SEARCH · Engineering Papers
Results for “HIGH TEMPERATURE”
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.
High-Temperature-High-Volume Lifting for Enhanced Geothermal Systems
This report summarizes the progress made during the April 01, 2010 – December 30, 2013 period under Cooperative Agreement DE-EE0002752 for the U.S. Department of Energy entitled “High-Temperature-High-Volume Lifting for Enhanced Geothermal Systems.” The overall objective of this program is to advance the technology for well fluids lifting systems to meet the foreseeable pressure, temperature, and longevity needs of the Enhanced Geothermal Systems (EGS) industry for the coming ten years. In this program, lifting system requirements for EGS wells were established via consultation with industry experts and site visits. A number of artificial lift technologies were evaluated with regard to their applicability to EGS applications; it was determined that a system based on electric submersible pump (ESP) technology was best suited to EGS. Technical barriers were identified and a component-level technology development program was undertaken to address each barrier, with the most challenging being the development of a power-dense, small diameter motor that can operate reliably in a 300°C environment for up to three years. Some of the targeted individual component technologies include permanent magnet motor construction, high-temperature insulation, dielectrics, bearings, seals, thrust washers, and pump impellers/diffusers. Advances were also made in thermal management of electric motors. In addition to the overall system design for a full-scale EGS application, a subscale prototype was designed and fabricated. Like the full-scale design, the subscale prototype features a novel “flow-through-the-bore” permanent magnet electric motor that combines the use of high temperature materials with an internal cooling scheme that limits peak internal temperatures to <330°C. While the full-scale high-volume multi-stage pump is designed to lift up to 80 kg/s of process water, the subscale prototype is based on a production design that can pump 20 kg/s and has been modified for high-temperature operation. In parallel with the design and fabrication of the subscale prototype ESP system, a subscale test facility consisting of a high-temperature-high-pressure flow loop was designed, fabricated, and installed at GE Global Research in Niskayuna, NY. A test plan for the prototype system was also established. The original plan of testing the prototype hardware in the flow loop was delayed until a future date.
High Temperature, High Reliability Integrated Hybrid Packaging for Radiation Hardened Spacecraft Micromachined Tunneling Accelerometer
This paper summarizes and reports a radiation hardened spacecraft high temperature, high reliability Sensor/Circut Integrated Packaging Technology.
Study to determine suitable high temperature, high altitude, total temperature sensors Final report
High temperature, high altitude total temperature sensor development - thermocouple device
High Temperature, High Pressure Stability of Aqueous Foams for Potential Application in Enhanced Geothermal System (EGS)
Enhanced Geothermal Systems (EGS) are typically constructed by injecting high-pressure water into deep hot dry rocks (HDR) under carefully controlled conditions to create new or re-open existing fractures, which usually uses an immense quantity of water. In lieu, a more sustainable technique is to utilize aqueous foams as fracturing fluid to reduce water consumption and waste-water treatments of conventional hydraulic fracturing. Although foam-based fracturing has shown promising results in oil and gas industries, its feasibility is not demonstrated in EGS conditions that usually involve high temperature and high pressures. One potential barrier of utilizing foams in EGS applications is that foams are thermodynamically unstable and will become more unstable with increasing temperature due to liquid drainage, bubble coarsening, and coalescence. This work focuses on evaluation of the stability of selected aqueous foams under high-temperature and high-pressure conditions. Specifically, foams generated with surfactant alfa olefin sulfonate (AOS) were studied at temperature up to 200oC, while the pressure ranged between 100 psi and 1000 psi. The effect of additional stabilizing agents was also examined, including guar gum, bentonite clay, borate salt crosslinker, silicon dioxide nanoparticles (SiO2), and graphene oxide (GO) dispersion. Results showed that the stabilizing agents can enhance the foam thermal stability. Foams made with AOS and the borate salt crosslinker exhibited the longest half-life of 20 min at 200°C when the pressure was at 1000 psi. Data fitting showed that foam stability decreased exponentially as temperature increased. On the other hand, pressure increased the foam half-life which followed a power model. This study indicates that it may be possible to obtain highly stable foams at high-temperature and high-pressure conditions with appropriate stabilizing agents.
High temperature, high intensity solar array
The solar array for the Venus Radar Mapper mission will operate in the high temperature, high intensity conditions of a low Venus orbit environment. To fulfill the performance requirements in this environment at minimum cost and mass while maximizing power density and packing factor on the panel surface, several features were introduced into the design. These features included the use of optical surface reflectors (OSR's) to reduce the operating temperature; new adhesives for conductive bonding of OSR's to avoid electrostatic discharges; custom-designed large area cells and novel shunt diode circuit and panel power harness configurations.
