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This paper presents the laser-based powder bed fusion (L-PBF) using various glass powders (borosilicate and quartz glass). Compared to metals, these require adapted process strategies. First, the glass powders were characterized with regard to their material properties and their processability in the powder bed. This was followed by investigations of the melting behavior of the glass powders with different laser wavelengths (10.6 µm, 1070 nm). In particular, the experimental setup of a CO2 laser was adapted for the processing of glass powder. An experimental setup with integrated coaxial temperature measurement/control and an inductively heatable build platform was created. This allowed the L-PBF process to be carried out at the transformation temperature of the glasses. Furthermore, the component’s material quality was analyzed on three-dimensional test specimen with regard to porosity, roughness, density and geometrical accuracy in order to evaluate the developed L-PBF parameters and to open up possible applications.
Solar sailcraft provide a wide range of opportunities for high-energy low-cost missions. To date, most mission studies require a rather demanding performance that will not be realized by solar sailcraft of the first generation.
However, even with solar sailcraft of moderate performance, scientifically relevant missions are feasible. This is demonstrated with a Near Earth Asteroid sample return mission and various planetary rendezvous missions.
Solar sails are propelled in space by reflecting solar photons off large mirroring surfaces, thereby transforming the momentum of the photons into a propulsive force. This innovative concept for low-thrust space propulsion works without any propellant and thus provides a wide range of opportunities for highenergy low-cost missions. Offering an efficient way of propulsion, solar sailcraft could close a gap in transportation options for highly demanding exploration missions within our solar system and even beyond. On December 17th, 1999, a significant step was made towards the realization of this technology: a lightweight solar sail structure with an area of 20 m × 20 m was successfully deployed on ground in a large facility at the German Aerospace Center (DLR) at Cologne. The deployment from a package of 60 cm × 60 cm × 65 cm with a total mass of less than 35 kg was achieved using four extremely light-weight carbon fiber reinforced plastics (CFRP) booms with a specific mass of 100 g/m. The paper briefly reviews the basic principles of solar sails as well as the technical concept and its realization in the ground demonstration experiment, performed in close cooperation between DLR and ESA. Next possible steps are outlined. They could comprise the in-orbit demonstration of the sail deployment on the upper stage of a low-cost rocket and the verification of the propulsion concept by an autonomous and free flying solar sail in the frame of a scientific mission. It is expected that the present design could be extended to sail sizes of about (40 m)2 up to even (70 m)2 without significant mass penalty. With these areas, the maximum achievable thrust at 1 AU would range between 10 and 40 mN – comparable to some electric thrusters. Such prototype sails with a mass between 50 and 150 kg plus a micro-spacecraft of 50 to 250 kg would have a maximum acceleration in the order of 0.1 mm/s2 at 1 AU, corresponding to a maximum ∆V-capability of about 3 km/s per year. Two near/medium-term mission examples to a near-Earth asteroid (NEA) will be discussed: a rendezvous mission
and a sample return mission.
Near-Earth asteroid (NEA) 99942 Apophis provides a typical example for the evolution of asteroid orbits that lead to Earth-impacts after a close Earth-encounter that results in a resonant return. Apophis will have a close Earth-encounter in 2029 with potential very close subsequent Earth-encounters (or even an impact) in 2036 or later, depending on whether it passes through one of several less than 1 km-sized gravitational keyholes during its 2029-encounter. A pre-2029 kinetic impact is a very favorable option to nudge the asteroid out of a keyhole. The highest impact velocity and thus deflection can be achieved from a trajectory that is retrograde to Apophis orbit. With a chemical or electric propulsion system, however, many gravity assists and thus a long time is required to achieve this. We show in this paper that the solar sail might be the better propulsion system for such a mission: a solar sail Kinetic Energy Impactor (KEI) spacecraft could impact Apophis from a retrograde trajectory with a very high relative velocity (75-80 km/s) during one of its perihelion passages. The spacecraft consists of a 160 m × 160 m, 168 kg solar sail assembly and a 150 kg impactor. Although conventional spacecraft can also achieve the required minimum deflection of 1 km for this approx. 320 m-sized object from a prograde trajectory, our solar sail KEI concept also allows the deflection of larger objects. For a launch in 2020, we also show that, even after Apophis has flown through one of the gravitational keyholes in 2029, the solar sail KEI concept is still feasible to prevent Apophis from impacting the Earth, but many KEIs would be required for consecutive impacts to increase the total Earth-miss distance to a safe value
The planned coal phase-out in Germany by 2038 will lead to the dismantling of power plants with a total capacity of approx. 30 GW. A possible further use of these assets is the conversion of the power plants to thermal storage power plants; the use of these power plants on the day-ahead market is considerably limited by their technical parameters. In this paper, the influence of the technical boundary conditions on the operating times of these storage facilities is presented. For this purpose, the storage power plants were described as an MILP problem and two price curves, one from 2015 with a relatively low renewable penetration (33 %) and one from 2020 with a high renewable energy penetration (51 %) are compared. The operating times were examined as a function of the technical parameters and the critical influencing factors were investigated. The thermal storage power plant operation duration and the energy shifted with the price curve of 2020
increases by more than 25 % compared to 2015.
