Aero-structural rapid screening of new design concepts for offshore wind turbines
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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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Aero-Thermal Characterization of Accelerating and Diffusing Passages Downstream of Rotating Detonation Combustors
Presentation from ASME Turbo Expo 2021
Braun, James↗
Method of making an aero-derivative gas turbine engine
A method of making an aero-derivative gas turbine engine (100) is provided. A combustor outer casing (68) is removed from an existing aero gas turbine engine (60). An annular combustor (84) is removed from the existing aero gas turbine engine. A first row of turbine vanes (38) is removed from the existing aero gas turbine engine. A can annular combustor assembly (122) is installed within the existing aero gas turbine engine. The can annular combustor assembly is configured to accelerate and orient combustion gasses directly onto a first row of turbine blades of the existing aero gas turbine engine. A can annular combustor assembly outer casing (108) is installed to produce the aero-derivative gas turbine engine (100). The can annular combustor assembly is installed within an axial span (85) of the existing aero gas turbine engine vacated by the annular combustor and the first row of turbine vanes.
42 ENGINEERING↗
Aero-MINE (Motionless INtegrated Energy) for Distributed Scalable Wind Power.
The proposed Aero-MINE technology will extract energy from wind without any exterior moving parts. Aero-MINEs can be integrated into buildings or function stand-alone, and are scalable. This gives them advantages similar to solar panels, but with the added benefit of operation in cloudy or dark conditions. Furthermore, compared to solar panels, Aero-MINEs can be manufactured at lower cost and with less environmental impact. Power generation is isolated internally by the pneumatic transmission of air and the outlet air-jet nozzles amplify the effectiveness. Multiple units can be connected to one centrally located electric generator. Aero-MINEs are ideal for the built-environment, with numerous possible configurations ranging from architectural integration to modular bolt-on products. Traditional wind turbines suffer from many fundamental challenges. The fast-moving blades produce significant aero-acoustic noise, visual disturbances, light-induced flickering and impose wildlife mortality risks. The conversion of massive mechanical torque to electricity is a challenge for gears, generators and power conversion electronics. In addition, the installation, operation and maintenance of wind turbines is required at significant height. Furthermore, wind farms are often in remote locations far from dense regions of electricity customers. These technical and logistical challenges add significantly to the cost of the electricity produced by utility-scale wind farms. In contrast, distributed wind energy eliminates many of the logistical challenges. However, solutions such as micro-turbines produce relatively small amounts of energy due to the reduction in swept area and still suffer from the motion-related disadvantages of utility-scale turbines. Aero-MINEs combine the best features of distributed generation, while eliminating the disadvantages.
17 WIND ENERGY↗
Aero-Optics of Hypersonic Turbulent Boundary Layers
Aero-optics refers to optical distortions due to index-of-refraction gradients that are induced by aerodynamic density gradients. At hypersonic flow conditions, the bulk velocity is many times the speed of sound and density gradients may originate from shock waves, compressible turbulent structures, acoustic waves, thermal variations, etc. Due to the combination of these factors, aero-optic distortions are expected to differ from those common to sub-sonic and lower super-sonic speeds. This report summarizes the results from a 2019-2022 Laboratory Directed Research and Development (LDRD) project led by Sandia National Laboratories in collaboration with the University of Notre Dame, New Mexico State University, and the Georgia Institute of Technology. Efforts extended experimental and simulation methodologies for the study of turbulent hypersonic boundary layers. Notable experimental advancements include development of spectral de-aliasing techniques for highspeed wavefront measurements, a Spatially Selective Wavefront Sensor (SSWFS) technique, new experimental data at Mach 8 and 14, a Quadrature Fringe Imaging Interferometer (QFII) technique for time-resolved index-of-refraction measures, and application of QFII to shock-heated air. At the same time, model advancements include aero-optic analysis of several Direct Numerical Simulation (DNS) datasets from Mach 0.5 to 14 and development of wall-modeled Large Eddy Simulation (LES) techniques for aero-optic predictions. At Mach 8 measured and predicted root mean square Optical Path Differences agree within confidence bounds but are higher than semi-empirical trends extrapolated from lower Mach conditions. Overall, results show that aero-optic effects in the hypersonic flow regime are not simple extensions from prior knowledge at lower speeds and instead reflect the added complexity of compressible hypersonic flow physics.
