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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.

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At least 1,423 records · Page 79
All sourcesNASA NTRSDOE OSTI
NASA NTRS2019

Channel Wall Nozzle Manufacturing Technology Advancements for Liquid Rocket Engines

A regeneratively-cooled nozzle is a critical component for expansion of the hot gases to enable high temperature and performance liquid rocket engines systems. Channel wall nozzles are a design solution used across the propulsion industry as a simplified method to fabricate the nozzle structure with internal coolant passages. The scale and complexity of the channel wall nozzle (CWN) design is challenging to fabricate leading to extended lead times and higher costs. Some of these challenges include: 1) unique and high temperature materials, 2) Tight tolerances during manufacturing and assembly to contain high pressure propellants, 3) thin-walled features to maintain adequate wall temperatures, and 4) Unique manufacturing process operations and tooling. The United States (U.S.) National Aeronautics and Space Administration (NASA) along with U.S. specialty manufacturing vendors are maturing modern fabrication techniques to reduce complexity and decrease costs associated with channel wall nozzle manufacturing technology. Additive Manufacturing (AM) is one of the key technology advancements being evaluated for channel wall nozzles. Much of additive manufacturing for propulsion components has focused on powder bed fusion, but the scale is not yet feasible for application to large scale nozzles. NASA is evolving directed energy deposition (DED) techniques for nozzles including arc-based deposition, blown powder deposition, and Laser Wire Direct Closeout (LWDC). There are different approaches being considered for fabrication of the nozzle and each of these DED processes offer unique process steps for rapid fabrication. The arc-based and blown powder deposition techniques are being used for the forming of the CWN liner. A variety of materials are being demonstrated including Inconel 625, Haynes 230, JBK-75, and NASA HR-1. The blown powder DED process is also being demonstrated for forming an integral channel nozzle in a single operation in similar materials. The LWDC process is a method for closing out the channels within the liner and forming the structural jacket using a localized laser wire deposition technique. Identical materials mentioned above have been used for this process in addition to bimetallic closeout (C-18150–SS347, and C-18150–Inconel 625). NASA has completed process development, material characterization, and hot-fire testing on a variety of these channel wall nozzle fabrication techniques. This paper will present an overview of the various processes and materials being evaluated and the results from the hot-fire testing. Future development and technology focus areas will also be discussed relative to channel wall nozzle manufacturing.

Gradl, Paul R.↗
NASA NTRS2010

TPSAS-NF1676L-10636-DND

A new impedance eduction technique that is void of microphones in the liner test section has been developed. The new impedance eduction technique is ideally suited for curved ducts. When used with synthesized data, the new technique is as robust as the one requiring the use of wall mounted microphones in the liner test section

Willie R Watson↗
NASA NTRS2020

Technology Advancements for Channel Wall Nozzle Manufacturing In Liquid Rocket Engines

A regeneratively-cooled or dump-cooled nozzle is a critical component for expansion of hot gases to enable high temperature and performance in liquid rocket engines systems. Regeneratively-cooled channel wall nozzles are a design solution used across the propulsion industry as a simplified method to fabricate the nozzle structure with internal coolant passages. The scale and complexity of the channel wall nozzle (CWN) design can be challenging to fabricate which results in extended lead times and higher costs. Some of these challenges include: 1) Unique and high temperature materials, 2) Tight tolerances on large parts during manufacturing and assembly to contain high pressure propellants, 3) Thin-walled features to maintain adequate wall temperatures, and 4) Unique manufacturing process operations and complex tooling. The United States (U.S.) National Aeronautics and Space Administration (NASA) and U.S. specialty manufacturing vendors are maturing modern fabrication techniques to reduce complexity and decrease costs associated with channel wall nozzle manufacturing technology. Additive Manufacturing (AM) is one of the key technology advancements under evaluation for channel wall nozzles. Much of additive manufacturing for propulsion components has focused on laser powder bed fusion (L-PBF), but the scale is not yet feasible for application to large scale nozzles. NASA is evolving directed energy deposition (DED) techniques for nozzles including arc-based deposition, blown powder deposition, and Laser Wire Direct Closeout (LWDC). There are different approaches being considered for fabrication of the nozzle, and each of these DED processes offer unique process steps for rapid fabrication. The arc-based and blown powder deposition techniques are used for the forming of the CWN liner. A variety of materials are being demonstrated including Inconel 625, Haynes 230, JBK-75, and NASA HR-1. The blown powder DED process is also being demonstrated for forming an integral channel nozzle in a single operation in similar materials. The LWDC process is a method for closing out the channels within the liner and forming the structural jacket using a localized laser wire deposition technique. Identical materials mentioned above have been used for this process in addition to bimetallic closeout (C-18150–SS347, and C-18150–Inconel 625). NASA has completed process development, material characterization, and hot-fire testing on a variety of these channel wall nozzle fabrication technique. This publication presents an overview of the various channel wall nozzle manufacturing processes and materials under evaluation including results from the hot-fire testing. Future development and technology focus areas is also discussed relative to channel wall nozzle manufacturing.

