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At least 145 records · Page 8
All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

Updated Filter Leak Frequencies for Use in Risk Assessments

Quantitative risk assessment (QRA) is highly dependent on data, leading to more robust models as new and updated data is acquired. The Hydrogen Plus Other Alternative Fuels Risk Assessment (HyRAM+) QRA capabilities include calculations of individual risk from leaks in a gaseous hydrogen facility due to the potential effects of jet fires and explosions. Leak frequencies are acquired through statistical analysis of published data from a variety of sources and industries. The filter leak frequencies in previous versions of the HyRAM+ software are substantially greater than the leak frequencies of other components, leading to QRA results for gaseous hydrogen in which filters consistently dominate the overall risk. Data that were previously used to derive the filter leak frequencies were reevaluated for applicability and additional data points were added to update the filter leak frequencies. The new frequencies are more comparable to leak frequencies for other components.

08 HYDROGEN↗
DOE OSTI2026

Assessment of Vibration and Shock Loading Environments on Steels Used in Railroad Applications Considering Hydrogen Embrittlement

Studies that examine the combined effects of hydrogen and rail loading environments in the context of hydrogen embrittlement of steels have not been performed. Large-scale hydrogen storage requires either gaseous hydrogen stored in pressure vessels and tubing or liquid hydrogen in cryogenic, insulated tanks. Since the focus of this study is on steels, we examine the influence of hydrogen on stainless steel used for high pressure tubing and cryogenic tanks and Cr-Mo steel liners used in gaseous pressure vessels. Literature studies show that despite hydrogen degradation, these steels can be used effectively and safely if the stresses are managed. The shock and vibration environment on railcars present unique environments where stresses and loading rates can be high. A literature review was conducted to understand the accelerations experienced in rail by examining instrumented railcars of nuclear fuel casks. Hydrogen studies were examined that focused on steel pressure hardware with an emphasis on fatigue, fast loading rates, and low temperatures. A simplified fatigue assessment was performed to examine design cycles for three different hydrogen components: stainless steel tubing, stainless steel cryogenic tanks, and gaseous pressure vessels. The assessments were idealized and used bounding cases of accelerations in both normal rail conditions and coupling events. In normal shock and vibration environments when accelerations were less than 2 g, infinite design life was calculated. In extreme shock or coupling environments, finite design life was calculated which was shown to be dependent on unsupported lengths of pressure components. It was shown that adjusting the unsupported length can reduce the bending stress thereby increasing design life.

36 MATERIALS SCIENCE↗
NASA NTRS2003

Hydrogen Fuel Capability Added to Combustor Flametube Rig

Facility capabilities have been expanded at Test Cell 23, Research Combustor Lab (RCL23) at the NASA Glenn Research Center, with a new gaseous hydrogen fuel system. The purpose of this facility is to test a variety of fuel nozzle and flameholder hardware configurations for use in aircraft combustors. Previously, this facility only had jet fuel available to perform these various combustor flametube tests. The new hydrogen fuel system will support the testing and development of aircraft combustors with zero carbon dioxide (CO2) emissions. Research information generated from this test rig includes combustor emissions and performance data via gas sampling probes and emissions measuring equipment. The new gaseous hydrogen system is being supplied from a 70 000-standard-ft3 tube trailer at flow rates up to 0.05 lb/s (maximum). The hydrogen supply pressure is regulated, and the flow is controlled with a -in. remotely operated globe valve. Both a calibrated subsonic venturi and a coriolis mass flowmeter are used to measure flow. Safety concerns required the placement of all hydrogen connections within purge boxes, each of which contains a small nitrogen flow that is vented past a hydrogen detector. If any hydrogen leaks occur, the hydrogen detectors alert the operators and automatically safe the facility. Facility upgrades and modifications were also performed on other fluids systems, including the nitrogen gas, cooling water, and air systems. RCL23 can provide nonvitiated heated air to the research combustor, up to 350 psig at 1200 F and 3.0 lb/s. Significant modernization of the facility control systems and the data acquisition systems was completed. A flexible control architecture was installed that allows quick changes of research configurations. The labor-intensive hardware interface has been removed and changed to a software-based system. In addition, the operation of this facility has been greatly enhanced with new software programming and graphic operator interface stations. Glenn s RCL23 facility systems were successfully checked out in the spring of 2002, and hydrogen combustor research testing began in the summer of 2002.

Frankenfield, Bruce J.↗
NASA NTRS1985

Molten-Salt Electrolysis

Concept of electrolytic decomposition of gaseous hydrogen sulfide to yield gaseous sulfur at anode and hydrogen gas at cathode considered.

