Engineering topics

Russell, D. A.

Publications and source records attributed to Russell, D. A..

At least 19 records

DOE OSTI2022

Correlation between the relative blob fraction and plasma parameters in NSTX

Here, we present a simple analysis of the fraction of blobs observed in the scrape-off layer of NSTX and calculates the correlation between this blob fraction and various plasma parameters. The measurements were made using the gas puff imaging (GPI) diagnostic on a database of 103 shots from 2010 with neutral beam power P NBI = 0–6 MW. The blob fraction ranged from f b = 0.1% to 4.8%, where f b is defined as the fraction of time the GPI signal was larger than three times its average value within 0–7.5 cm outside the separatrix. The blob fraction generally decreased with increasing neutral beam injection power and was lower on average in H-mode plasmas than Ohmic and L-mode plasmas. The blob fraction had its highest correlation with the measured poloidal turbulence velocity and its radial gradient just inside the separatrix. This is in part consistent with a model in which the blob generation rate increases with the poloidal velocity shear.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2021

Reduced-model scrape-off layer turbulence (nSOLT) simulations comparing three fueling scenarios

The 2D scrape-off-layer turbulence code (nSOLT) includes 1D Boltzmann neutral–plasma interactions, a model of divertor recycling (introduced here), and a fixed source of plasma concentrated at the core-side boundary. Three fueling methods are considered herein: (1) neutral injection in the far-SOL is accomplished by specifying the density of Franck–Condon distributed neutrals streaming in from the boundary. (2) Divertor recycling is modeled by injecting a fraction of the particle parallel flux in the scrape-off layer (SOL) back into the edge region as a source of plasma. (3) A constant source fuels the edge plasma from the core-side boundary to model pellet injection. For machine parameters (B, R m , and L // ) illustrative of the MAST-U device, and for a deuterium plasma, turbulent equilibria are obtained that share the same plasma fueling rate for each of the three fueling methods, with only one of the sources on in each case. In the presence of self-consistent turbulence, quasi-steady plasma and neutral (deuterium) profiles, fueling efficiencies, SOL transparencies, and heat flux widths are compared. Characteristics of the turbulent fluctuations, including skewness, cross-phases, and power spectra, are described. The calculated fueling efficiencies, SOL transparencies to neutral penetration, and many of the turbulent properties are remarkably similar for all three fueling methods despite significant differences in the plasma profiles. The nonlinear states of the three cases are dominated by separatrix-spanning vortex cells that control particle and heat losses into the SOL.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2020

Reduction of blob-filament radial propagation by parallel variation of flows: Analysis of a gyrokinetic simulation

Data from the XGC1 gyrokinetic simulation is analyzed to understand the three-dimensional spatial structure and the radial propagation of blob-filaments generated by quasisteady turbulence in the tokamak edge pedestal and scrape-off layer plasma. Spontaneous toroidal flows vary in the poloidal direction and shear the filaments within a flux surface resulting in a structure that varies in the parallel direction. Here, this parallel structure allows the curvature and grad-B induced polarization charge density to be shorted out via parallel electron motion. As a result, it is found that the blob-filament radial velocity is significantly reduced from estimates which neglect parallel electron kinetics, broadly consistent with experimental observations. Conditions for when this charge shorting effect tends to dominate blob dynamics are derived and compared with the simulation.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2019

Blob wakes in NSTX

Transient small-scale structures were identified in the wake of blobs moving poloidally through the scrape-off layer of high-powered H-mode plasmas in NSTX, using the gas puff imaging (GPI) diagnostic. These blob wakes had a poloidal wavelength in the range of λ pol = 3.5 ± 0.7 cm, which is significantly smaller than the average blob scale of L pol ~12 cm, and the wakes had a poloidal velocity of V pol = 1.5 ± 1.0 km/s in the electron diamagnetic direction, which is opposite to the blob poloidal velocity in these shots. These wakes were radially localized 0–4 cm outside the separatrix and occurred within ~50 μs after the passage of a blob through the GPI field of view. The clearest wakes were seen when the GPI viewing angle was well aligned with the local B field line, as expected for such small-scale structures given the diagnostic geometry. In conclusion, a plausible theoretical interpretation of the wakes is discussed: the observed wakes share some features of drift waves and/or drift-Alfvén waves which could be excited by the blobs.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

NASA NTRS1999

Development of a Practical Methodology for Elastic-Plastic and Fully Plastic Fatigue Crack Growth

A practical engineering methodology has been developed to analyze and predict fatigue crack growth rates under elastic-plastic and fully plastic conditions. The methodology employs the closure-corrected effective range of the J-integral, delta J(sub eff) as the governing parameter. The methodology contains original and literature J and delta J solutions for specific geometries, along with general methods for estimating J for other geometries and other loading conditions, including combined mechanical loading and combined primary and secondary loading. The methodology also contains specific practical algorithms that translate a J solution into a prediction of fatigue crack growth rate or life, including methods for determining crack opening levels, crack instability conditions, and material properties. A critical core subset of the J solutions and the practical algorithms has been implemented into independent elastic-plastic NASGRO modules. All components of the entire methodology, including the NASGRO modules, have been verified through analysis and experiment, and limits of applicability have been identified.

