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At least 235 records · Page 13

Friction-based recycling: an evaluation of friction extrusion for fabricating Ti-6Al-4 V wire fabricated from machining chip feedstock

Abstract Titanium and its alloys are used in aviation and automobile industries due to their remarkable strength to weight ratio, but machining loss commonly is high with ~ 80 wt% of the material being converted to scrap. Recycling post-consumer Ti scrap directly into solid bulk products is a potential solution for repurposing valuable material. Further, eliminating fresh Ti sponge during recycling might lead to lower energy and greenhouse gas emissions. In this study, a solid-phase process known as friction extrusion was utilized to recycle Ti-6Al-4 V machining chips into solid wires which could be used as feedstock in additive manufacturing. The friction consolidation technique was first used to convert chips with varying degrees of oxygen content into solid billets for its use as feedstock material in subsequent friction extrusion. The extrudates were fabricated above the beta transition temperature, which was achieved by selecting the rotation rate and feed rate, to process the billets near 1000 °C using a tungsten-lanthana extrusion die. This work presents the first occurrence of friction extruded titanium alloy wires. The effect of friction extrusion on microstructural features, tensile properties, and texture are reported. Overall, the friction extrusion method is capable of directly recycling Ti-6Al-4 V scrap into extruded wire.

Friction Extrusion↗

Wind tunnel turning vanes of modern design

Rehabilitation of the Altitude Wind Tunnel includes the need for new corner turning vanes to match its upgraded performance. The design and experimental performance results from a 0.1-full scale model of the highest speed corner (M = 0.35) are presented and discussed along with some two dimensional inviscid analyses of two vaned corners. With a vane designed by an inverse two dimensional technique, the overall corner loss was about 12% of the inlet dynamic pressure of which about 4% was caused by vane skin friction. Comparable values with a conventionally designed circular arc vane were about 14% overall with about 7% due to skin friction.

Gelder, T. F.↗

Boundary layer manipulators at high Reynolds numbers

Airfoil large-eddy breakup (LEBU) devices were tested on an axisymmetric body in the Langley Two Tank up to speeds of 50 ft/sec. NACA-0009, NACA-2412, E-193, and Clark Y contours were tested in single and tandem configurations. At the higher Reynolds numbers local skin friction downstream of the devices showed minimal reductions O (10 percent) and total body drag was increased 1 to 3 percent. At lower Reynolds numbers skin-friction reductions as large as 25 percent were measured and total body drag tended toward net reductions. The loss of effectiveness with increasing Reynolds number of conventional, outer layer devices suggests a decoupling of the outer and inner scales in high Reynolds number turbulent boundary layers.

Anders, J. B.↗

Micromechanical and Electrical Properties of Monolithic Aluminum Nitride at High Temperatures

Micromechanical spectroscopy of aluminum nitride reveals it to possess extremely low background internal friction at less than 1x10(exp-4) logarithmic decrement (log dec) from 20 to 1200 T. Two mechanical loss peaks were observed, the first at 350 C approximating a single Debye peak with a peak height of 60x10(exp-4) log dec. The second peak was seen at 950 'C with a peak height of 20x 10' log dec and extended from 200 to over 1200 C. These micromechanical observations manifested themselves in the electrical behavior of these materials. Electrical conduction processes were predominately intrinsic. Both mechanical and electrical relaxations appear to be thermally activated processes, with activation energies of 0.78 and 1.32 eV respectively.

Goldsby, Jon C.↗

Linearized force representations for turbopump liquid annular seals

The analysis and the accompanying FORTRAN code, SEALPAL1, to simulate liquid annular seals with axial taper, Moody friction factors, and pre-swirl, are discussed. The output of the code includes all dynamic coefficients (stiffness, dampings, and inertias), leakage rate, torque, and horsepower loss. The computer code results were compared with five cases from the literature. The agreement was very good in almost all instances, except several predicted cross coupled stiffnesses were significantly lower than those appearing in the literature. This disagreement could reflect a theoretical or a programming error by the researcher or in the literature, or it could be a result of the difference in friction factor models or other assumptions employed.