Cubicciotti, D.↗
NASA NTRS2005

Low Emission Hydrogen Combustors for Gas Turbines Using Lean Direct Injection

One of the key technology challenges for the use of hydrogen in gas turbine engines is the performance of the combustion system, in particular the fuel injectors. To investigate the combustion performance of gaseous hydrogen fuel injectors flame tube combustor experiments were performed. Tests were conducted to measure the nitrogen oxide (NOx) emissions and combustion performance at inlet conditions of 600 to 1000 deg F, 60 to 200 pounds per square inch absolute (psia), and equivalence ratios up to 0.48. All the injectors were based on Lean Direct Injection (LDI) technology with multiple injection points and quick mixing. One challenge to hydrogen based premixing combustion systems is flashback since hydrogen has a reaction rate over seven times that of Jet-A. To reduce the risk, design mixing times were kept short and velocities high to minimize flashback. Five fuel injector designs were tested in 2.5 and 3.5-in. diameter flame tubes with non-vitiated heated air and gaseous hydrogen. Data is presented on measurements of NOx emissions and combustion efficiency for the hydrogen injectors at 1.0, 3.125, and 5.375 in. from the injector face. Results show that for some configurations, NOx emissions are comparable to that of state of the art Jet-A LDI combustor concepts.

Marek, C. John↗
NASA NTRS2007

Low-Emission Hydrogen Combustors for Gas Turbines Using Lean Direct Injection

One of the key technology challenges for the use of hydrogen in gas turbine engines is the performance of the combustion system, in particular the fuel injectors. To investigate the combustion performance of gaseous hydrogen fuel injectors flame tube combustor experiments were performed. Tests were conducted to measure the nitrogen oxide (NO(x)) emissions and combustion performance at inlet conditions of 588 to 811 K, 0.4 to 1.4 MPa, and equivalence ratios up to 0.48. All the injectors were based on Lean Direct Injection (LDI) technology with multiple injection points and quick mixing. One challenge to hydrogen-based premixing combustion systems is flashback since hydrogen has a reaction rate over 7 times that of Jet-A. To reduce the risk, design mixing times were kept short and velocities high to minimize flashback. Five fuel injector designs were tested in 6.35- and 8.9-cm-diameter flame tubes with non-vitiated heated air and gaseous hydrogen. Data is presented on measurements of NO(x) emissions and combustion efficiency for the hydrogen injectors at 2.540, 7.937, and 13.652 cm from the injector face. Results show that for some configurations, NO(x) emissions are comparable to that of state of the art Jet-A LDI combustor concepts.

Marek, C. John↗
NASA NTRS2023

Effects of Strain Rate and Surface Finish on Tensile Properties in High Pressure Hydrogen — A Case Study for LP-DED NASA HR-1

NASA has advanced NASA HR-1 as a solution for liquid rocket engine components that operate in hydrogen rich environments using various AM techniques. The NASA HR-1 for AM applications was specifically formulated for high ductility in high pressure gaseous hydrogen environment in addition to high strength and low cycle fatigue (LCF) resistance. NASA HR-1 meets materials requirements for liquid rocket engine components, including good hydrogen resistance, high conductivity, good LCF performance, and high elongation and strength for components in medium heat flux environments. NASA has completed fabrication of several subscale and full-scale channel wall nozzles in LP-DED NASA HR-1 and completed hot-fire testing. This includes refinement of the process to produce thin-walls and various channel geometries to meet the requirements for channel wall nozzle applications. The main objective of this investigation is to better understand the effects of tensile test strain rate and specimen surface finish on the amount of tensile ductility degradation in high pressure gaseous hydrogen environments. Performing smooth tensile tests in high pressure hydrogen and nitrogen environments can serve as a rapid and economical screening method to determine the relative susceptibility of materials to HEE. This paper presents the tensile test results for LP-DED NASA HR-1 in hydrogen and details the material evaluation on the effects of strain rate and surface finish condition on surface cracking behavior and fracture characteristics. The resistance to HEE for LP-DED NASA HR-1 and the wrought alloy is compared under the same testing conditions. Loss of tensile ductility is quantified in terms of changes in elongation at failure in hydrogen to compare HEE susceptibility. The most suitable strain rate and specimen surface finish condition for future HEE screening testing at MSFC are recommended.

