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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 19 records
All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

Effect of nozzle translation on a bounded vortex flow

A bounded vortex flow is generated by a nozzle that combines azimuthally tilted downward jets in a circular array and a central suction port. When the nozzle is directed toward a bottom surface (called the impingement surface), the flow develops a strong intake vortex spanning from the impingement surface to the suction port, which acts to generate strong shear stress on the impingement surface. This strong shear stress can aid in removing particles attached to the impingement surface or in enhancement of heat or mass transfer, where in typical applications, the nozzle would be translated along the impingement surface. This paper reports on a computational study of the effect of nozzle translation on the bounded vortex flow field. The nozzle translation induces a bending of the bounded vortex in the downstream flow direction, which becomes larger with increase in the nozzle translation speed. We identify an interesting oscillatory phenomenon by which the bounded vortex can resist the bending induced by the translational flow and rotate about a mean position downstream of the suction port. At sufficiently high translation speeds, the oscillatory process can no longer resist the downwash effect from nozzle translation and the vortex eventually detaches from the impingement surface, limiting the effectiveness of this flow device.

42 ENGINEERING↗
DOE OSTI2024

Flow and Performance Characterization of Rotating Detonation Combustor Integrated with Various Convergent Nozzles

In this study, convergent nozzles of various area ratios (ARs) are used downstream of an annular rotating detonation combustor (RDC) to increase the operating pressure and approach sonic conditions at the nozzle throat. Reactant methane and oxygen-enriched air (67% [Formula: see text] and 33% [Formula: see text] by volume) are supplied in counterflow arrangement from two separate plenums located at the base of the RDC annulus. Based on experimentation, a total mass flow rate of [Formula: see text] was chosen to achieve stable, single-wave mode RDC operation for all test cases, allowing for one-to-one comparisons. The internal performance of the RDC was characterized by ion probes and pressure measurements (wall static and oscillating) in supply plenums and across different axial locations of the combustor. Particle image velocimetry (PIV) at 100 kHz was utilized to measure axial and circumferential velocity components within a two-dimensional region of interest located downstream of the converging nozzle exit. Results show higher internal performance of the RDC with increasing AR of the convergent nozzle. PIV measurement illustrated that the flow oscillation amplitudes decrease with an increasing AR of the converging nozzle. The exit flow contained significant nonuniformity and unsteadiness even with a converging nozzle of AR 2.0, indicating incomplete choking of the flow at the nozzle throat.

Engineering↗
DOE OSTI2024

Validation of predictive performance models for supersonic gas-jet nozzles at the Laboratory for Laser Energetics

We present results characterizing the neutral-density distributions produced by the supersonic nozzles used in experiments on the OMEGA-60 and OMEGA-EP laser systems at the University of Rochester’s Laboratory for Laser Energetics (LLE). Axisymmetric Fluent® simulations using LLE nozzle specifications capture the viscous effects, gas expansion, and shock waves that complicate flow predictions for offsets above the nozzle exit. Here, these simulations show good agreement with neutral-density measurements obtained using a four-wave shearing interferometer. An analytical form is given for the plateau length. Fits to simulation data for boundary layer thickness, mean plateau density, and density ramps are given as functions of nozzle offset and nozzle backing pressure for a number of nozzles and gases.

47 OTHER INSTRUMENTATION↗
DOE OSTI2025

Experimental Investigation of Vapor Formation in Liquid CO2 Flow Through a Converging-Diverging Nozzle