Additive manufacturing↗
NASA NTRS2020

Composite Overwrapped Pressure Vessel (COPV) Damage Tolerance Life Analysis Methodology and Test Best Practices

The NASA Engineering and Safety Center (NESC) Deputy Director requested an independent assessment to develop data to understand the limitations of linear elastic fracture mechanics (LEFM) computational methods used to predict fatigue crack growth rate (da/dN) behavior of small detectable cracks in thin metal liners for composite overwrapped pressure vessels (COPVs). The NESC assessment team was also requested to demonstrate a test-based methodology for validating damage tolerance requirements for COPVs with elastically responding metal liners where LEFM methods are not appropriate. This report contains the outcome of the NESC assessment.

Composite Overwrapped Pressure Vessels; Linear Ela↗
NASA NTRS2020

Composite Overwrapped Pressure Vessel (COPV) Damage Tolerance Life Analysis Methodology and Test Best Practices: Appendices

The NASA Engineering and Safety Center (NESC) Deputy Director requested an independent assessment to develop data to understand the limitations of linear elastic fracture mechanics (LEFM) computational methods used to predict fatigue crack growth rate (da/dN) behavior of small detectable cracks in thin metal liners for composite overwrapped pressure vessels (COPVs). The NESC assessment team was also requested to demonstrate a test-based methodology for validating damage tolerance requirements for COPVs with elastically responding metal liners where LEFM methods are not appropriate. This document contains the appendices to the main report.

Composite Overwrapped Pressure Vessels; Linear Ela↗
NASA NTRSDate not supplied

Fan Acoustic Flight Effects on the PAA & ASN Flight Test

Accurate and reliable prediction of noise emitted from turbofan aircraft engines is an ongoing challenge. For continued progress, it is necessary to assess the performance of the most recent prediction methods in the NASA Aircraft NOise Prediction Program (ANOPP), and to examine the effects of flight condition on fan noise. The assessment is based on an extensive acoustic dataset acquired as part of the Propulsion Airframe Aeroacoustics and Aircraft System Noise (PAA&ASN) Flight Test conducted on a Boeing 787-10 aircraft. Engine operating condition was varied to study the characteristics of fan noise in flight. In a subset of the flight test matrix, the influence of the aft duct acoustic liner was studied by covering the lined area with aluminum tape to simulate a hardwall duct. The combination of test data at different flight conditions, along with rigorous predictions of jet noise, is used in this paper to extract fan noise from the measured total aircraft noise levels. The measured fan noise levels are compared with those predicted using the latest methods for fan source noise, liner attenuation, and PAA effect prediction. Detailed analyses are undertaken to understand agreement between data and various aspects of the prediction models, including spectral shape, directivity, and response to throttle setting. An additional investigation was undertaken to study the effect of aircraft speed on fan noise, as current models do not directly account for this parameter.

Aircraft System Noise↗
NASA NTRSDate not supplied

Validation of Noise Propagation for Lined Inlets

Commercial finite element modeling tools are validated for use on inlet radiated noise predictions for an acoustically lined subsonic aircraft inlet tested in the NASA Glenn 9-foot by 15-foot low-speed wind tunnel. An in-depth review and prediction of the acoustic liner properties on the Advanced Ducted Propulsor were conducted for use in the noise predictions. Agreement between the inlet radiated noise predictions to the measured tones at approach was used as the validation for the prediction tools. Similar follow-up predictions were conducted for an acoustically lined supersonic inlet. A follow-up investigation on the effect of the acoustic liner placement within the supersonic inlet was undertaken.

