The Penn State Low-Carbon Power and Propulsion REU will host students in a number of laboratories. Learn more about our research here!
Steady Thermal Aero Research Turbine (START)
The Steady Thermal Aero Research Turbine (START) Laboratory focuses on sustainable propulsion and power generation through increasing the efficiency of gas turbine engines while still maintain component life. The pillars for our lab include innovating turbine cooling using true-scale engine hardware, developing sensors and instrumentation for smart turbines, advancing additive manufacturing for turbine applications, and integrating and embedding sensors into turbine components through additive manufacturing. Included in the START Lab is a test turbine in which state-of-art instrumentation provides a direct measure of spatially-resolved, turbine blade temperatures as well as methods for quantifying turbine stage efficiency. Research is conducted in conjunction with many industry supporters as well as federal agencies such as DOE, NASA, the FAA, and ARPA-E.
Project for Summer 2024: Evaluating Infrared Thermal Image Calibrations for Turbine Measurements – Non-contact infrared (IR) thermal imaging is a common technique for evaluating surface temperature and heat transfer, and it is becoming increasingly commonplace in advanced turbine research applications. The START Lab at Penn State utilizes a unique thermal imaging system capable of fast integration times to measure turbine blades spinning at more than 10,000 rpm (500 mph). However, the accuracy of IR temperature measurements is only as good as the calibration procedures. This project will investigate the contributions of high-emissivity coatings, and inherent complexities associated with imaging highly-curved turbine blades. Candidates will design new calibration fixtures, apply coatings, and operate IR systems in the laboratory to assess calibration influences.
Project for Summer 2024: Turbine Inlet and Exit Profile Optimization – Turbine research conducted in the START Lab at Penn State relies heavily on accurate measurements of inlet and exit profiles. These profiles of temperature, pressure, flow angles (and more) can vary depending on the location of the measurement and the operation of the facility. This project will work with motion control systems and data acquisition systems to optimize measurement processes and improve profile measurement accuracy for future research programs. Activities may include low-voltage electrical wiring, pressure tubing connections, hands-on hardware probe installations on the turbine facility, LabView computer programming, and offline data analysis.
Reacting Flow Dynamics Laboratory
The Reacting Flow Dynamics Laboratory focuses on issues of reacting flows for energy and propulsion applications. High-speed laser diagnostics and other state-of-the-art experimental techniques are used in research areas such as hydrodynamic instability, thermoacoustic instability, combustor durability, and alternative fuels. With a particular focus on engine combustion and flow fields, the goal of this lab’s work is to understand fundamental issues that have been distilled from real-world technologies. Study of these “unit problems” helps to bridge the gap between real-world technological issues and university-level, fundamental research. Our current work focuses on a number of different issues related to low-carbon combustion, including both high-hydrogen systems and bio-derived liquid and solid fuels.
Project for Summer 2024: Measuring Heat Flux through High-Temperature Materials in Reacting Environments – High-temperature materials will need to withstand new environmental conditions in high-hydrogen gas turbines and so testing them in realistic environments is critical to predicting their performance. Obtaining the heat flux through materials in combustion environments is vital to predicting material life but is often difficult and expensive to implement. We are commissioning a new facility for testing high-temperature materials in reacting environments with realistic gas turbine combustor flow features at a range of fuel compositions. A key component of this new facility is the heat flux block, which provides steady-state heat flux measurements by inducing one-dimensional heat transfer through the test material and block. In this project, we will use this device to measure the heat flux through a variety of high-temperature ceramic materials. Further, high-speed mid-wave infrared imaging will be used to understand the temperature distribution on these materials in reacting environments.
Experimental and Computational Convection Lab (ExCCL)
Student researchers in the Experimental and Computational Convection Lab (ExCCL) use state of the art optical diagnostic tools such as particle image velocimetry or infrared sensitive cameras to measure fluid flow and surface temperatures in aerospace or power generation convective heat transfer applications. There are multiple wind tunnels for testing large scale turbine or heat exchanger parts, and a high speed wind tunnel (up to supersonic Mach numbers!) for testing real-scale parts. The lab also develops computational design tools and experimental performance measurements for compact heat exchangers made using metal additive manufacturing.
