary layer with full coverage film cooling through an array of discrete holes and with injection 30 deg to the wall surface in the downstream direction. Stanton numbers were measured for a staggered hole pattern with pitch-to-diameter ratios of 5 and 10, an injection mass flux ratio range of 0.1 to 1.3, and a range of Reynolds number Re sub x of 150,000 to 5 million. Air was used as the working fluid, and the mainstream velocity varied from 9.8 to 34.2 m/sec (32 to 112 ft/sec). The data were taken for secondary injection temperature equal to the wall temperature and also equal to the mainstream temperature. The data may be used to obtain Stanton number as a continuous function of the injectant temperature by use of linear superposition theory. The heat transfer coefficient is defined on the basis of a mainstream-to-wall temperature difference. This definition permits direct comparison of performance between film cooling and transpiration cooling. A differential prediction method was developed to predict the film cooling data base. The method utilizes a two-dimensional boundary layer program with routines to model the injection process and turbulence augmentation. The program marches in the streamwise direction, and when a row of holes is encountered, it stops and injects fluid into the boundary layer. The turbulence level is modeled by algebraically augmenting the mixing length, with the augmentation keyed to a penetration distance for the injected fluid.

Crawford, M. E.↗
NASA NTRS1977

Model of climate evolution based on continental drift and polar wandering

The thermodynamic meteorologic model of Adem is used to trace the evolution of climate from Triassic to present time by applying it to changing geography as described by continental drift and polar wandering. Results show that the gross changes of climate in the Northern Hemisphere can be fully explained by the strong cooling in high latitudes as continents moved poleward. High-latitude mean temperatures in the Northern Hemisphere dropped below the freezing point 10 to 15 m.y. ago, thereby accounting for the late Cenozoic glacial age. Computed meridional temperature gradients for the Northern Hemisphere steepened from 20 to 40 C over the 200-m.y. period, an effect caused primarily by the high-latitude temperature decrease. The primary result of the work is that the cooling that has occurred since the warm Mesozoic period and has culminated in glaciation is explainable wholly by terrestrial processes.

Donn, W. L.↗
NASA NTRS1981

Undercooling measurement in a low-gravity containerless environment

A technique is described for measuring the amount of undercooling for samples processed in a low-gravity containerless environment. The time of undercooling is determined by measuring the time of cooling before nucleation and recalescence by two infrared detectors. Once the cooling curve for each drop is calculated, the amount of undercooling can then be found. The technique is demonstrated by measuring the amount of undercooling for drops of pure niobium and select compositions of the niobium-germanium alloy system while free falling in a 32 n evacuated drop tube. The total hemispherical emissivities and specific heats for these materials were measured using a high-temperature containerless calorimeter. An overview of the effect of undercooling on drops of niobium and niobium-germanium is given.

Robinson, M. B.↗
NASA NTRS1981

Low NO sub x heavy fuel combustor concept program

A gas turbine technology program to improve and optimize the staged rich lean low NOx combustor concept is described. Subscale combustor tests to develop the design information for optimization of the fuel preparation, rich burn, quick air quench, and lean burn steps of the combustion process were run. The program provides information for the design of high pressure full scale gas turbine combustors capable of providing environmentally clean combustion of minimally of minimally processed and synthetic fuels. It is concluded that liquid fuel atomization and mixing, rich zone stoichiometry, rich zone liner cooling, rich zone residence time, and quench zone stoichiometry are important considerations in the design and scale up of the rich lean combustor.

Russell, P.↗
NASA NTRS1984

Accretion by magnetic neutron stars. II - Plasma entry into the magnetosphere via diffusion, polar cusps, and magnetic field reconnection

A variety of entry modes were investigated to determine whether most of the accreting plasma enters the magnetosphere as a result of hydromagnetic instability or via other means. It is shown that diffusion is never important under the conditions of interest, nor is the loss-cone entry through the polar cusps when the plasma is collisionless. Although the loss-cone entry rate can be significantly increased if the plasma in the cusps cools and becomes collisional, this cannot stabilize the magnetosphere. The descent of the cusps cannot be the dominant entry process if the star has a persistent luminosity greater than about 10 to the 36th erg/s and a substantial fraction of the magnetosphere is illuminated. This, however, can be a significant entry process for much lower luminosities or strongly anisotropic illumination. The possibility that plasma entry via reconnection can stabilize the magnetosphere is also unlikely.

Elsner, R. F.↗
NASA NTRS1985

A study on radiative damping of planetary waves utilizing stratospheric observations

Satellite ozone observations made by the Stratospheric Aerosol and Gas Experiment (SAGE) and corresponding meteorological temperature data are used to study the radiative damping processes associated with planetary waves during stratospheric warmings. Ramanathan's model has been adapted for the radiative heating and cooling calculations. The derived infrared damping coefficients, based on observed stratospheric ozone and temperature, are compared with the Newtonian cooling coefficients of Dickinson and Fels. It is also shown that the negative correlation between temperature and ozone solar heating in the upper stratosphere accelerates the damping rate due to infrared cooling alone, in agreement with the theoretical analysis and an earlier report based on observations. In addition, it is also found in this analysis that the phase relationship between ozone and solar heating waves is characterized by its behavior in three distinct layers. In the regions above about 2 mb and also below about 10 mb, the waves are closely in-phase. Between approximately 2 and 10 mb, they show a departure from the in-phase relationship which can be attributed to the so-called 'opacity effect'. This effect significantly determines the magnitude of radiative damping.

Ghazi, A.↗