Carbon dioxide is an attractive working fluid for many cycles, including for pumped thermal energy storage (PTES). A challenge with some proposed sCO2 PTES cycles is the operation of sCO2 machinery outside the typical bounds of experience, with local phase change from the liquid state being particularly unknown. Presently, there is insufficient data in the literature regarding multiphase CO2 to adequately design a multiphase-tolerant turbine, so generation of foundational data is required. This experimental study investigates the flow characteristics of sub-sonic liquid CO2 undergoing expansion and phase change in a converging-diverging nozzle. The nozzle is instrumented to measure static pressure, unsteady pressure, temperature, and density. The static pressure transducers are located at 27 axial locations to accurately characterize the pressure profile in the nozzle. High-accuracy RTDs are located at the entrance and exit of the nozzle, and three dynamic pressure transducers are strategically located to capture any unsteady phenomena. During testing, values of mass flow and nozzle inlet pressure are swept to vary the pressure drop and fluid properties. The measured total pressure drop in the nozzle is compared to a homogenous model and the Lockhart-Martinelli correlation method, with the latter predicting loss quite closely. The resulting data set is valuable for validating multiphase numerical models in a simple geometry before implementation of these models in turbomachinery design.

25 ENERGY STORAGE↗
DOE OSTI2024

Micro-cold Spray Deposition of YSZ Films from Ultrafine Powders Using a Pressure Relief Channel Nozzle

Abstract The use of ultrafine powders in the micro-cold spray (MCS) process, also referred to as the aerosol deposition method, typically results in porous and/or poorly adhering films because the particles do not impact at a high enough velocity for sufficient plastic deformation and interparticle bonding to occur. Under typical operating conditions, particles < 100 nm accelerate to high velocities but then are slowed by the stagnant gas in the bow shock that forms just upstream of the substrate. Using larger particles reduces particle slowing, but large particles can cause erosion of the film at high impact velocity, decreasing deposition efficiency. In this study, a pressure relief channel nozzle using helium as a carrier gas is proposed such that high-velocity deposition of yttria-stabilized zirconia particles as small as 10 nm in diameter is possible. This is well below the size range of powders previously used for MCS. The proposed nozzle design increases impact velocities for 10, 20, and 50 nm particles by ~ 880, 560, and 160 m/s, respectively, when compared to a conventional nozzle. Experimental deposition of ultrafine 8YSZ powder shows that the pressure relief channel nozzle results in lower porosity and more uniform deposits, with a ∼ 186% increase in deposition efficiency.

Materials Science↗
DOE OSTI2024

Simulations of nozzle gas flow and gas-puff Z-pinch implosions on the Weizmann Z-pinch

We present simulations of an oxygen gas puff Z-pinch on a University scale generator at the Weizmann Institute of Science. The work accounts for the detailed geometry of the nozzle, the initial neutral gas density distribution, and the subsequent implosion. The modeling results show significant improvement with data for the current at the time of stagnation in comparison with a previous effort [Rosenzweig et al., Phys. Plasmas 27, 022705 (2020)]. As a first step, we performed simulations of the flow of neutral diatomic oxygen from a plenum through a nozzle within a recessed cathode, across a gap, and into the anode with a recessed grounded honeycomb. These simulations show an agreement with the measured initial gas density profiles within the region not blocked by the recesses and accessible to visible measurements. The computed neutral gas flow profile serves as the initial condition for a radiation magnetohydrodynamic simulation of the implosion using the MACH2-TCRE code. By considering the specific details of the nozzle and chamber geometry, we find agreement with the measured current profile, including the inductive notch. The simulations predict that the plasma undergoes a strong pinch within the hidden anode recess. The simulations also predict the strongest radiation pulse occurs within the anode recess and at the time of the observed inductive notch.