Palazzolo, Alan B.↗

Physical Theories of Winds From Cool Stars

Cool stars in the late stages of their evolution generally lose mass at a prodigious rate. This includes low mass stars on the red giant branch, on the asymptotic giant branch, and those transiting from the asymptotic giant branch to the planetary nebula phase, as well as massive supergiants. All of these objects are surrounded by dense circumstellar gas and often dust envelopes. This mass loss is an important source of gas and dust for the interstellar medium. For some of these objects, the mass loss rate exceeds the nuclear burning rate and, hence, mass loss determines the subsequent evolution of the star. A variety processes have been invoked to explain the mass loss of these objects. A consensus has developed over the last decade: photospheric processes create an extended atmosphere which extends to several stellar radii. At this height above the photosphere, dust grains can form and radiation pressure drives the dust out. The gas is dragged along by friction. While the detailed processes involved, in particular those lifting the atmosphere, may differ from object to object, this paradigm seems applicable to all of these objects. The process of mass loss breaks up into three parts: 1) The formation of the extended atmosphere; 2) the nucleation and condensation of dust; and 3) The radiation pressure driven wind. Each of these processes will be discussed with an emphasis on those processes that play a role in the mass loss from asymptotic giant branch stars for which the most detailed theories have been developed.

Tielens, A. G. G. M.↗

Heat Transfer and Pressure Loss of Additively Manufactured Internal Cooling Channels With Various Shapes

Abstract Additive manufacturing (AM) provides the ability to fabricate highly customized internal cooling passages that are relevant to gas turbine components. This experimental study examines the pressure loss and heat transfer performance of a range of fundamental channel shapes that were produced using direct metal laser sintering. Circular, hexagonal, pentagonal, elliptical, diamond, square, rectangular, trapezoidal, and triangular channel cross sections were investigated. To maintain the same convective surface area between shapes, the wetted perimeters of the channel cross sections were kept constant. Parallel computational fluid dynamic simulations were performed to understand the relationships in cooling performance between several channel shapes. Several characteristic length scales were evaluated to scale the pressure loss and heat transfer measurements. Among the channel shapes investigated, the diamond channel showed the lowest Nusselt number and friction factor. The pentagon exhibited a similar Nusselt number as the circular channel despite having a lower friction factor. There was no difference in scaling the friction factor or Nusselt number results of the different channel shapes between using the square root of cross-sectional area compared to hydraulic diameter as the characteristic length scale

Engineering↗

Studies of mechanochemical interactions in the tribological behavior of materials

Mechanochemical interaction studies can contribute to the understanding of wear and friction of materials. Specific examples of experimental results relative to the subject are discussed. There are two parts: one describes the synergistic effect of corrosion and wear of iron sliding on sapphire in sulfuric acid, and the other describes the effect of surface films on the wear and friction of plasma-deposited diamondlike carbon (amorphous hydrogenated carbon) films in sliding contact with silicon nitride. The concentration of acid (pH) is an important factor in controlling the iron loss caused by wear-corrosion processes in sulfuric acid. The mechanical action can cause chemical reactions to proceed much faster than they would otherwise. The diamondlike carbon (DLC) films are shown to behave tribologically much like bulk diamond. In a dry nitrogen environment, a mechanochemical reaction produces a substance which greatly decreases the coefficient of friction. In a moist air environment, mechanochemical interactions drastically reduce the wear life of DLC films and water vapor greatly increases friction.

Miyoshi, Kazuhisa↗

Studies of mechano-chemical interactions in the tribological behavior of materials

Mechano-chemical interaction studies can contribute to the understanding of wear and friction of materials. Specific examples of experimental results relative to the subject are discussed. There are two parts: one describes the synergistic effect of corrosion and wear of iron sliding on sapphire in sulfuric acid, and the other describes the effect of surface films on the wear and friction of plasma-deposited diamondlike carbon (amorphous hydrogenated carbon) films in sliding contact with silicon nitride. The concentration of acid (pH) is an important factor in controlling the iron loss caused by wear-corrosion processes in sulfuric acid. The mechanical action can cause chemical reactions to proceed much faster than they would otherwise. The diamondlike carbon (DLC) films are shown to behave tribologically much like bulk diamond. In a dry nitrogen environment, a mechano-chemical reaction produces a substance which greatly decreases the coefficient of friction. In a moist air environment, mechano-chemical interactions drastically reduce the wear life of DLC films and water vapor greatly increases friction.

Miyoshi, Kazuhisa↗

Skin friction on a flat perforated acoustic liner

The report concerns the measurement of friction coefficients of a typical perforated acoustic liner installed in the side of a wind tunnel. The results are compared with measured friction coefficients of a smooth hard wall for the same mean flow velocities in a wind tunnel. At a velocity of 61 m/sec, an increase in the local skin coefficient of only a few percent was observed, but at the highest velocity of 213 m/sec an increase of about 20% was obtained. This velocity is a realistic velocity for turbo-machinery components utilizing such liners, so a loss in performance is to be expected. Some tests were also performed to see if changes in the mean boundary layer induced by imposed noise would result in friction increase, but only at low velocity levels was such an increase in friction noted.