Acoustics↗
NASA NTRSDate not supplied

Expanding the Capability of A Legacy Combustion Flametube to Test High Temperature Engine Materials in Relevant Environments

New materials and component designs are needed to advance gas turbine engine technology and provide the performance and efficiency needs for future applications. In order to advance these materials, testing in combustion environments is a critical step prior to engine testing. In this work, we detail the design and the fabrication of a materials test sector in a flametube combustor facility. The facility simulates a combustion environment similar to that experienced by components in gas turbine engines. The flow regime is characterized by a combination of high-temperature, high-velocity, high-heat flux, and high-velocity that components experience in gas turbine engines. Exposure of components in this facility allows for the study of combined environmental effects and the impact on both coating and substrate durability. The test facility may operate across a wide range of pressures from 275-400 psig (1,896-2,758 kPa) and an air flow rate of 5 lb/s (2.27 kg/s). While combustion gas temperature is expected in excess of 3,000°F (1,649°C), 900°F (482°C) cooling air may be supplied to the backside of components or test articles. The flametube combustor was previously used to evaluate fuel injectors and combustion products, and the new test configuration will also allow for materials exposure to complex, engine-like conditions. The interior of the Test Section was additively manufactured from GRCop-84 and cryogenically fit and brazed to a stainless steel 304 housing. The use of a copper liner minimizes welds and with active cooling, is expected to provide better durability over traditional hardware using stainless steel or Inconel with a ceramic liner. The Test Section has two opposing removable windows approximately 230 mm x 80 mm that can accommodate articles up to 85 mm tall. This modular design allows for custom platforms to hold coupons, panels, or airfoil shapes to be tested with minimal re-engineering or fabrication. The bolted joint and sealing remains consistent, so any new testing only needs to work within the existing design footprint. This paper will provide an overview of the facility capabilities, design considerations, as well as thermal and structural analysis of the hardware. Future testing of ceramic matrix composite (CMC) airfoils and advanced environmental barrier coatings (EBCs) will also be discussed.

Combustion↗
NASA NTRS2024

Background Turbulence Characterization of the Curved Duct Test Rig

Interest in applying acoustic treatment to nontraditional locations of turbofan engines has led to recent testing of acoustically treated airfoils in the NASA Langley Curved Duct Test Rig. Current testing focuses only on sound attenuation by the sample when exposed to an incident sound field driven by a loudspeaker array. However, there may be much to gain from an aeroacoustic study of the interaction of turbulence with treated airfoils, especially in the case of acoustically treated outlet guide vane designs. Thus, the intent of this study is to take the first step in assessing the aeroacoustic quality of the NASA Langley Curved Duct Test Rig (typically only used for grazing flow studies) by examining the flow quality. The background turbulence levels are measured using hot-wire anemometry just upstream of the test section. Measurements indicate that the turbulence intensity is less than 0.3% in the core region of the flow. The autospectral densities show cavity tones and weak vortex shedding present in the core. The vortex shedding is determined to be from the upstream total pressure probe used to determine flow speed. The cavity tones are found to be the fundamental and harmonic frequencies of a porous ceramic tubular acoustic liner sample that separates the acoustic drivers from the flow region. Recommendations for improving the aeroacoustic quality of the tunnel are provided, such as removing the upstream probe and redesigning the ceramic tubular liner. Future acoustic characterization of the background levels is also recommended to further understand the feasibility of aeroacoustic studies in CDTR.

Wind Tunnel Characterization↗
NASA NTRS2024

Hybrid Thermally Efficient Core (HyTEC) HyTEC Phase 1 – Combustor Final Report

The objective of the HyTEC – Combustor Technology project is to develop technology for a compact, low emissions, rich-burn combustor that maintains a high-level of durability. To accomplish this, the combustor will incorporate CMC liners and a CMC Dome to enable improved air utilization for mixing and NOx reduction. In particular, three technology areas were matured: metallic swirler attachment to the CMC dome, Nickel diffusion in CMC, and EBC advancements with improved durability. The maturation of these technology areas is critical to successfully designing a combustor for an engine intended to demonstrate increased thermal efficiency with integrated high-power density-core engine technologies. As part of the project, multiple swirler attachment architectures were matured through the design process, manufactured, and tested in simulated engine conditions. These architectures utilized two different approaches to attachment: a pressure loaded approach and a clamped approach. Each approach required testing at simulated engine conditions to mature the technology. These tests were developed to ensure that the probable failure mechanisms for each architecture were assessed relative to its long-term durability. After successfully testing both approaches, the pressure loaded approach was chosen based on its simplicity and its similarity to the attachment approach used on lean burn combustors. Finally, this successful testing resulted in the swirler attachment technology achieving TRL 4 status. Another aspect of concern with the metallic swirler attachment is the potential for nickel diffusion into the CMC to cause durability shortfalls. A series of tests were completed to understand both the amount of nickel that is expected to diffuse into the CMC and the effect this diffusion will have on mechanical properties of the CMC. After successfully completing this testing, the reduction in local mechanical properties was found to not have an impact on the overall durability of the CMC Dome. To further improve the overall durability, three different EBC coating architectures were also studied. One of these coatings being the current state of the art for CMC liners with the other two being proposed improvements. Coupons were produced using each coating and subjected to a series of laboratory testing. One coating was found to have an overall superior durability in laboratory testing and survived rig testing without indication of degradation. This successful testing resulted in the EBC technology achieving TRL 5 status. Overall, a design approach was successfully down-selected that achieves both the TPM requirements and the need for TRL 4+ status. This design incorporates a pressure loaded swirler attachment with an improved EBC coating (Architecture 1). This combination allows the continued use of a CMC dome and results in an improved durability for the proposed compact core combustor.