The role of frequency on fretting corrosion of Alloy 690TT against 304 stainless steel in high temperature high pressure water
Highlights: • Delamination, material transfer and oxidation dominated fretting corrosion behavior in HTHP water. • Delamination was pure mechanical wear to produce fresh surface exposed to HTHP water for oxidation. • Increased frequency enhanced the maximum thickness of oxide film in worn surface. • Increased frequency accelerated the formation of tribologically transformed structure (TTS). • Increased frequency accelerated the escape of wear debris, which originated from the TTS and crushed oxide particles. - Abstract: In high temperature high pressure (HTHP) water, the role of frequency in fretting corrosion behavior and mechanism of Alloy 690TT against Type 304 stainless steel were investigated. Results indicated that wear mechanisms of delamination, material transfer and oxidation collectively dominated the fretting corrosion behavior. The delamination was related to pure mechanical wear to produce fresh surface exposed to HTHP water for oxidation, resulting in the increase of wear depth and volume. The increasing frequency played little role in oxide type of worn surfaces, which consisted of (Ni,Fe)(Fe,Cr){sub 2}O{sub 4} and Cr{sub 2}O{sub 3}. However, it enhanced the maximum thickness of oxide film in the worn surface. The increasing frequency resulted in the acceleration of the formation of nanostructured tribologically transformed structure (TTS) layer because it could aggravate the plastic deformation and increase the contact temperature for dynamic recrystallization. The increasing frequency accelerated the escape of the ultra-fine grained wear debris, which originated from not only the damage of TTS layer but also the crushed oxide particles generated in the contact gap.
In Situ High Temperature High Pressure MAS NMR Study on the Crystallization of AlPO 4 -5
A damped oscillating crystallization process of AlPO4-5 at the presence of small amount of water is demonstrated by in situ high temperature high pressure multinuclear MAS NMR. Crystalline AlPO4-5 is formed from an intermediate semicrystalline phase via continuous rearrangement of the local structure of amorphous precursor gel. Activated water catalyzes the rearrangement via repeatedly hydrolysis and condensation reaction. Strong interactions between organic template and inorganic species facilitate the ordered rearrangement. During the crystallization process, excess water, phosphate, and aluminums are expelled from the precursor. The oscillating crystallization reflects mass transportation between the solid and liquid phase during the crystallization process. This crystallization process is also applicable to AlPO4-5 crystallized in the presence of a relatively large amount of water.
High Temperature, High Pressure Equation of State: Solidification of Hydrocarbons and Measurement of Krytox Oil Using Rolling-Ball Viscometer Validation
The global consumption of oil and gas continues to rise and has led to the search and recovery of petroleum sources from reservoirs exhibiting increasingly high-temperature, high-pressure conditions. For example, ultra-deep petroleum formations found at depths of approximately 5 km or more, can exhibit pressure and temperature values as high as 240 MPa (35,000 psi) and 533 K (260°C). The hydrocarbons produced from these ultra-deep formations experience significant decreases in temperature and pressure from reservoir to platform conditions. Hence, it is highly desirable to develop accurate equation of state models (EOS) and fluid properties databases that covers the entire temperature and pressure ranges associated with this process to promote the efficient, safe, and environmentally responsible production from these reservoirs at extreme conditions. Currently available databases and EOS models are generally limited to approximately 69 MPa and do not correlate accurately when extrapolated to the extreme environments associated with ultra-deep reservoirs where temperatures can reach as high as 533 K and pressures up to 240 MPa. Despite recent exploration and production of petroleum from ultra-deep formations, there are major gaps in the databases for pure and mixture density and viscosity of hydrocarbons. These are the most important fluid properties that enable accurate booking of reserves as well as the design of size and equipment to safely bring these fluids to the platform. The overall objective of this project is to develop methodologies to provide crude oil thermodynamic and transport properties—including density, viscosity, and phase composition— at extreme temperature and pressure conditions. The knowledge of these crude oil properties reduces uncertainties associated with deep drilling and promotes safer and reliable access to domestic energy resources. This report is an extension of work reported in our first Technical Report Series (TRS) released July 31, 2012: High Temperature, High Pressure Equation of State Density Correlations and Viscosity Correlations (Tapriyal et al., 2012). New experimental data were obtained by utilizing density cell and rolling-ball viscometer (both designed by our team) rated up to 533 K and 275 MPa. This report focuses on the solidification of hydrocarbons at elevated temperatures and pressures and
High Temperature / High Frequency Temperature Measurement: Achieving MHz Response at Temperatures > 1000 Deg-F
High frequency temperature measurements are not possible with current SOA temperature measurement devices at temperatures higher than ~700 deg-F. Temperature measurements above ~1000 deg-F are typical for entry vehicle thermal protection systems (TPS), rocket engines, ram/scramjet engines, etc. A new technology capable of achieving ~1200 deg-F temperature measurements with MHz response has been achieved. Investigations are underway to extend the concept to even higher temperatures. A U.S. patent application is about to be submitted.