Experimental and numerical investigation on the effect of pressure on micromix hydrogen combustion
(2021)
The micromix (MMX) combustion concept is a DLN gas turbine combustion technology designed for high hydrogen content fuels. Multiple non-premixed miniaturized flames based on jet in cross-flow (JICF) are inherently safe against flashback and ensure a stable operation in various operative conditions.
The objective of this paper is to investigate the influence of pressure on the micromix flame with focus on the flame initiation point and the NOx emissions. A numerical model based on a steady RANS approach and the Complex Chemistry model with relevant reactions of the GRI 3.0 mechanism is used to predict the reactive flow and NOx emissions at various pressure conditions. Regarding the turbulence-chemical interaction, the Laminar Flame Concept (LFC) and the Eddy Dissipation Concept (EDC) are compared. The numerical results are validated against experimental results that have been acquired at a high pressure test facility for industrial can-type gas turbine combustors with regard to flame initiation and NOx emissions.
The numerical approach is adequate to predict the flame initiation point and NOx emission trends. Interestingly, the flame shifts its initiation point during the pressure increase in upstream direction, whereby the flame attachment shifts from anchoring behind a downstream located bluff body towards anchoring directly at the hydrogen jet. The LFC predicts this change and the NOx emissions more accurately than the EDC. The resulting NOx correlation regarding the pressure is similar to a non-premixed type combustion configuration.
Kawasaki Heavy Industries, LTD. (KHI) has research and development projects for a future hydrogen society. These projects comprise the complete hydrogen cycle, including the production of hydrogen gas, the refinement and liquefaction for transportation and storage, and finally the utilization in a gas turbine for electricity and heat supply. Within the development of the hydrogen gas turbine, the key technology is stable and low NOx hydrogen combustion, namely the Dry Low NOx (DLN) hydrogen combustion.
KHI, Aachen University of Applied Science, and B&B-AGEMA have investigated the possibility of low NOx micro-mix hydrogen combustion and its application to an industrial gas turbine combustor. From 2014 to 2018, KHI developed a DLN hydrogen combustor for a 2MW class industrial gas turbine with the micro-mix technology. Thereby, the ignition performance, the flame stability for equivalent rotational speed, and higher load conditions were investigated. NOx emission values were kept about half of the Air Pollution Control Law in Japan: 84ppm (O2-15%). Hereby, the elementary combustor development was completed.
From May 2020, KHI started the engine demonstration operation by using an M1A-17 gas turbine with a co-generation system located in the hydrogen-fueled power generation plant in Kobe City, Japan. During the first engine demonstration tests, adjustments of engine starting and load control with fuel staging were investigated. On 21st May, the electrical power output reached 1,635 kW, which corresponds to 100% load (ambient temperature 20 °C), and thereby NOx emissions of 65 ppm (O2-15, 60 RH%) were verified. Here, for the first time, a DLN hydrogen-fueled gas turbine successfully generated power and heat.
This study investigates the influence of pressure on the temperature distribution of the micromix (MMX) hydrogen flame and the NOx emissions. A steady computational fluid dynamic (CFD) analysis is performed by simulating a reactive flow with a detailed chemical reaction model. The numerical analysis is validated based on experimental investigations. A quantitative correlation is parametrized based on the numerical results. We find, that the flame initiation point shifts with increasing pressure from anchoring behind a downstream located bluff body towards anchoring upstream at the hydrogen jet. The numerical NOx emissions trend regarding to a variation of pressure is in good agreement with the experimental results. The pressure has an impact on both, the residence time within the maximum temperature region and on the peak temperature itself. In conclusion, the numerical model proved to be adequate for future prototype design exploration studies targeting on improving the operating range.
Solar sails enable missions to the outer solar system and beyond, although the solar
radiation pressure decreases with the square of solar distance. For such missions, the solar sail may gain a large amount of energy by first making one or more close approaches to the sun. Within this paper, optimal trajectories for solar sail missions to the outer planets and into near interstellar space (200 AU) are presented. Thereby, it is shown that even near/medium-term solar sails with relatively moderate performance allow reasonable transfer times to the boundaries of the solar system.