CMC↗
NASA NTRSDate not supplied

Beyond Guesswork: Code Verification for Acoustic Duct Mode Prediction

The code used in the work (Swirl) is a frequency-domain linearized Euler equation solver that is designed to predict the effect of acoustic liners on acoustic modes propagating in realistic sheared and swirling mean flows, guiding the design of more efficient liner configurations. The purpose of this study is to validate Swirl using the Method Of Manufactured Solutions (MMS). This study also investigated the effect of the integration and spatial differencing methods on the convergence for a given Manufactured Solution. In addition, the effect of boundary condition implementation was tested. Through rigorous validation of the Swirl code using the MMS, this research underscores the significance of integration and spatial differencing methods on convergence, evaluates boundary condition implementations, and systematically assesses the impact of various filters.

Code Verification↗
NASA NTRSDate not supplied

An Extension of the Truncated Ingard-Myers Impedance Boundary Condition for High Mach Number Grazing Flows

The Ingard-Myers impedance boundary condition is widely recognized to be prone to hydrodynamic Kelvin-Helmholtz-type instability, primarily due to its use of a vortex sheet to model the flow at the boundary. Recently, a stabilized approximation of the Ingard-Myers condition, called the Truncated Ingard-Myers Impedance Boundary Condition (TIMIBC), has been introduced. This approximation offers a good representation of the Ingard-Myers condition for grazing flows characterized by low to mid subsonic Mach numbers. This paper explores an extension of the TIMIBC, referred to as TIMIBC-ext, designed for liners in grazing flows with high subsonic Mach numbers. The TIMIBC-ext introduces a tunable parameter and demonstrates that by judiciously selecting the parameter value, the accuracy of the TIMIBC can be improved for either upstream or downstream propagating waves in grazing flows with high subsonic Mach numbers. Consequently, the TIMIBC-ext represents an enhancement to the TIMIBC when the location of the source relative to the liner (upstream or downstream) is known. Time domain implementations of the TIMIBC-ext are also provided, employing a multipole expansion model for the impedance function. A numerical example is provided to assess the performance of the TIMIBC-ext, comparing computational results with measurements from a recent set of measurements in the NASA Langley Grazing Flow Impedance Tube.

time domain acoustic scattering↗
DOE OSTI2014

Hanford Double-Shell Tank AY-102 Radioactive Waste Leak Investigation Update - 15302

Tank AY-102 was the first of 28 double-shell radioactive waste storage tanks constructed at the U. S. Department of Energy’s Hanford Site, near Richland, WA. The tank was completed in 1970, and entered service in 1971. In August, 2012, an accumulation of material was discovered at two sites on the floor of the annulus that separates the primary tank from the secondary liner. The material was sampled and determined to originate from the primary tank. This paper summarizes the changes in leak behavior that have occurred during the past two years, inspections to determine the capability of the secondary liner to continue safely containing the leakage, and the initial results of testing to determine the leak mechanism.

Washenfelder, D. J.↗
DOE OSTI2013

Insulation assembly for electric machine

An insulation assembly is provided that includes a generally annularly-shaped main body and at least two spaced-apart fingers extending radially inwards from the main body. The spaced-apart fingers define a gap between the fingers. A slot liner may be inserted within the gap. The main body may include a plurality of circumferentially distributed segments. Each one of the plurality of segments may be operatively connected to another of the plurality of segments to form the continuous main body. The slot liner may be formed as a single extruded piece defining a plurality of cavities. A plurality of conductors (extendable from the stator assembly) may be axially inserted within a respective one of the plurality of cavities. The insulation assembly electrically isolates the conductors in the electric motor from the stator stack and from other conductors.