Additive manufacturing↗
DOE OSTI2025

Investigating the Combustion Performance of Dual Fuel Combustion with Diesel and Port Injected Hydrogen in a Large Bore Locomotive Engine

The heavy-duty transportation sector has primarily relied on conventional diesel combustion engines given their reliability and high thermal efficiency relative to spark ignition engines, but increased focus on reducing greenhouse gas emissions has led to investigation into alternative fuels. Gaseous hydrogen fuel has garnered a great deal of recent interest in the engine community given it has zero carbon, but hydrogen is not available at the scale and cost that petroleum fuels are currently available, and this is a barrier to adoption for industries that are looking to decarbonize their operations. Because of the fuel flexibility provided, dual fuel technology offers a pathway for some industries to adopt hydrogen as a fuel source while maintaining sufficient flexibility in times and locations where the new fuel is not yet available. This computational study investigates dual fuel combustion in a large bore locomotive engine architecture using direct injected diesel and port injected gaseous hydrogen fuel. With an optimal port fuel injection configuration from previous work, simulations of varying substitution ratio, compression ratio, manifold air temperature, diesel injection timing, and diesel injection pressure were performed to understand their effect on combustion performance. Results indicated that both increased substitution ratio and higher intake air temperature accelerates hydrogen flame propagation and can result in high peak cylinder pressures. Additionally, diesel injection timing and injection pressure were demonstrated as effective methods for controlling dual fuel combustion heat release rates.

ODonnell, Patrick Christopher↗
NASA NTRS2004

Fuel Flexible Gas Turbine Combustor Flametube Facility Upgraded

In fiscal year 2003, test cell 23 of the Research Combustion Laboratory (RCL 23) at the NASA Glenn Research Center was upgraded with the addition of gaseous hydrogen as a working propellant and the addition of a 450-psig air-supply system. Test flexibility was further enhanced by upgrades to the facility control systems. RCL 23 can now test with gaseous hydrogen flow rates up to 0.05 lbm/sec and jet fuel flow rates up to 0.62 lbm/sec. Research airflow rates up to 3 lbm/sec are possible with the 450-psig supply system over a range of inlet temperatures. Nonvitiated, heated air is supplied from a shell and tube heat exchanger. The maximum nonvitiated facility air temperature is 1100 F at 1.5 lbm/sec. Research-section exhaust temperatures are limited to 3200 F because of material and cooling capacity limits. A variety of support systems are available depending on the research hardware configuration. Test section ignition can be provided via either a hydrogen air torch system or an electronic spark system. Emissions measurements are obtained with either pneumatically or electromechanically actuated gas sample probes, and the electromechanical system allows for radial measurements at a user-specified axial location for measurement of emissions profiles. Gas analysis data can be obtained for a variety of species, including carbon monoxide (CO), carbon dioxide (CO2), nitrogen oxides (NO and NOx), oxygen (O2), unburnt hydrocarbons, and unburnt hydrogen. Facility control is accomplished with a programmable logic control system. Facility operations have been upgraded to a system based on graphical user interface control screens. A data system is available for real-time acquisition and monitoring of both measurements in engineering units and performance calculations. The upgrades have made RCL 23 a highly flexible facility for research into low emissions gas turbine combustor concepts, and the flame tube configuration inherently allows for a variety of fuel nozzle configurations to be tested in a cost-effective manner. RCL 23 is poised to be a leading facility for developing modern low-emission fuel nozzles for use with jet fuel and alternative fuels.

Little, James E.↗
NASA NTRS2016

Hydrogen Embrittlement

Hydrogen embrittlement (HE) is a process resulting in a decrease in the fracture toughness or ductility of a metal due to the presence of atomic hydrogen. In addition to pure hydrogen gas as a direct source for the absorption of atomic hydrogen, the damaging effect can manifest itself from other hydrogen-containing gas species such as hydrogen sulfide (H2S), hydrogen chloride (HCl), and hydrogen bromide (HBr) environments. It has been known that H2S environment may result in a much more severe condition of embrittlement than pure hydrogen gas (H2) for certain types of alloys at similar conditions of stress and gas pressure. The reduction of fracture loads can occur at levels well below the yield strength of the material. Hydrogen embrittlement is usually manifest in terms of singular sharp cracks, in contrast to the extensive branching observed for stress corrosion cracking. The initial crack openings and the local deformation associated with crack propagation may be so small that they are difficult to detect except in special nondestructive examinations. Cracks due to HE can grow rapidly with little macroscopic evidence of mechanical deformation in materials that are normally quite ductile. This Technical Memorandum presents a comprehensive review of experimental data for the effects of gaseous Hydrogen Environment Embrittlement (HEE) for several types of metallic materials. Common material screening methods are used to rate the hydrogen degradation of mechanical properties that occur while the material is under an applied stress and exposed to gaseous hydrogen as compared to air or helium, under slow strain rates (SSR) testing. Due to the simplicity and accelerated nature of these tests, the results expressed in terms of HEE index are not intended to necessarily represent true hydrogen service environment for long-term exposure, but rather to provide a practical approach for material screening, which is a useful concept to qualitatively evaluate the severity of hydrogen embrittlement. The effects of hydrogen gas on mechanical properties such as tensile strength, ductility, fracture, low and high cycle fatigue, crack growth rate, and creep rupture are analyzed with respect to the general trends established from the HEE index values. It is observed that the severity of HE effects is also influenced by environmental factors such as pressure, temperature, and hydrogen gas purity. The severity of HE effects is also influenced by material factors such as surface finish, heat treatment, and product forms, compositions, grain direction, and crystal orientations.

