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DOE OSTI2023

Porthole die extrusion of aluminum 6063 industrial scrap by shear assisted processing and extrusion

Shear Assisted Processing and Extrusion (ShAPE) is presented as a new manufacturing technology for converting aluminum scrap directly into extruded products. In this work, a porthole die configuration is integrated within the rotating ShAPE process to extrude circular, square, trapezoidal, and two-cell trapezoidal profiles from aluminum alloy 6063 industrial scrap. This is the first time that a rotating billet has been used to impart severe plastic deformation (SPD) during extrusion of noncircular profiles. Microstructural characterization is presented for a trapezoidal profile having an average grain size of 6.7 µm in the as-extruded condition. Dimensional stability was evaluated by measuring wall thickness along the extrusion length; the thickness varied by <5%. Round tubes achieved yield strength (246.9 ± 10.4 MPa), ultimate tensile strength (270.8 ± 9.6 MPa), and uniform elongation (16.5 ± 2.4%) exceeding industry standards.

36 MATERIALS SCIENCE↗

NASA NTRS1980

A visual investigation of turbulence in stagnation flow about a circular cylinder

A diagnostic visualization study of turbulence in stagnation flow around a circular cylinder was carried out to gain physical insight into the coherent structure of turbulence in flow around a bluff body advanced by the vorticity-amplification theory. The visualization was conducted at a cylinder-diameter Reynolds number of 8000 utilizing titanium dioxide white smoke for an approaching flow containing turbulence at scales larger than the neutral wavelength of the stagnation flow. Analyses of the flow events focused on tracing out the temporal and spatial evolution of a cross-vortex tube outlined by the entrained smoke filaments from its emergence near the stagnation zone through its penetration into the cylinder boundary layer.

Sadeh, W. Z.↗

DOE OSTI2021

A Poisson equation method for prescribing fully developed non-Newtonian inlet conditions for computational fluid dynamics simulations in models of arbitrary cross-section

Prescribing inlet boundary conditions for computational fluid dynamics (CFD) simulations of internal flow in complex geometries such as anatomical vascular models is challenging. In the absence of patient-specific inlet velocity data, a common approach for long blood vessels is to assume that the inlet flow is fully developed. In vessels of irregular cross section, however, prescribing fully developed conditions is complicated due to the lack of a general closed-form analytical solution. In this study, we develop a simple Poisson equation method for prescribing fully developed inlet conditions for the flow of either Newtonian or non-Newtonian fluids in CFD models of arbitrary cross-section. We first derive the generalized Poisson equation for fully developed flow of a non-Newtonian fluid and we then develop and verify a methodology for numerically computing the solution on any planar boundary domain. In addition, we develop a simple extension of the method for prescribing a non-orthogonal inlet velocity that represents fully developed flow from an upstream tube that is connected to the CFD inlet at a non-orthogonal angle. This may be used to investigate a common source of uncertainty in CFD simulations of internal flow that is due to a lack of information concerning the exact streamwise flow direction at the inlets. Comparison to several Newtonian and non-Newtonian benchmark verification solutions shows the method to be extremely accurate. As a practical demonstration case, we use the method to prescribe fully developed conditions on multiple non-circular inlets for the non-Newtonian flow of blood in a patient-specific model of the inferior vena cava (IVC). Finally, we further demonstrate the utility of the method by performing a sensitivity study using the patient-specific IVC model, wherein we investigate the influence of inlet velocity flow direction on the non-Newtonian IVC hemodynamics. Given its simplicity and computational efficiency, the method is shown to be far superior to alternative approaches for prescribing fully developed inlet conditions in such complicated geometries. In conclusion, to facilitate the adoption of our Poisson equation method, we have distributed our OpenFOAM source code and the associated test cases from this study as open-source software.

97 MATHEMATICS AND COMPUTING↗

NASA NTRS1984

Wind tunnel wall interference in closed, ventilated and adaptive test sections

A wall interference correction method for closed rectangular test sections was developed which uses measured wall pressures. Measurements with circular discs for blockage and a rectangular wing as a lift generator in a square closed test section validate this method. These measurements are intended to be a basis of comparison for measurements in the same tunnel using ventilated (in these case, slotted) walls. Using the vortex lattice method and homogeneous boundary conditions, calculations were performed which show sufficiently high pressure levels at the walls for correction purposes in test sections with porous walls. In Gottingen, an adaptive test section (which is a deformable rubber tube of 800 mm diameter) was built and a computer program was developed which is able to find the necessary wall adaptation for interference-free measurements in a single step. To check the program prior to the first run, the vortex lattice method was used to calculate wall pressure distributions in the nonadapted test section as input data for the one-step method. Comparison of the pressure distribution in the adapted test section with free-flight data shows nearly perfect agreement. An extension of the computer program can be made to evaluate the remaining interference corrections.

Holst, H.↗

DOE OSTI2025

Plasma Focused Ion Beam Milling of High-Aspect-Ratio Holes in Diamond

Plasma focused ion beam (PFIB) technology has a great potential for applications requiring rapid micro-machining of high-aspect-ratio features. Here, we use 30-keV Ar, Xe, and O 2 ion beams to study PFIB milling of high-aspect-ratio circular holes in polycrystalline diamond. Our results show that Xe and O 2 ion beams have the highest milling efficiency for low-aspect-ratio and high-aspect-ratio hole milling, respectively. Each ion beam species produces holes with its characteristic shape and wall surface morphology. In conclusion, based on these results, we demonstrate a “hybrid” hole milled in a two-step process with Xe and O 2 ion beams with the geometry and wall morphology attractive for the attachment of a fuel fill tube to the inertial confinement fusion capsule.