Physics↗
DOE OSTI2024

OPERATION OF FT4000® SINGLE NOZZLE COMBUSTOR WITH HIGH HYDROGEN

This paper reports initial results from an effort to develop a retrofittable fuel/air injector for the FT4000® aeroderivative gas turbine that enables use of hydrogen as a carbon-free fuel for efficient power generation. The FT4000 engine’s low-NOx combustor was developed by Pratt & Whitney and RTX Technology Research Center with core technology from the Pratt & Whitney PW4000 turbofan aircraft engine. The work reported here advances the technology readiness level of the FT4000 combustor for operation with hydrogen, starting with an experimental assessment of the current production hardware with increasing hydrogen content mixed with natural gas. High-pressure single-sector combustor rig tests have been completed, demonstrating the ability for the dual fuel nozzle to operate an FT4000 combustor on 100% hydrogen with low nitrogen oxide (NOx) missions. Metal temperature measurements and video images of the flame structure from zero to 100% hydrogen highlight opportunities to improve the fuel nozzle robustness for high hydrogen conditions. The current FT4000 production engine operates on either natural gas or No. 2 fuel oil with water injection to achieve high thermal efficiency and low emissions. This engine is fielded by Mitsubishi Power Aero and delivers 70 MW of power with a simple-cycle efficiency of over 41% when operating with wet compression. Results from this study have cleared the current production FT4000 engines with dual fuel nozzles to operate at baseload power on blends of hydrogen mixed with natural gas and water.

power generation↗
DOE OSTI2026

Nozzle geometry optimization for high-current aluminum ion beam acceleration via direct plasma injection scheme

We report the generation of a record aluminum ion beam current exceeding 58 mA at the Al 11+ charge state, accelerated to an energy of 5.5 MeV using the direct plasma injection scheme, which integrates a laser ion source (LIS) with a radio frequency quadrupole (RFQ) accelerator. The effect of nozzle geometry on beam extraction was systematically investigated using 8 and 12 mm tapered designs and an 18 mm cylindrical configuration. The 18 mm nozzle achieved the highest Al 11+ beam current, while the 12 mm aperture provided a favorable balance between beam intensity and current density. Beam extraction simulations confirmed effective RFQ matching across multiple charge states, and solenoidal field tuning further enhanced plasma collimation. This work not only establishes a new benchmark for high-current ion beam generation but also provides a fundamental understanding of plasma–beam interface dynamics crucial for the next generation of high-intensity particle accelerators, particularly those employing LIS-RFQ systems.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗
DOE OSTI2026

Towards time-resolved MicroED grid preparation using mix-and-inject gas dynamic virtual nozzles

Recent progress in gas dynamic virtual nozzle (GDVN) technologies in combination with high-brilliance synchrotron and X-ray free-electron lasers (XFELs) has allowed the visualization of protein dynamics in crystallo by mixing macromolecular protein crystals with a substrate using tunable mixing times on the order of milliseconds to seconds prior to serial X-ray diffraction data collection. This has become the method of choice for high-resolution structure determination of intermediate states. However, such experiments require large counts of crystals of proper sizes for high-resolution data collection, and premium beam times for screening efforts. Cryogenic microcrystal electron diffraction (MicroED) represents a complementary technique that may be a more accessible avenue for time-resolved nanocrystallography compared with serial X-ray diffraction experiments. MicroED can produce full diffraction datasets from just a few submicrometre-thick crystals, and the approach is more readily accessible, requiring standard cryogenic transmission electron microscopy (TEM) equipment available at many universities and institutes. Cryogenic MicroED, like other forms of cryo-EM, begins with rapidly freezing biological material on electron microscopy grids. In the case of MicroED, micro- to nano-crystals (<500 nm thick) are deposited onto electron microscopy grids and plunge-frozen for subsequent electron diffraction data collection. Here, we have incorporated GDVN technology developed originally for XFEL experiments into the freezing process as a first step towards time-resolved studies. We describe the limited deposition efficiency of the model MicroED protein proteinase K on TEM grids using GDVNs, preceding sample vitrification and successful MicroED data collection. We discuss both the initial results from such experiments and the methodological challenges in developing this approach into a reliable workflow for millisecond-to-second time-resolved structural studies of macromolecules. Our results promise a strategy to deposit crystals on grids using GDVNs and determine high-resolution structures by MicroED, constituting a first step towards development of time-resolved MicroED experiments.