Comparison of high temperature, high frequency core loss and dynamic B-H loops of two 50 Ni-Fe crystalline alloys and an iron-based amorphous alloy
The availability of experimental data that characterizes the performance of soft magnetic materials for the combined conditions of high temperature and high frequency is almost nonexistent. An experimental investigation was conducted over the temperature range of 23 to 300 C and frequency range of 1 to 50 kHz to determine the effects of temperature and frequency on the core loss and dynamic B-H loops of three different soft magnetic materials; and oriented grain 50Ni-50Fe alloy, a nonoriented grain 50Ni-Fe alloy, and an iron based amorphous material (Metglas 2605SC). A comparison of these materials shows that the nonoriented grain 50Ni-50Fe alloy tends to have either the lowest or next lowest core loss for all temperatures and frequencies investigated.
Comparison of high temperature, high frequency core loss and dynamic B-H loops of two 50 Ni-Fe crystalline alloys and an iron-based amorphous alloy
The availability of experimental data that characterize the performance of soft magnetic materials for the combined conditions of high temperature and high frequency is almost nonexistent. An experimental investigation was conducted over the temperature range of 23 to 300 C and frequency range of 1 to 50 kHz to determine the effects of temperature and frequency on the core loss and dynamic B-H loops of three different soft magnetic materials: an oriented-grain 50Ni-50Fe alloy, a nonoriented-grain 50Ni-50Fe alloy, and an iron-based amorphous material (Metglas 2605SC). A comparison of these materials shows that the nonoriented-grain 50Ni-50Fe alloy tends to have either the lowest or the next lowest core loss for all temperatures and frequencies investigated.
Comparison of high temperature, high frequency core loss and dynamic B-H loops of a 2V-49Fe-49Co and a grain oriented 3Si-Fe alloy
The design of power magnetic components such as transformers, inductors, motors, and generators, requires specific knowledge about the magnetic and electrical characteristics of the magnetic materials used in these components. Limited experimental data exists that characterizes the performance of soft magnetic materials for the combined conditions of high temperature and high frequency over a wide flux density range. An experimental investigation of a 2V-49-Fe-49Co (Supermendur) and a grain oriented 3 Si-Fe (Magnesil) alloy was conducted over the temperature range of 23 to 300 C and frequency range of 0.1 to 10 kHz. The effects of temperature, frequency, and maximum flux density on the core loss and dynamic B-H loops for sinusoidal voltage excitation conditions are examined for each of these materials. A comparison of the core loss of these two materials is also made over the temperature and frequency range investigated.
Comparison of high temperature, high frequency core loss and dynamic B-H loops of a 2V-49Fe-49Co and a grain oriented 3Si-Fe alloy
The design of power magnetic components such as transformers, inductors, motors, and generators, requires specific knowledge about the magnetic and electrical characteristics of the magnetic materials used in these components. Limited experimental data exists that characterizes the performance of soft magnetic materials for the combined conditions of high temperature and high frequency over a wide flux density range. An experimental investigation of a 2V-49-Fe-49Co (Supermendur) and a grain oriented 3 Si-Fe (Magnesil) alloy was conducted over the temperature range of 23 to 300 C and frequency range of 0.1 to 10 kHz. The effects of temperature, frequency, and maximum flux density on the core loss and dynamic B-H loops for sinusoidal voltage excitation conditions are examined for each of these materials. A comparison of the core loss of these two materials is also made over the temperature and frequency range investigated.
Experimental Evaluation of Heat Transfer in a High Temperature High Pressure Test Facility
Performance of film cooling holes is generally evaluated near ambient conditions, so scaling the film cooling performance from ambient to engine conditions is important. These performance metrics can be reported in terms of net heat flux reduction, heat transfer enhancement, and effectiveness. There are several challenges and penalties in conducting experiments on a real engine or even on a stationary flat plate test article at near engine conditions. In this study, an experimental methodology capable of delivering film cooling performance for the experiments conducted in the high-temperature high-pressure test facility at NETL will be explored. More specifically, this study focuses on various challenges that are present and how these concerns are addressed to evaluate the heat transfer coefficient on the test article. Steady state experiments were conducted on a flat plate test article whose surface temperature distribution was obtained using an IR camera calibrated with a combination of bench top experiments and in-situ calibrations based on embedded thermocouple measurements. A detailed radiation analysis is conducted to enable differentiation of heat transfer by convection from heat transfer by radiation. The estimated surface heat flux and heat transfer coefficient were found to be higher than the one obtained from flat plate correlation.