Jonathan A. Lee↗
NASA NTRS2004

Fuel-Flexible Gas Turbine Combustor Flametube Facility

Facility modifications have been completed to an existing combustor flametube facility to enable testing with gaseous hydrogen propellants at the NASA Glenn Research Center. The purpose of the facility is to test a variety of fuel nozzle and flameholder hardware configurations for use in aircraft combustors. Facility capabilities have been expanded to include testing with gaseous hydrogen, along with the existing hydrocarbon-based jet fuel. Modifications have also been made to the facility air supply to provide heated air up to 350 psig, 1100 F, and 3.0 lbm/s. The facility can accommodate a wide variety of flametube and fuel nozzle configurations. Emissions and performance data are obtained via a variety of gas sample probe configurations and emissions measurement equipment.

Little, James E.↗
NASA NTRS2002

Experimental Evaluation of a Subscale Gaseous Hydrogen/gaseous Oxygen Coaxial Rocket Injector

The next generation reusable launch vehicle may utilize a Full-Flow Stage Combustion (FFSC) rocket engine cycle. One of the key technologies required is the development of an injector that uses gaseous oxygen and gaseous hydrogen as propellants. Gas-gas propellant injection provides an engine with increased stability margin over a range of throttle set points. This paper summarizes an injector design and testing effort that evaluated a coaxial rocket injector for use with gaseous oxygen and gaseous hydrogen propellants. A total of 19 hot-fire tests were conducted up to a chamber pressure of 1030 psia, over a range of 3.3 to 6.7 for injector element mixture ratio. Post-test condition of the hardware was also used to assess injector face cooling. Results show that high combustion performance levels could be achieved with gas-gas propellants and there were no problems with excessive face heating for the conditions tested.

Smith, Timothy D.↗
NASA NTRS1981

Study of Near-Threshold Fatigue Crack Propagation in Pipeline Steels in High Pressure Environments

Near threshold fatigue crack propagation in pipeline steels in high pressure environments was studied. The objective was to determine the level of threshold stress intensity for fatigue crack growth rate behavior in a high strength low alloy X60 pipeline-type steel. Complete results have been generated for gaseous hydrogen at ambient pressure, laboratory air at ambient pressure and approximately 60% relative humidity as well as vacuum of 0.000067 Pa ( 0.0000005 torr) at R-ratios = K(min)/K(max) of 0.1, 0.5, and 0.8. Fatigue crack growth rate behavior in gaseous hydrogen, methane, and methane plus 10 percent hydrogen at 6.89 MPa (100 psi) was determined.

Mitchell, M.↗
NASA NTRS1988

Catalytic ignition of hydrogen/oxygen

An experimental program was conducted to evaluate the catalytic ignition of gaseous hydrogen and oxygen. Shell 405 granular catalyst and a unique monolithic sponge catalyst were tested. Mixture ratio, mass flow rate, propellant inlet temperature, and back pressure were varied parametrically in testing to determine the operational limits of a catalytic igniter. The test results showed that the gaseous hydrogen/oxygen propellant combination can be ignited catalytically using Shell 405 catalyst over a wide range of mixture ratios, mass flow rates, and propellant injection temperatures. These operating conditions must be optimized to ensure reliable ignition for an extended period of time. The results of the experimental program and the established operational limits for a catalytic igniter using both the granular and monolithic catalysts are presented. The capabilities of a facility constructed to conduct the igniter testing and the advantages of a catalytic igniter over other ignition systems for gaseous hydrogen and oxygen are also discussed.