36 MATERIALS SCIENCE↗
Towards optimal gas cooling with minimal aero-optical distortion for a laser amplifier head
Next-generation lasers combining high-peak-power, ultrashort pulses with high repetition rates have the potential to efficiently deliver the high-average-power outputs required by many emerging technologies and areas of research. This work introduces a three-stage workflow consisting of low- and high-fidelity fluid simulations, in addition to aero-optical analyses. The final goal is to optimize gas cooling within a laser amplifier head while maintaining minimal aero-optical distortions. Low-fidelity RANS simulations are used to obtain mean flow solutions and transition locations. High-fidelity LES simulations, informed by their RANS counterparts, provide solutions containing density fluctuations, which are then passed on to the aero-optical analysis. The aero-optical analysis provides insight into the optical quality of the laser beam passing through the flow found in the LES results.
42 ENGINEERING↗
Aero-structural design and optimization of 50 MW wind turbine with over 250-m blades
The quest for reduced levelized cost of energy has driven significant growth in wind turbine size; however, larger rotors face significant technical and logistical challenges. The largest published rotor design is 25 MW, and here we consider an even larger 50 MW design with blade length over 250 m. This paper shows that a 50 MW design is indeed possible from a detailed engineering perspective and presents a series of aero-structural blade designs, and critical assessment of technology pathways and challenges for extreme-scale rotors. The 50 MW rotor design begins with Monte Carlo simulations focused on optimizing carbon spar cap and root design. A baseline design resulted in a 250-m blade with mass of 502 tonnes. Subsequently, an aero-structural design and optimization were performed to reduce the blade mass/cost with more than 25% mass reduction and 30% cost reduction by determining optimal blade chord and airfoil thickness for best aero-structural performance.
Yao, Shulong↗
Optimal gas cooling with minimal aero-opticaldistortion for next generation high-average-power lasers (Progress report, Year 2)
Next-generation lasers that combine high-peak-power ultrashort pulses with high repetition rates have the potential to efficiently deliver the high-average-power outputs required for inertial fusion energy generation, laser-based particle acceleration, and to generate compact secondary x- and 𝛾-ray radiation sources, among others. The combination of long gain length with high surface-to-volume ratio to remove residual heat makes gas-cooled multi-slab amplifier heads an inherently aperture- and average power scalable technology that enables this new class of solid-state lasers, and their thermal management becomes the most pressing technical challenge. As the index-of refraction depends on the gas density, heat removal from the slab surfaces unavoidably entails scattering of propagated light from regions of high temperature fluctuations. The requirement to maximize convective heat extraction from the gain medium under the constraint of minimum optical aberration of the beam renders amplifier slab cooling a technological challenge at the intersection of aero-optics, fluid-mechanics and heat transfer. The goal of this research is to leverage computational fluid dynamics and aero optics simulations of different levels of fidelity to devise a numerical modeling and optimization framework for gas-cooled multi-slab amplifiers. The project will be conducted in close collaboration with the Advanced Photon Technologies Group at Lawrence Livermore National Laboratory, where a gas-cooled test stand for laser materials and thermal management structures will be developed and installed. The final goal of the collaborative effort is to manufacture and benchmark a physical prototype of an numerically optimized amplifier head design. Measurement data on solid-state and thermo-optical distortions will be used for the validation of the numerical models. The key technical challenge in this multi-objective design problem is that of balancing optimal heat removal with minimal optical distortion. To facilitate computationally efficient design optimization and, at the same time, deepen our basic understanding of the interaction of light with turbulence, a complementary study that combines high and low-fidelity flow simulations and aero-optical models is proposed. Along the lines of these two objectives and solution strategies, the project is organized into two thrusts.
42 ENGINEERING↗
Efficient derivative computation for unsteady fatigue-constrained nonlinear aero-structural wind turbine blade optimization
Gradient-based optimization offers significant efficiency advantages for wind turbine blade design, but its application has often been limited by the cost and accuracy of finite-difference derivative calculations, especially when fatigue constraints are considered. In this work, we systematically compare and evaluate four differentiation techniques, namely algorithmic differentiation, implicit differentiation, sparsity exploitation, and parallelization, to determine their effectiveness in computing accurate gradients through time-domain aero-structural simulations. By integrating these techniques with unsteady nonlinear aerodynamic and structural models, we develop software designed for accurate gradient computation. We show that combining these techniques addresses memory and runtime challenges associated with long simulations required by design load cases. Specifically, the most effective combination reduces derivative computation wall time by over an order of magnitude compared to finite differencing while maintaining superior accuracy. We demonstrate this approach in a proof-of-concept aero-structural optimization of a wind turbine blade that improves the cost of energy by 12.78 %. This comparative study establishes a viable approach for fatigue-aware blade design that balances computational efficiency with modeling accuracy.