Boldman, D. R.↗

Ignition and combustion of metals in oxygen

Tests in which metals were rubbed against themselves in oxygen have revealed that increasing oxygen pressure does not always increase the potential for ignition. It is believed that there exists a specific pressure above which convective heat loss due to higher oxygen density will overcome the potential increase in the oxidation rate afforded by the increase in oxygen pressure. Test results have shown that, once a specific oxygen pressure is exceeded, greater rates of frictional energy were required for ignition of metals as pressure is increased. Other test results have indicated that as oxygen pressure is increased during the rubbing process, the bulk sample equilibrium temperatures decrease. These results support the belief that increases in convective heat loss as pressure is increased can raise the energy requirements for ignition of metals or lower their ignition potentials. Testing has also indicated that, when metals were exposed to a rubbing process and oxygen pressure was increased, metals such as carbon steel exhibited a decrease in their bulk ignition temperatures, whereas metals such as Monel showed bulk ignition temperatures independent of pressure.

Benz, Frank J.↗

Wind tunnel turning vanes of modern design

Rehabilitation of the Altitude Wind Tunnel includes the need for new corner turning vanes to match its upgraded performance. The design and experimental performance results from a 0.1-full scale model of the highest speed corner (M = 0.35) are presented and discussed along with some two dimensional inviscid analyses of two vaned corners. With a vane designed by an inverse two dimensional technique, the overall corner loss was about 12 percent of the inlet dynamic pressure of which about 4 percent was caused by vane skin friction. Comparable values with a conventionally designed circular arc vane were about 14 percent overall with about 7 percent due to skin friction.

Gelder, T. F.↗

Comparison of two procedures for predicting rocket engine nozzle performance

Two nozzle performance prediction procedures which are based on the standardized JANNAF methodology are presented and compared for four rocket engine nozzles. The first procedure required operator intercedence to transfer data between the individual performance programs. The second procedure is more automated in that all necessary programs are collected into a single computer code, thereby eliminating the need for data reformatting. Results from both procedures show similar trends but quantitative differences. Agreement was best in the predictions of specific impulse and local skin friction coefficient. Other compared quantities include characteristic velocity, thrust coefficient, thrust decrement, boundary layer displacement thickness, momentum thickness, and heat loss rate to the wall. Effects of wall temperature profile used as an input to the programs was investigated by running three wall temperature profiles. It was found that this change greatly affected the boundary layer displacement thickness and heat loss to the wall. The other quantities, however, were not drastically affected by the wall temperature profile change.

Davidian, Kenneth J.↗

Comparison of two procedures for predicting rocket engine nozzle performance

Two nozzle performance prediction procedures which are based on the standardized JANNAF methodology are presented and compared for four rocket engine nozzles. The first procedure required operator intercedence to transfer data between the individual performance programs. The second procedure is more automated in that all necessary programs are collected into a single computer code, thereby eliminating the need for data reformatting. Results from both procedures show similar trends but quantitative differences. Agreement was best in the predictions of specific impulse and local skin friction coefficient. Other compared quantities include characteristic velocity, thrust coefficient, thrust decrement, boundary layer displacement thickness, momentum thickness, and heat loss rate to the wall. Effects of wall temperature profile used as an input to the programs was investigated by running three wall temperature profiles. It was found that this change greatly affected the boundary layer displacement thickness and heat loss to the wall. The other quantities, however, were not drastically affected by the wall temperature profile change.

Davidian, Kenneth J.↗

Micromechanical and Electrical Properties of Monolithic Aluminum Nitride at High Temperatures

Micromechanical spectroscopy of aluminum nitride reveals it to possess extremely low background internal friction at less than 1 x 10 (exp -4) logarithmic decrement (log dec.) from 20 to 1200 C. Two mechanical loss peaks were observed, the first at 350 C approximating a single Debye peak with a peak height of 60 x 10 (exp -4) log dec. The second peak was seen at 950 C with a peak height of 20 x 10 (exp -4) log dec. and extended from 200 to over 1200 C. These micromechanical observations manifested themselves in the electrical behavior of these materials. Electrical conduction processes were predominately intrinsic. Both mechanical and electrical relaxations appear to be thermally activated processes, with activation energies of 0.78 and 1.32 eV respectively.