McClung, R. C.↗

NASA NTRS1999

Guidelines for Proof Test Analysis

These guidelines integrate state-of-the-art elastic-plastic fracture mechanics (EPFM) and proof test implementation issues into a comprehensive proof test analysis procedure in the form of a road map which identifies the types of data, fracture mechanics based parameters, and calculations needed to perform flaw screening and minimum proof load analyses of fracture critical components. Worked examples are presented to illustrate the application of the road map to proof test analysis. The state-of-the art fracture technology employed in these guidelines is based on the EPFM parameter, J, and a pictorial representation of a J fracture analysis, called the failure assessment diagram (FAD) approach. The recommended fracture technology is validated using finite element J results, and laboratory and hardware fracture test results on the nickel-based superalloy Inconel 718, the aluminum alloy 2024-T3511, and ferritic pressure vessel steels. In all cases the laboratory specimens and hardware failed by ductile mechanisms. Advanced proof test analyses involving probability analysis and multiple-cycle proof testing (MCPT) are addressed. Finally, recommendations are provided on how to account for the effects of the proof test overload on subsequent service fatigue and fracture behaviors.

Chell, G. G.↗

NASA NTRS1999

A Comparison of Single-Cycle Versus Multiple-Cycle Proof Testing Strategies

Single-cycle and multiple-cycle proof testing (SCPT and MCPT) strategies for reusable aerospace propulsion system components are critically evaluated and compared from a rigorous elastic-plastic fracture mechanics perspective. Earlier MCPT studies are briefly reviewed. New J-integral estimation methods for semielliptical surface cracks and cracks at notches are derived and validated. Engineering methods are developed to characterize crack growth rates during elastic-plastic fatigue crack growth (FCG) and the tear-fatigue interaction near instability. Surface crack growth experiments are conducted with Inconel 718 to characterize tearing resistance, FCG under small-scale yielding and elastic-plastic conditions, and crack growth during simulated MCPT. Fractography and acoustic emission studies provide additional insight. The relative merits of SCPT and MCPT are directly compared using a probabilistic analysis linked with an elastic-plastic crack growth computer code. The conditional probability of failure in service is computed for a population of components that have survived a previous proof test, based on an assumed distribution of initial crack depths. Parameter studies investigate the influence of proof factor, tearing resistance, crack shape, initial crack depth distribution, and notches on the MCPT versus SCPT comparison. The parameter studies provide a rational basis to formulate conclusions about the relative advantages and disadvantages of SCPT and MCPT. Practical engineering guidelines are proposed to help select the optimum proof test protocol in a given application.

McClung, R. C.↗

NASA NTRS1999

Development of a Practical Methodology for Elastic-Plastic and Fully Plastic Fatigue Crack Growth

A practical engineering methodology has been developed to analyze and predict fatigue crack growth rates under elastic-plastic and fully plastic conditions. The methodology employs the closure-corrected effective range of the J-integral, (Delta)J(sub eff), as the governing parameter. The methodology contains original and literature J and (Delta)J solutions for specific geometries, along with general methods for estimating J for other geometries and other loading conditions, including combined mechanical loading and combined primary and secondary loading. The methodology also contains specific practical algorithms that translate a J solution into a prediction of fatigue crack growth rate or life, including methods for determining crack opening levels, crack instability conditions, and material properties. A critical core subset of the J solutions and the practical algorithms has been implemented into independent elastic-plastic NASGRO modules. All components of the entire methodology, including the NASGRO modules, have been verified through analysis and experiment, and limits of applicability have been identified.