MicroED↗
DOE OSTI2025

Distributed Sapphire Fiber Bragg Gratings Based Thermal Profiling of Submerged Entry Nozzles

This research focuses on the application of sapphire fiber Bragg gratings (FBGs) for instrumentation in submerged entry nozzles (SEN) within the steelmaking industry. The SEN is pivotal for transferring molten steel from a tundish to a mold, while preventing the infiltration of oxygen and nitrogen from the surrounding environment. Maintaining optimal flow conditions in the mold is crucial for ensuring casting process stability and maintaining high quality steel. Sapphire FBG sensors have been instrumented in SENs to enable distributed thermal mapping for monitoring the health of the SEN. The optical sensor comprises three cascaded sapphire FBGs inscribed using femtosecond laser technology into a one-meter-long sapphire crystalline fiber. The sensor underwent characterization in a laboratory setting up to 1600°C and was tested for long-term stability over 40 hours under extreme environmental conditions. The coupling between silica and sapphire fibers was investigated and implemented during sensor packaging. Here, the sensor successfully captured the pre-heat sequence of the SEN in real-world steelmaking operations. Compared to conventional thermocouples, sapphire FBG sensors demonstrated exceptional efficiency and precision. They offer potential benefits such as increased productivity, reduced energy consumption, and minimized carbon footprint in the steel industry.

Sapphire Fiber Bragg Grating↗
DOE OSTI2025

High Pressure Hydrogen Nozzle Assembly and Dispenser for Heavy Duty Vehicles (Final Technical Report)

Electricore, Inc. along with partners Bennett Pump Company (Bennett), WEH Technologies, Inc. (WEH), National Renewable Energy Laboratory (NREL), and Quong & Associates, Inc. (QAI) have developed a high-pressure hydrogen nozzle assembly and dispenser for heavy-duty (HD) vehicles. The system was installed, tested and demonstrated at NREL’s Hydrogen Infrastructure Testing and Research Facility (HITRF). The system was designed to have a maximum operating pressure of 87.5 MPa and an approximate average flow rate of 10 kg/min over 10 minutes at fuel temperatures of -40°C. To further develop the specifications and design of the system, the team performed an industry survey to ensure the system met the needs of potential users.

08 HYDROGEN↗
DOE OSTI2025

Predicting multi-nodal in-nozzle particle interactions in high-viscosity fluid mediums for acoustophoretic direct-ink writing of line-patterned composites

Patterned functional materials offer improved properties (electrical, thermal, etc.) over their bulk counterparts in many applications, including energy storage, flexible electronics, and sensors. However, manufacturing approaches for patterning materials over large areas with features on the order of hundreds of microns or less are limited. Acoustophoresis, which uses acoustic forces to control particle arrangement in a fluid medium, is a pathway to address this challenge. This process is dependent on particle and fluid properties and enables patterning of a broad range of materials. Herein, a model with experimental validation is presented to demonstrate that acoustophoresis can be combined with direct-ink writing (DIW) to fabricate line patterns over large cm-scale areas. An in-nozzle particle interaction model was developed to investigate the impact of processing conditions on multi-nodal acoustophoretic DIW. The model predicts patterned line widths within a factor of two relative to experimental results for a high viscosity case study. Here, the model was used to investigate the impact of frequency, particle loading, particle radius, and acoustic pressure on line width and patterning time, providing critical feedback regarding the processing conditions suitable for a target application. Model results illustrate that frequency has the greatest impact on line patterns: increasing from 1 to 3 MHz resulted in a greater than 65% reduction in line width and a greater than 85% reduction in patterning time. Additionally, experiments were conducted with an alumina-epoxy ink and a ~21 cm 2 area pattern was rastered in ~5.5 minutes, demonstrating a path towards large-area line-patterned composite fabrication.