17 WIND ENERGY↗
Swept Blade Aero-Elastic Model for a Small Wind Turbine (Presentation)
A preprocessor for analyzing preswept wind turbines using the in-house aero-elastic tool coupled with a multibody dynamic simulator was developed. A baseline 10-kW small wind turbine with straight blades and various configurations that featured bend-torsion coupling via blade-tip sweep were investigated to study their impact on ultimate loads and fatigue damage equivalent loads.
17 WIND ENERGY↗
Aero‐servo‐elastic co‐optimization of large wind turbine blades with distributed aerodynamic control devices
Abstract This work introduces automated wind turbine optimization techniques based on full aero‐servo‐elastic models and investigates the potential of trailing edge flaps to reduce the levelized cost of energy (LCOE) of wind turbines. The Wind Energy with Integrated Servo‐control (WEIS) framework is improved to conduct the presented research. Novel methods for the generic implementation and tuning of trailing edge flap devices and their controller are also introduced. Primary flap and controller parameters are optimized to demonstrate potential maximum blade tip deflection reductions of 21 % . Concurrent design optimization (i.e., co‐design) of a novel segmented wind turbine blade with trailing edge flaps and its controller is then conducted to demonstrate blade cost savings of 5 % . Additionally, rotor diameter co‐design optimization is demonstrated to reduce the LCOE by 1.3 % without significant load increases to the tower. These results demonstrate the efficacy of control co‐design optimization using trailing edge flaps, and the entirety of this work provides a foundation for numerous control co‐design‐oriented studies for distributed aerodynamic control devices.
17 WIND ENERGY↗
Aerosol Vacuum-Assisted Plasma Ionization (Aero-VaPI) Coupled to Ion Mobility-Mass Spectrometry
In this communication, we report on the real-time analysis of organic aerosol particles by Vacuum-assisted Plasma Ionization-Mass Spectrometry (Aero-VaPI-MS) using a home-built VaPI ion source coupled to a Synapt G2-S HDMS ion mobility-mass spectrometry (IM-MS) system. Standards of organic molecules of interest in prebiotic chemistry were used to generate aerosols. Monocaprin and decanoic acid aerosol particles were successfully detected in both the positive and negative ion modes, respectively. A complex aerosol mixture of different sizes of polymers of L-malic acid was also examined through ion mobility (IM) separations, resulting in the detection of polymers of up to eight monomeric units. This noncommercial plasma ion source is proposed as a low cost alternative to other plasma ionization platforms used for aerosol analysis, and a higher-performance alternative to more traditional aerosol mass spectrometers. VaPI provides robust online ionization of organics in aerosols without extensive ion activation, with the coupling to IM-MS providing higher peak capacity and excellent mass accuracy. .
46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
High-order parabolic beam approximation for aero-optics
The parabolic beam equations are solved using high-order compact differences for the Laplacians and Runge-Kutta integration along the beam path. The solution method is verified by comparison to analytical solutions for apertured beams and both constant and complex index of refraction. An adaptive 4th-order Runge-Kutta using an embedded 2nd-order method is presented that has demonstrated itself to be very robust. For apertured beams, the results show that the method fails to capture near aperture effects due to a violation of the paraxial approximation in that region. Initial results indicate that the problem appears to be correctable by successive approximations. A preliminary assessment of the effect of turbulent scales is undertaken using high-order Lagrangian interpolation. The results show that while high fidelity methods are necessary to accurately capture the large scale flow structure, the method may not require the same level of fidelity in sampling the density for the index of refraction. The solution is used to calculate a phase difference that is directly compared with that commonly calculated via the optical path difference. Propagation through a supersonic boundary layer shows that for longer wavelengths, the traditional method to calculate the optical path is less accurate than for shorter wavelengths. While unlikely to supplant more traditional methods for most aero-optics applications, the current method can be used to give a quantitative assessment of the other methods as well as being amenable to the addition of more physics.
97 MATHEMATICS AND COMPUTING↗
A semi-coupled aero-servo-hydro numerical model for floating vertical axis wind turbines operating on TLPs
Floating vertical axis wind turbines (VAWTs) have many advantages over floating horizontal axis wind turbines (HAWTs) at large scales in deep water; however, there are several key challenges to overcome as well. One of the challenges is accurate prediction of the dynamic motion and loads performance of a floating VAWT. Here, a new semi-coupled aero-servo-hydro method is developed to assess dynamic responses of a floating VAWT by modeling the system as a 7-degree-of-freedom (7-DOF) model: the supporting platform is considered as a 6-DOF rigid body; the rotation of the rotor is considered as the 7th DOF. Aerodynamic, hydrodynamic, and mooring loads and control of the rotor speed are fully considered. This model can predict performance of floating VAWTs with reasonable fidelity according to validation with OrcaFlex through static and dynamic responses of a floating VAWT with Darrieus rotor operating on a new tension-leg platform (TLP). Being a reduced complexity model, the 7-DOF model can be efficiently applied to assess performance of the newly designed floating VAWT. This model is used to examine the relative contributions of aerodynamic and wave loads imparted to the floating system and the benefits of a three-bladed VAWT over a two-bladed VAWT through dynamic and fatigue analysis.