Green, James M.↗
NASA NTRSDate not supplied

Development of Laser Powder Bed Fusion NASA HR-2 for Hydrogen Sensitive Liquid Rocket Engine Applications

The National Aeronautics and Space Administration (NASA) has been involved in the development and maturation of metal additive manufacturing (AM) for space applications since the late 2000s. AM has provided new design and manufacturing opportunities to reduce cost and schedule, consolidate parts, and optimize performance. Laser Powder Bed Fusion (L-PBF) is one of the most commonly used AM processes to fabricate components of complex shape requiring fine feature resolution. Due to exposure to high-pressure gaseous hydrogen, mechanical property degradation caused by hydrogen environment embrittlement (HEE) is a critical concern for many materials in liquid hydrogen propulsion systems. NASA has identified the need to develop and advance new materials in unique engine applications using liquid hydrogen as a propellant. One such material being developed at NASA Marshall Space Flight Center is L-PBF NASA HR-2 (Hydrogen Resistant-2), a high-strength Fe-Ni-based superalloy resistant to HEE. The chemistry of NASA HR-2 was formulated to meet requirements for key liquid rocket engine (LRE) components that operate in high-pressure hydrogen environments. Initial development and material characterization found that NASA HR-2 has excellent L-PBF printability, and its microstructure evolves well after heat treatment. This new alloy has undergone fundamental metallurgical evaluations, heat treatment studies, detailed microstructure characterization, and mechanical testing across a range of temperatures. Tensile testing was performed in a pressurized gaseous hydrogen (GH2) environment to assess its resistance to HEE. L-PBF NASA HR-2 has an average yield stress of 95 ksi, an ultimate tensile stress of 165 ksi, and a very high fracture elongation of 34 - 36% when tested in a high-pressure (5 ksi) hydrogen environment. The tensile property data confirms hydrogen has little influence on HR-2’s ductility, strength, and fracture behavior. L-PBF NASA HR-2 is a promising option for many hydrogen-sensitive LRE components that require exceptional resistance to HEE. This paper will provide an overview of the L-PBF process development, material characterization, mechanical and thermophysical properties, and LRE hardware development for NASA HR-2.

Po S Chen↗
NASA NTRSDate not supplied

Development of Laser Powder Bed Fusion NASA HR-2 for Hydrogen Sensitive Liquid Rocket Engine Applications

The National Aeronautics and Space Administration (NASA) has been involved in the development and maturation of metal additive manufacturing (AM) for space applications since the late 2000’s. AM has provided new design and manufacturing opportunities to reduce cost and schedule, consolidate parts, and optimize performance. Laser Powder Bed Fusion (L-PBF) is one of the most commonly used AM processes to fabricate components that have complex shape and need fine feature resolution. Due to exposure to high pressure gaseous hydrogen, mechanical property degradation caused by hydrogen environment embrittlement (HEE) is a critical concern for many materials in liquid hydrogen propulsion systems. NASA has identified the need to develop and advance new materials in unique engine applications using liquid hydrogen as a propellant. One such material being developed at NASA Marshall Space Flight Center is L-PBF NASA HR-2 (Hydrogen Resistant-2), a high-strength Fe-Ni-based superalloy resistant to HEE. The chemistry of NASA HR-2 was formulated to meet requirements for key liquid rocket engine (LRE) components that operate in high-pressure hydrogen environments. Initial development and material characterization found NASA HR-2 has excellent L-PBF printability and its microstructure evolves well after heat treatment. This new alloy has undergone fundamental metallurgical evaluations, heat treatment studies, detailed microstructure characterization, and mechanical testing across a range of temperatures. Tensile testing was performed in pressurized gaseous hydrogen (GH2) environment to assess its resistance to HEE. L-PBF NASA HR-2 has an average yield stress of 95 ksi, ultimate tensile stress of 165 ksi, and very high fracture elongation at 34 - 36% when tested in a 5 ksi high pressure hydrogen environment. The tensile property data confirms hydrogen has little influence on its ductility, strength, and fracture behavior. L-PBF NASA HR-2 is a promising option for many hydrogen sensitive LRE components that require exceptional resistance to HEE. The development of L-PBF NASA HR-2 is funded under the grants provided by Jacobs TIPI program and the Liquid Engine Office at NASA Marshall Space Flight Center. This paper will provide an overview of the L-PBF process development, material characterization, mechanical and thermophysical properties, and LRE hardware development for NASA HR-2.

NASA HR-2↗