McClung, R. C.↗

NASA NTRS1997

NASA Contractor Report: Guidelines for Proof Test Analysis

These Guidelines integrate state-of-the-art Elastic-Plastic Fracture Mechanics (EPFM) and proof test implementation issues into a comprehensive proof test analysis procedure in the form of a Road Map which identifies the types of data, fracture mechanics based parameters, and calculations needed to perform flaw screening and minimum proof load analyses of fracture critical components. Worked examples are presented to illustrate the application of the Road Map to proof test analysis. The state-of-the-art fracture technology employed in these Guidelines is based on the EPFM parameter, J, and a pictorial representation of a J fracture analysis, called the Failure Assessment Diagram (FAD) approach. The recommended fracture technology is validated using finite element J results, and laboratory and hardware fracture test results on the nickel-based superalloy IN-718, the aluminum alloy 2024-T351 1, and ferritic pressure vessel steels. In all cases the laboratory specimens and hardware failed by ductile mechanisms. Advanced proof test analyses involving probability analysis and Multiple Cycle Proof Testing (MCPT) are addressed. Finally, recommendations are provided on to how to account for the effects of the proof test overload on subsequent service fatigue and fracture behaviors.

Chell, G. G.↗

NASA NTRS1996

A Comparison of Single-Cycle Versus Multiple-Cycle Proof Testing Strategies

Single-cycle and multiple-cycle proof testing (SCPT and MCPT) strategies for reusable aerospace propulsion system components are critically evaluated and compared from a rigorous elastic-plastic fracture mechanics perspective. Earlier MCPT studies are briefly reviewed. New J-integral estimation methods for semi-elliptical surface cracks and cracks at notches are derived and validated. Engineering methods are developed to characterize crack growth rates during elastic-plastic fatigue crack growth (FCG) and the tear-fatigue interaction near instability. Surface crack growth experiments are conducted with Inconel 718 to characterize tearing resistance, FCG under small-scale yielding and elastic-plastic conditions, and crack growth during simulated MCPT. Fractography and acoustic emission studies provide additional insight. The relative merits of SCPT and MCPT are directly compared using a probabilistic analysis linked with an elastic-plastic crack growth computer code. The conditional probability of failure in service is computed for a population of components that have survived a previous proof test, based on an assumed distribution of initial crack depths. Parameter studies investigate the influence of proof factor, tearing resistance, crack shape, initial crack depth distribution, and notches on the MCPT vs. SCPT comparison. The parameter studies provide a rational basis to formulate conclusions about the relative advantages and disadvantages of SCPT and MCPT. Practical engineering guidelines are proposed to help select the optimum proof test protocol in a given application.

McClung, R. C.↗

NASA NTRS1996

A Comparison of Single-Cycle Versus Multiple-Cycle Proof Testing Strategies

Single-cycle and multiple-cycle proof testing (SCPT and MCPT) strategies for reusable aerospace propulsion system components are critically evaluated and compared from a rigorous elastic-plastic fracture mechanics perspective. Earlier MCPT studies are briefly reviewed. New J-integral estimation methods for semi-elliptical surface cracks and cracks at notches are derived and validated. Engineering methods are developed to characterize crack growth rates during elastic-plastic fatigue crack growth (FCG) and the tear-fatigue interaction near instability. Surface crack growth experiments are conducted with Inconel 718 to characterize tearing resistance, FCG under small-scale yielding and elastic-plastic conditions, and crack growth during simulated MCPT. Fractography and acoustic emission studies provide additional insight. The relative merits of SCPT and MCPT are directly compared using a probabilistic analysis linked with an elastic-plastic crack growth computer code. The conditional probability of failure in service is computed for a population of components that have survived a previous proof test, based on an assumed distribution of initial crack depths. Parameter studies investigate the influence of proof factor, tearing resistance, crack shape, initial crack depth distribution, and notches on the MCPT vs. SCPT comparison. The parameter studies provide a rational basis to formulate conclusions about the relative advantages and disadvantages of SCPT and MCPT. Practical engineering guidelines are proposed to help select the optimum proof test protocol in a given application.

McClung, R. C.↗

NASA NTRS1994

Significant issues in proof testing: A critical appraisal

Issues which impact on the interpretation and quantification of proof test benefits are reviewed. The importance of each issue in contributing to the extra quality assurance conferred by proof testing components is discussed, particularly with respect to the application of advanced fracture mechanics concepts to enhance the flaw screening capability of a proof test analysis. Items covered include the role in proof testing of elastic-plastic fracture mechanics, ductile instability analysis, deterministic versus probabilistic analysis, single versus multiple cycle proof testing, and non-destructive examination (NDE). The effects of proof testing on subsequent service life are reviewed, particularly with regard to stress redistribution and changes in fracture behavior resulting from the overload. The importance of proof test conditions are also addressed, covering aspects related to test temperature, simulation of service environments, test media and the application of real-time NDE. The role of each issue in a proof test methodology is assessed with respect to its ability to: promote proof test practice to a state-of-the-art; aid optimization of proof test design; and increase awareness and understanding of outstanding issues.