17 WIND ENERGY↗
Servo-aero-gravo-elastic (SAGE) scaling and its application to a 13-MW downwind turbine
Reduced scale wind turbines can be extremely cost-effective to test new rotor concepts since prototype costs are heavily dependent on the rotor diameter. Ideally, the scaled model would have the same non-dimensional deflections, dynamics, and control behavior as the full-scale model. This would provide a high-fidelity demonstration of the full-scale performance, which is ideal if the full-scale turbine has significant aeroelastic interactions. To this end, servo-aero-gravo-elastic (SAGE) scaling is developed and applied to a 13-MW turbine that is scaled to a 20% scale model. The scaling preserves the tip-speed ratio, the rotor speed normalized by the flapping frequency, and the tip deflections normalized by the blade length. In addition, the controller employs the same control structure (gain-scheduled pitch control and variable speed torque control) and is scaled dynamically (e.g., matching non-dimensional time constant of the pitch angle, etc.). Furthermore, the thrust, gravity, and centrifugal moments are scaled such that the load angles are preserved as a function of a non-dimensional wind speed. However, the environmental scaling must consider differences in Reynolds number (since this parameter cannot be held constant) and subsequent changes in the axial induction factor. While the presented results showcase these differences during operational conditions, the non-dimensional tip deflections remain comparable through all wind speed ranges, indicating the viability of the SAGE scaling method in matching full-scale aeroelastic responses.
Kaminski, Meghan (ORCID:0000000322334784)↗
Density of molten oxides measured in an aero-acoustic levitator
Knowing the thermophysical properties of high-temperature melts can aid the design of melt processes and validate atomic structural models, such as those used in studying glass formation. Property measurements on such melts are challenging, however, due to container-related contamination and heterogeneous nucleation. Containerless processing techniques that employ levitation can be used to avoid these obstacles. In that context, we demonstrate here the application of silhouette imaging to measure the density of molten oxides in an aero-acoustic levitation instrument (AAL). The AAL combines gas jet levitation with actively controlled acoustic positioning to enable full optical access to samples ca. 2–4 mm in diameter, which are laser beam heated and melted. The cross sections of molten drops are imaged using a monochromatic light source and narrowband-filtered camera. Melt volume is calculated from the cross sections and used to find density at several temperatures ranging 1530–1920 K, including up to 350 K of supercooling. We report densities for CaAl 2 O 4 , Ca 12 Al 14 O 33 , CaSiO 3 , their Fe 2 O 3 -bearing analogs, and 83TiO 2 -17RE 2 O 3 (RE = La or Nd). These provide important benchmarks of the capabilities, measurement uncertainties, and future outlook for this technique.
36 MATERIALS SCIENCE↗
Numerical Investigation of Wall-Cooling Effect on Aero-Optical Distortions for Hypersonic Boundary Layer
Compressible wall-modeled large-eddy simulations of Mach 8 turbulent boundary-layer flows over a flat plate were carried out for the conditions of the hypersonic wind tunnel at Sandia National Laboratories. The simulations provide new insight into the effect of wall cooling on the aero-optical path distortions for hypersonic turbulent boundary-layer flows. Four different wall-to-recovery temperature ratios, 0.3, 0.48, 0.71, and 0.89, are considered. Despite the much lower grid resolution, the mean velocity, temperature, and resolved Reynolds stress profiles from the simulation for a temperature ratio of 0.48 are in good agreement with those from a reference direct numerical simulation. The normalized root-mean-square optical path difference obtained from the present simulations is compared with that from reference direct numerical simulations, Sandia experiments, as well as predictions obtained with a semi-analytical model by Notre Dame University. Here the present analysis focuses on the effect of wall cooling on the wall-normal density correlations, on key underlying assumptions of the aforementioned model such as the strong Reynolds analogy, and on the elevation angle effect on the optical path difference. Wall cooling is found to increase the velocity fluctuations and decrease the density fluctuations, resulting in an overall reduction of the normalized optical path distortion. Compared to the simulations, the basic strong Reynolds analogy overpredicts the temperature fluctuations for cooled walls. Also different from the strong Reynolds analogy, the velocity and temperature fluctuations are not perfectly anticorrelated. Finally, as the wall temperature is raised, the density correlation length, away from the wall but inside the boundary layer, increases significantly for beam paths tilted in the downstream direction.
42 ENGINEERING↗