42 ENGINEERING↗
DOE OSTI2016

Cladding material, tube including such cladding material and methods of forming the same

A multi-layered cladding material including a ceramic matrix composite and a metallic material, and a tube formed from the cladding material. The metallic material forms an inner liner of the tube and enables hermetic sealing of thereof. The metallic material at ends of the tube may be exposed and have an increased thickness enabling end cap welding. The metallic material may, optionally, be formed to infiltrate voids in the ceramic matrix composite, the ceramic matrix composite encapsulated by the metallic material. The ceramic matrix composite includes a fiber reinforcement and provides increased mechanical strength, stiffness, thermal shock resistance and high temperature load capacity to the metallic material of the inner liner. The tube may be used as a containment vessel for nuclear fuel used in a nuclear power plant or other reactor. Methods for forming the tube comprising the ceramic matrix composite and the metallic material are also disclosed.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2017

Variable volume combustor with an air bypass system

The present application provides a combustor for use with flow of fuel and a flow of air in a gas turbine engine. The combustor may include a number of micro-mixer fuel nozzles positioned within a liner and an air bypass system position about the liner. The air bypass system variably allows a bypass portion of the flow of air to bypass the micro-mixer fuel nozzles.

42 ENGINEERING↗
DOE OSTI2017

Alternative High-Performance Motors with Non-Rare Earth Materials, Final Publishable Report

Electric drive systems, which include electric machines and power electronics, are a key enabling technology for advanced vehicle propulsion systems that reduce the petroleum dependence of the transportation sector. To have significant effect, electric drive technologies must be economical in terms of cost, weight, and size while meeting performance and reliability expectations. The goal of the project is to develop traction motors that reduce or eliminate the use of rare-earth materials and meet the DoE specifications for such a traction motor. This is accomplished by evaluating and developing multiple motor topologies in conjunction with advanced materials. Eight non-permanent magnet motor topologies and two reduced or non-rare earth motor topologies are analyzed and compared using a common set of requirements. Five of the motors are built and tested to validate the analysis. This paper provides a detailed quantitative comparison of the different machine topologies that reduce or eliminate rare-earth materials. Conclusions are drawn from the analysis and test data to show the tradeoffs related to selecting each of the motor topologies with the hope of providing practicing engineers and researchers in the field enough guidelines for choosing the “optimum” machine topology that suits their applications and set of performance requirements. Four materials technologies were investigated for their ability to enable a reduced rare earth electric motor. Two of the technologies were soft magnetic materials, one was a non-rare-earth containing permanent magnet technology, and the last was an insulation material. These processing and performance of these materials were first demonstrated in small coupons. The coupon tests justified proceeding to larger scale processing for two of the materials technologies: 1) a dual-phase soft magnetic material for use in rotor laminates and 2) a high temperature insulation material for use as a slot liner in the stator. The dual phase soft magnetic material was produced at a scale sufficient to build and test a sub-scale motor prototype. The high temperature insulation material was first evaluated in a series of “statorettes” before being demonstrated in the stator of one of the full-scale motor prototypes. Testing of the dual phase material revealed issues with process variability in larger production volumes that are being addressed in a subsequent project. The performance of the high-temperature slot liner insulation was demonstrated during the operation of a full-scale prototype. Furthermore, the insulation material was shown to survive aging tests of 2000 hours and 280 °C and 800 hours at 300 °C. This program provides analysis and data to accelerate the introduction of hybrid electric vehicles into the U.S. road vehicle fleet and bring the added benefits of reduced fuel consumption and environmental impacts

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2017

Oxy-combustor operable with supercritical fluid

An oxy-combustor is provided which comprises a combustion vessel including at least one solid fuel slurry inlet port, at least one oxygen inlet port and at least one supercritical fluid inlet port, wherein the combustion vessel is operable at an operating pressure of at least 1,100 psi; an interior of the combustion vessel comprises a combustion chamber and a supercritical fluid infusion chamber surrounding at least a part of the combustion chamber, the supercritical fluid infusion chamber and the combustion chamber are separated by a porous liner surrounding the combustion chamber, and the supercritical infusion chamber is located between the porous liner and an outer casing of the combustion vessel.

36 MATERIALS SCIENCE↗