Project for Summer 2024: Use of genetic algorithms for novel design for additive manufacturing – Metal additive manufacturing can enable more complex designs for compact heat exchangers that are prevalent in aerospace, but design tools to accommodate wide geometric flexibility are rare. The ExCCL lab has recently developed a voxel-based design tool (https://doi.org/10.1016/j.ijheatmasstransfer.2021.121002) that leverages genetic algorithms to design novel heat exchanger fins. The goal of this research would be to execute the existing design tool to understand sensitivities to input variables, and possibly develop a novel design that could be 3D printed at the ExCCL lab and tested in a specialized wind tunnel. No background expertise is necessary but an interest in computational fluid dynamics and motivation to learn Linux and Python are important.
Guimarães Instrumentation, Measurements, and Aerodynamic Sensing Laboratory
The Guimarães Instrumentation, Measurements, and Advanced Sensing Laboratory (GIMAS Lab) focuses on improving experimental fluid dynamics through instrumentation and measurement technique development. We focus on experimental work in aerodynamics, vortical flows and heat transfer for applications in low speed rigs and wind tunnels. We also use additive manufacturing to integrate and improve measurement capabilities for different instruments and experimental models.
Project for Summer 2024: Impact of 5-Hole-Probe Head Design on Flow Measurement Quality – Part 2: Experimental Assessment of Probe Performance for Different Geometries – Accurate pressure and temperature measurements are essential for the development and improvement of efficiency in aerodynamic and fluid dynamic systems. During Summer 2024, the student participating in this REU will use our calibration wind tunnel to assess the quality of the measurements of multi-hole pressure probes of different geometries. The student will be responsible for running several experiments in the wind tunnel for probes with different head geometries (hemispherical and conical) and sizes. The results from the experiments will be statistically analyzed by the student to decide which geometry and size is more appropriate for each flow speed.
Basak Research Group
Basak Research Group is a multidisciplinary team directed by Dr. Amrita Basak. We are a part of the Department of Mechanical Engineering at the Pennsylvania State University – University Park. We research metallic (e.g., nickel- and iron-based alloys), polymeric (e.g., cellulose), and ceramic (e.g., piezoelectric/ferroelectric) materials to fabricate novel structures for engineering applications through additive manufacturing processes such as laser powder bed fusion, laser directed energy deposition, and direct ink writing. We integrate computational modeling and machine learning, develop materials, perform experiments, and characterize microstructures and relevant properties to enhance our understanding of the composition-process-structure-postprocess-property linkages in advanced manufacturing.
Project for Summer 2024: Multi-step optimization for maximizing thermal performance of pin-fin arrays – As additive manufacturing unlocks the door for creating complex internal geometries, machine learning methods bridge the gap into the future of convective cooling. The use of computational fluid dynamics provides the foundation for analyzing the performance of heat sinks, aerospace components, and all things alike. Machine learning possesses the ability to recognize hidden trends and make predictions for more optimal geometries. In this project, an automated framework which connects CFD with machine learning models will be used to conduct a multi-step optimization for pin-fin arrays. The project objective is to explore a complex design space to find a geometry which minimizes the pressure drop while maximizing heat transfer. This will be conducted by first creating an initial population of complex geometry. An optimization will then be completed for the maximization or minimization of a desired objective (heat transfer, pressure drop). The results of the optimization will then be added to the initial sample space, building a more complex and robust model. This process will then be repeated to maximize the exploration of the complex design space leading to a final optimal geometry which satisfies the desired objective.
Pangborn Advanced Controls Lab (PACLab)
The Pangborn Advanced Controls Lab (PAC Lab) researches modeling, optimization, and control for vehicle energy management. Broadly speaking, we study the science of automated decision-making in complex systems. A particular focus is coordinating propulsion, power, and thermal management to maximize efficiency while ensuring safety. The PAC Lab develops new theory for formulating and verifying advanced control algorithms and also validates that theory via application to experimental testbeds. Our goal is to enable new capabilities for sustainable transportation while training the next generation of leaders to solve exigent engineering challenges.
Project for Summer 2024: Development of a Scaled Powertrain Testbed for Hybrid-electric Aircraft – Hybrid-electric aircraft are increasingly a focus of research in sustainable aviation. This project will focus on developing a scaled testbed for hybrid-electric aviation consisting of multiple motor-dynamometer pairs that emulate aircraft engines, generators, electric machines, and distributed propellers. This will be coupled in real time to hardware-in-the-loop simulations that represent additional aircraft dynamics and systems.
The Advanced Composites and Engineered Materials Group
Our lab, Advanced Composites and Engineered Materials Group (ACEMG), has the capabilities to make, surface-treat, and organize nano/micro particles (such as carbon nanotubes) within composites aimed for aerospace applications (such as carbon fiber reinforced plastics). One of the unique devices is triaxial Helmholtz coil system to magnetically assembly small particles. In addition to experiments, our lab is adding modeling capabilities to capture features of the manufactured engineered micro-structures and processes, and then to create and test “virtual” sample sets with collaborators.