Comparative Analysis of Heat Exchangers for High Temperature High Pressure Helium Component Testing
Helium gas loops have been designed and built to gain a better understanding of the gas thermohydraulic phenomena that take place in a helium system. Some of these loops are used for validation and testing of components for high temperature gas-cooled reactors (HTGRs). However, most of them operate at lower pressure and temperature than an HTGR. While these loops can provide valuable information about gas-cooled reactor components, the operating envelope of the experiment is constrained by the maximum operating conditions of the helium loop. In response to the lack of an experimental facility that can provide the infrastructure needed to validate and test components at nominal pressures and temperatures of HTGRS, the HElium Component Testing Out-of-pile Research (HECTOR) facility was designed at Idaho National Laboratory with the assistance of University of Idaho and Walsh Engineering. With the capability to test at temperatures up to 800°C and pressures of 8MPa, HECTOR serves as a critical tool for the advancement of HTGR technology. The facility's primary role is to provide a controlled, high-fidelity environment for the assessment of component resilience and efficiency under nominal HTGR conditions. In the quest to enhance the efficiency and performance of HECTOR, a comparative analysis of three distinct types of heat exchangers—shell and tube, offset strip fin, and printed-circuit—was conducted, focusing primarily on two critical metrics: the required surface area and pressure drop characteristics. The shell and tube heat exchanger, renowned for its robust design and widespread industrial application, was evaluated against the offset strip fin and the cuttingedge printed-circuit heat exchangers, both of which are lauded for their compactness and thermal effectiveness. This comparative study aims to provide detailed insights into the thermal management capabilities of each heat exchanger type under the conditions inherent to HECTOR, thereby facilitating an informed selection for systems demanding high operational integrity and efficiency.
Sealed rotors for in situ high temperature high pressure MAS NMR
Magic angle spinning (MAS) nuclear magnetic resonance (NMR) investigations on heterogeneous samples containing solids, semi-solids, liquid and gases or a mixture of them under non-conventional conditions of a combined high pressure and high temperature, or cold temperature suffer from the unavailability of a perfectly sealed rotor. Here, we report the design of reusable and perfectly-sealed all-zircornia MAS rotors. The rotors are easy to use and are suitable for operation temperatures from below 0 to 250 °C and pressures up to 100 bar. As an example of potential applications we performed in situ MAS NMR investigations of AlPO₄-5 molecular sieve crystallization, a kinetic study of the cyclohexanol dehydration reaction using 13C MAS NMR, and an investigation of the metabolomics of intact biological tissue at low temperature using 1H HR-MAS NMR spectroscopy. The in situ MAS NMR experiments performed using the reported rotors allowed reproduction of the results from traditional batch reactions, while offering more detailed quantitative information at the molecular level, as demonstrated for the molecular sieve synthesis and activation energy measurements for cyclohexanol dehydration. The perfectly sealed rotor also shows promising application for metabolomics studies using 1H HR-MAS NMR.
High Temperature High Vacuum Mechanical Property Assessment of Zirconium Nuclear Fuel Cladding
This report presents the mechanical characterization of a specific Zry-4 cladding batch serving as the foundation for a diverse range of fuel performance research at Oak Ridge National Laboratory (ORNL). This effort supports research needs for the U.S. Department of Energy (DOE), particularly regarding evaluating accident tolerant fuel (ATF) cladding coating concepts, expanding understanding of cladding response to loss-of-coolant accidents (LOCA) transients, refining post-critical heat flux (CHF) limits (t@T), and upcoming irradiation campaigns. The central objective was to define the baseline performance of the substrate Zircaloy-4 (Zry-4) material leveraged across ORNL Advanced Fuel Campaign (AFC) efforts through controlled high-temperature vacuum tensile testing. This work begins to address gaps in existing models where implementation based on nominal heat-treatment labels, such as stress relief annealed (SRA), often fail to capture the interplay of recovery, recrystallization, and grain growth. To quantify this, data was benchmarked against the Pacific Northwest National Laboratory (PNNL) stress strain model to determine where this material falls in comparison to assumed values for materials in the same heat treatment regime. Analysis of the tensile data revealed that this specific SRA batch exhibits a transitional microstructural state best described by an effective cold-work (CW) parameter of 0.09, diverging from the previous estimation of 0.5 for SRA materials. Additionally, comparative testing of Cr coated specimens demonstrated no distinct difference in axial strength relative to the bare substrate. This suggests that the strengthening benefits of Cr coatings observed in burst scenarios are driven by residual stress mechanisms acting solely in the hoop direction.