Chell, G. G.↗

NASA NTRS1992

Single-Cycle Versus Multicycle Proof Testing

Report compares single-cycle with multiple-cycle mechanical-stress tests of parts under mechanical stresses. Objective of proof testing: to screen out gross manufacturing or material deficiencies and provide additional assurance of quality. Report concludes that changes in distribution of crack sizes during multicycle proof testing depend on initial distribution, number of cycles, relationship between resistance of material and elastic/plastic fracture-mechanics parameter, relationship between load control and displacement control, and magnitude of applied load or displacement. Whether single-cycle or multicycle testing used depends on shape, material, and technique of fabrication of components tested.

Hudak, S. J., Jr.↗

NASA NTRS1991

Constitutive and damage material modeling in a high pressure hydrogen environment

Numerous components in reusable space propulsion systems such as the SSME are exposed to high pressure gaseous hydrogen environments. Flow areas and passages in the fuel turbopump, fuel and oxidizer preburners, main combustion chamber, and injector assembly contain high pressure hydrogen either high in purity or as hydrogen rich steam. Accurate constitutive and damage material models applicable to high pressure hydrogen environments are therefore needed for engine design and analysis. Existing constitutive and cyclic crack initiation models were evaluated only for conditions of oxidizing environments. The main objective is to evaluate these models for applicability to high pressure hydrogen environments.

Russell, D. A.↗

NASA NTRS1991

Examination of the effect of propulsion system performance variables on the life prediction for the SSME Lox Post

The main objective is to calculate damage evolution at the critical location of selected components of reusable space propulsion systems as the function of their operating environments and to relate the evolution of damage at the critical locations to the performance variables of the propulsion system using advanced constitutive and damage models. The models so developed will be oriented toward use in an advanced diagnostic/prognostic health monitoring system for reusable propulsion systems. The components to be modelled include a Lox Post (injector element), a thrust chamber, and a turbine blade. The study conducted on the Lox Post is reported.

Russell, D. A.↗

NASA NTRS1990

A comparison of single-cycle versus multiple-cycle proof testing strategies

An evaluation of single-cycle and multiple-cycle proof testing (MCPT) strategies for SSME components is described. Data for initial sizes and shapes of actual SSME hardware defects are analyzed statistically. Closed-form estimates of the J-integral for surface flaws are derived with a modified reference stress method. The results of load- and displacement-controlled stable crack growth tests on thin IN-718 plates with deep surface flaws are summarized. A J-resistance curve for the surface-cracked configuration is developed and compared with data from thick compact tension specimens. The potential for further crack growth during large unload/reload cycles is discussed, highlighting conflicting data in the literature. A simple model for ductile crack growth during MCPT based on the J-resistance curve is used to study the potential effects of key variables. The projected changes in the crack size distribution during MCPT depend on the interactions between several key parameters, including the number of proof cycles, the nature of the resistance curve, the initial crack size distribution, the component boundary conditions (load vs. displacement control), and the magnitude of the applied load or displacement. The relative advantages of single-cycle and multiple-cycle proof testing appear to be specific, therefore, to individual component geometry, material, and loading.

Hudak, S. J., Jr.↗

NASA NTRS1990

A numerical study of longitudinal vortex interaction with a boundary layer

A numerical study of vortex generator aerodynamics has been carried out with a reduced set of Navier-Stokes equations. These are used to model the physical process of longitudinal vortex interaction with a turbulent boundary layer on a flat plate in incompressible flow. Comparison with experimental data is used to validate the approach, and detailed predictions are made. Results show an increase in skin friction and a decrease in integral layer thicknesses where the flow is toward the wall, and the reverse where the flow is away from the wall. The major controlling parameters of vortex strength, spacing and height are each found to have optimum values for which the efficiency of boundary-layer thinning is maximized. Vortex core spreading and secondary vorticity produced in the layer are observed and studied, as well as circulation decay and other features of the flow.

Russell, D. A.↗

NASA NTRS1990

Probabilistic simulation for flaw acceptance by dye-penetrant inspection

This paper examines the problems encountered in assessing the reliability of dye-penetrant nondestructive inspection (NDI) techniques in preventing failures due to undetected surface flaws, as well as from flaw acceptance (Fitness-For-Purpose). A Monte Carlo simulation procedure which includes the major variables of the problem is presented as a means of quantifying reliability. Some issues associated with distribution selection are examined. A methodology for selecting the penetrant type and flaw acceptance size for the specific components analyzed using the simulation is proposed. Current methodology limitations are discussed along with possible future effort. Penetrant selection and acceptable sizes of detected flaws are based on a probabilistic assessment of the effect of component and dye-penetrant system variables on structural reliability.

Russell, D. A.↗