Project for Summer 2024: Understanding electromigration effect during field assisted sintering of advanced metal alloys – Field assisted sintering technology (FAST) can be a cost-efficient alternative to combine dissimilar solids and without altering their highly-engineered micro-structures. For example, one application is to form functionally-graded superalloys for turbine engines. Yet, currently, achieving the strong interphases by FAST has been requiring lengthy empirical process parameter adjustment and testing. In this work, an undergraduate student will be assigned to conduct molecular dynamics (MD) simulation to evaluate the effect of electromigration on atomic diffusion, and also to compare the trend observed by MD with images of FAST-bonded interphases, about advanced metal alloys.
Computational Multiphase Physics Laboratory
The Computational Multiphase Physics Laboratory develops and applies modern Computational Fluid Dynamics tools to flows with multiple constituents such as gas particles in air, bubbles in water, and many other complex systems of interest to Mechanical Engineers. Recent and current projects being carried out in the CMPL group include: CFD modeling of additively manufactured gas turbine cooling passages, Multiphase flow experiments and modeling of Powder Bed Fusion metal additive manufacturing systems, Fully coupled internal-external turbine aerodynamics, · Submarine wake CFD, Jet engine compressor damage due to particle ingestion, Micro-robot drug delivery systems, Multiphase modeling of cavitation on propellers and in fuel systems, Airfoil and engine icing, and, Aircraft engine high speed main shaft bearing analysis.
Project for Summer 2024: Impact of Particle Ingestion on Axial Compressor Erosion and Performance – Propulsion gas turbine engines often operate in environments where the fan and compressor ingest particles and droplets/ice across a wide range of size and shape morphologies. After extended periods of exposure (weeks to months) the damage and accumulation incurred by these high-speed components can significantly reduce the performance of the engine. The PI’s research team has recently developed Computational Fluid Dynamics (CFD) tools to model the physics of these damaged components. In this project, the student will advance existing CFD models for sand-erosion. These models have been validated to date and need significant refinement since the models overpredicts long term erosion. This will involve bringing inelastic deformation into the model set. The student will also apply the new models to an existing compressor rotor blade analysis. The student will work directly with the PI and a graduate member of the PI’s team, who has successfully carried out elements of the procedure once before with notional damaged hardware.
Linxiao Zhu Group
The Linxiao Zhu Group conducts experiments and modeling of radiation heat transfer. We study controlling radiative heat transfer in nano- and microstructures, as well as using the obtained knowledge for developing clean energy and improving energy efficiency. The Linxiao Zhu group is working on creating new solid-state devices for energy-free cooling and clean energy from the sky and sun, and refrigerant-free active cooling.
Project for Summer 2024: Spectrally-selective Radiative Cooling of Solar Cells – One key challenge of solar cells is that they heat up under the sun. Such heating greatly harms the power conversion efficiency and stability of solar cells. This project will be using spectrally selective coating to remove ultraviolet and near-infrared sunlight, while maintaining or enhancing the overall efficiency of solar cells. The student will have experience on instrumentation, thermal and electrical performance of solar cells.
SHAPE Lab: Systems for Hybrid-Additive Process Engineering Lab
The SHAPE Lab (Systems for Hybrid-Additive Process Engineering Lab) is a predominantly an experimental manufacturing research laboratory led by Dr. Guha Manogharan with a focus on advancing the fundamentals, applications, and knowledge transfer of advanced manufacturing for multi-disciplinary applications. Examples of recent efforts include Design for Additive Manufacturing (DfAM) of turbine components, fluid-elastic devices for mechanical systems, 3D sand-printing for novel casting methods, patient-specific biocompatible meta-implants, and engineered pore networks via AM.
Project for Summer 2024: Development of Additive Manufacturing Design Workflow for multi-material devices – Recent advancements in Multi-Material Laser-Powder Bed Fusion (MM-L-PBF) makes it possibly to fully realize manufacturing of multiple metals within a single AM structure. This project will focus on developing a new design workflow for multi-material surface fluidic thermal devices (e.g., heat pipes, sinks) for high performance application. This project will help the student learn cutting edge AM capabilities and incorporate DfAM (Design for Additive Manufacturing) guidelines for MM-LPBF to help manufacture functional devices. The student will also have an opportunity to learn computational methods and AM fabrication techniques.