25 ENERGY STORAGE↗
DOE OSTI2024

Enhancing physicochemical, bioactive, and nutritional properties of sweet potatoes: Ultrasonic contact drying with slot jet nozzles compared to hot-air drying and freeze drying

Sweet potatoes are a rich source of nutrients and bioactive compounds, but their quality can be impacted by the drying process. This study investigates the impact of slot jet reattachment (SJR) nozzle and ultrasound (US) combined drying (SJR + US) on sweet potato quality, compared to freeze-drying (FD), SJR drying, and hot air drying (HAD). SJR + US drying at 50 °C closely resembled FD in enhancing quality attributes and outperformed HAD and SJR in key areas such as rehydration, shrinkage ratios, and nutritional composition. Notably, SJR + US at 50 °C produced the highest total starch (36.84 g/100 g), total dietary fiber (8.48 g/100 g), total phenolic content (158.19 mg GAE/100 g), total flavonoid content (119.08 mg QE/g), DPPH antioxidant activity (6.44 μmol TE/g), β-carotene (31.98 mg/100 g), and vitamin C (5.27 mg/100 g). It also exhibited higher glass transition temperatures (Tg: 14.49 °C), indicating better stability at room temperature. The hardness values for SJR + US samples were similar to FD, while HAD samples had the highest hardness. SJR + US at 50 °C resulted in the lowest total color changes (ΔE), indicating minimal impact on appearance. Additionally, FTIR analysis revealed that peaks in specific spectral regions indicated superior preservation of bioactive compounds in SJR + US samples compared to other methods, which was also confirmed by principal component analysis (PCA) and heatmap visualization. Overall, these findings suggest that SJR + US is an effective alternative to conventional drying techniques, significantly improving the quality of dried sweet potatoes.

Color↗
DOE OSTI2024

Design, Analysis, and Experimental Testing of Hydrogen Lean Direct Injection Nozzles at Elevated Pressure

Abstract There are many challenges of commissioning a hydrogen combustor into future gas turbine engines; especially regarding achieving emissions goals. Previously, Escudero et al. and Tran et al. conducted a study to adapt the liquid fuel Lean Direct Injection (LDI) concept from Jet-A to gaseous natural gas-hydrogen blends and pure hydrogen [1], [2]. Experimental data was collected at atmospheric conditions using a Box Behnken design of experiments. The design of experiments suggested that biasing the air split in favor of the inner air circuit and increasing the swirl strength of this inner air passage resulted in improved NOx emissions, while the inverse was true for stability, which was quantified by studying the lean blowoff point (LBO) [1], [2]. The trends revealed by the original experiment [1], [2] provided a design direction for further iterations of the experimental hardware. The study presented herein describes the further investigation of such LDI injectors through experimental methods and computational fluid dynamic (CFD) simulations at atmospheric conditions, which were used to identify potential flow behaviors driving enhanced emissions performance. Further evaluation of select injectors from both studies was then conducted at elevated pressures up to 6 atmospheres. The results from both experiments are presented in this study, which include flame observations, emissions measurements, and operational challenges. NOx emissions results are reported on a volume basis in ppmvd corrected to 15% O2 and corrected for fuel. A predictive model for relating NOx emissions to test conditions at atmospheric conditions show high significance to adiabatic flame temperature while little to no significance to fuel composition for the best performing configurations. The results illustrate the connection between atmospheric testing and testing elevated pressures. The design direction indicated by the initial tests and CFD results in promising configurations for implementation into a Multi-point LDI array.

08 HYDROGEN↗
DOE OSTI2025

Attempting to Develop the World’s Most Cost-Effective Metal 3D Printing Technology Through Industrial Adoption of a High-Temperature Electro-Magnetic Nozzle for 3D Printing and Computer Numerical Control Integration

This project aimed to make a practical system capable of sustained metal deposition in air engineered with industrial integration and controls. The Al-Ce wire feedstock was tailored with appropriate deposition and solidification properties for direct reactive interface printing (DRIP), and the goal was to integrate onto a Hybrid Manufacturing Technologies system for producing test parts without a controlled environment.

36 MATERIALS SCIENCE↗