Goldsby, Jon C.↗

Ways to Increase Launch Velocities of 2-Stage Gas Guns

The amount of space debris is rapidly increasing and the debris is distributed over a wide variety of orbits. Satellites, manned space vehicles and space stations will have to pay increasing attention to the dangers of impacts with space debris. Various armoring techniques (i.e., double or triple layer armor) will have to tested extensively to determine the most effective armor per unit weight. Intersecting near-earth orbits can lead to impact velocities up to 15 km/sec. Conventional two-stage light gas guns can launch intact, controlled-shape projectiles with a density of 1.2 gm/cc and length- to-diameter ratios of 0.5-1.0 at velocities up to 8-9 km/sec. Higher velocities (10-11 km/sec) can be obtained' for very light projectiles. The higher launch velocities tend to be very severe on the high pressure coupling and barrel of the gun and lead to short component lifetimes. Clearly, the ability to raise the launch velocity of a gun (for reasonably massive projectile shapes) from 8-9 km/sec to 11-13 km/sec (or higher), without reduction of component lifetimes, would have significant benefits. This would allow much better simulation of the higher velocity debris impacts as well as better simulation of high speed re-entry into planetary atmospheres. Several techniques for increasing the launcher muzzle velocity above 8-9 km/sec have been studied using CFD simulations and appear to offer the potential for significant gains. The first technique is to use multiple compressions, instead of a single compression, in the pump tube of the light gas gun. In a sense, this is a kind of pre-heating of the gas in the pump tube; other types of pre-heating have yielded disappointing results in the past. The dynamics of the multiple compression pump tube is very different, however, from the earlier techniques, where the pump tube was typically heated ohmically before the gun 2 cycle was started. In this paper, we present CFD calculations that show that significant increases in muzzle velocity can be obtained with multiple compressions in the pump tube. With a conventional two-stage gun, an important limitation to obtaining higher velocities is friction and heat transfer to the barrel, which typically has a length- to- diameter ratio of 200-400. These viscous losses greatly reduce the effectiveness of the regions of the barrel far removed from the second stage breech. We have studied computationally the effect of adding an additional breech (or breeches) along the barrel to reduce these viscous losses. Velocity increases from 6.5 to 7.2 km/sec have been obtained using the main breech and one additional breech. In these results, both breeches were operated with hydrogen, heated electrothermally. We have also studied a gun geometry where the main breech is operated in the conventional manner, using piston compression. The additional breech is operated either with electrothermal heating or heating by using a high explosive charge in a novel geometry. The latter option provides very effective compression, heating and acceleration of the hydrogen working gas and is fully reusable. Calculations are presented which show that very substantial increases in muzzle velocity can be obtained this way, without overstressing the projectile or the 'gun. The third technique studied is to add a section of ram accelerator tube after the barrel to further accelerate the projectile. The ram accelerator used here is not the conventional premixed gas ram accelerator, but a new technique using high explosive as the energy source and pure hydrogen as the working gas in a geometry which can be made fully reusable. Preliminary results with this new rain accelerator geometry were presented and showed that stable ram accelerator drive can be established. Herein, detailed calculations axe presented which show that substantial velocity increases can be obtained using this ram accelerator technique in tandem with a conventional light gas gun.

Bogdanoff, David W.↗

An analysis code for the Rapid Engineering Estimation of Momentum and Energy Losses (REMEL)

Nonideal behavior has traditionally been modeled by defining efficiency (a comparison between actual and isentropic processes), and subsequent specification by empirical or heuristic methods. With the increasing complexity of aeropropulsion system designs, the reliability of these more traditional methods is uncertain. Computational fluid dynamics (CFD) and experimental methods can provide this information but are expensive in terms of human resources, cost, and time. This report discusses an alternative to empirical and CFD methods by applying classical analytical techniques and a simplified flow model to provide rapid engineering estimates of these losses based on steady, quasi-one-dimensional governing equations including viscous and heat transfer terms (estimated by Reynold's analogy). A preliminary verification of REMEL has been compared with full Navier-Stokes (FNS) and CFD boundary layer computations for several high-speed inlet and forebody designs. Current methods compare quite well with more complex method results and solutions compare very well with simple degenerate and asymptotic results such as Fanno flow, isentropic variable area flow, and a newly developed, combined variable area duct with friction flow solution. These solution comparisons may offer an alternative to transitional and CFD-intense methods for the rapid estimation of viscous and heat transfer losses in aeropropulsion systems.

Dechant, Lawrence J.↗