ICF targets↗

NASA NTRS2012

Experimental Investigation of Cavitation Induced Feedline Instability from an Orifice

This paper details the results of an experimental investigation into the cavitation instabilities created by a circular orifice conducted at the University of Alabama in Huntsville Propulsion Research Center. This experiment was conducted in concert with a computational simulation to serve as a reference point for the simulation. Testing was conducted using liquid nitrogen as a cryogenic propellant simulant. A 1.06 cm diameter thin orifice with a rounded inlet was tested in an approximately 1.25 kg/s flow with inlet pressures ranging from 504.1 kPa to 829.3 kPa. Pressure fluctuations generated by the orifice were measured using a high frequency pressure sensor located 0.64 tube diameters downstream of the orifice. Fast Fourier Transforms were performed on the high frequency data to determine the instability frequency. Shedding resulted in a primary frequency with a cavitation related subharmonic frequency. For this experiment, the cavitation instability ranged from 153 Hz to 275 Hz. Additionally, the strength of the cavitation occur red as a function of cavitation number. At lower cavitation numbers, the strength of the cavitation instability ranged from 2.4 % to 7 % of the inlet pressure. However, at higher cavitation numbers, the strength of the cavitation instability ranged from 0.6 % to 1 % of the inlet pressure.

Hitt, Matthew A.↗

NASA NTRS2017

A Comparison of Combustion Dynamics for Multiple 7-Point Lean Direct Injection Combustor Configurations

The combustion dynamics of multiple 7-point lean direct injection (LDI) combustor configurations are compared. LDI is a fuel-lean combustor concept for aero gas turbine engines in which multiple small fuel-air mixers replace one traditionally-sized fuel-air mixer. This 7-point LDI configuration has a circular cross section, with a center (pilot) fuel-air mixer surrounded by six outer (main) fuel-air mixers. Each fuel-air mixer consists of an axial air swirler followed by a converging-diverging venturi. A simplex fuel injector is inserted through the center of the air swirler, with the fuel injector tip located near the venturi throat. All 7 fuel-air mixers are identical except for the swirler blade angle, which varies with the configuration. Testing was done in a 5-atm flame tube with inlet air temperatures from 600 to 800 F and equivalence ratios from 0.4 to 0.7. Combustion dynamics were measured using a cooled PCB pressure transducer flush-mounted in the wall of the combustor test section.

lean direct injection↗

NASA NTRS1992

Fluid mechanics experiments in oscillatory flow. Volume 2: Tabulated data

Seume, J.↗

NASA NTRS2012

Quantitative Global Heat Transfer in a Mach-6 Quiet Tunnel

This project developed quantitative methods for obtaining heat transfer from temperature sensitive paint (TSP) measurements in the Mach-6 quiet tunnel at Purdue, which is a Ludwieg tube with a downstream valve, moderately-short flow duration and low levels of heat transfer. Previous difficulties with inferring heat transfer from TSP in the Mach-6 quiet tunnel were traced to (1) the large transient heat transfer that occurs during the unusually long tunnel startup and shutdown, (2) the non-uniform thickness of the insulating coating, (3) inconsistencies and imperfections in the painting process and (4) the low levels of heat transfer observed on slender models at typical stagnation temperatures near 430K. Repeated measurements were conducted on 7 degree-half-angle sharp circular cones at zero angle of attack in order to evaluate the techniques, isolate the problems and identify solutions. An attempt at developing a two-color TSP method is also summarized.

Sullivan, John P.↗

NASA NTRS1984

Heat transfer investigation in the junction region of circular cylinder normal to a flat plate at 90 deg location

External heat-transfer rates were measured on a flat plate in the junction region of a circular cylinder mounted normal to the plate at a location 90 deg from the stagnation point. This configuration simulates the junction of the shroud with gas-turbine vanes. Heat-transfer results are presented for laminar, transition, and turbulent boundary layers for a Mach number of 0.14 with gas temperatures of approximately 750 deg R over a flat plate at room temperature. The measurements were made in air for a unit Reynolds number, Re/cm, range of 11,000 to 58,000. Heat-transfer measurements were conducted in the 70-ft long, 4-in. diameter shock tube. A shock-wave reflection technique was used to produce a flow Mach number of 0.14. Thin-film platinum heat gages were mounted on the flat plate and along the line of the stagnation point of the cylinder to measure the local heat flux in the junction region. The experimental heat-transfer data were correlated with the laminar and turbulent boundary-layer theories for the flat plate. With the cylinder the heat fluxes on the flat plate were greatly increased in the junction region compared to the heat flux for the plate alone.

Nagamatsu, H. T.↗

NASA NTRS1998

Interaction of Vascular Smooth Muscle Cells Under Low Shear Stress

The blood vessel wall consists of three cellular layers, an outer adventitial, a middle medial and an inner intimal layer. When the blood vessel forms in the embryo it begins as a tube composed of a single cell type called endothelial cells. Over time, other cells are recruited from the surrounding tissue to form additional layers on the outer surface of the endothelial tube. The cells that are recruited are called mesenchymal cells. Mesenchymal cells are responsible for the production of connective tissue that holds the blood vessel together and for developing into vascular smooth muscle cells that are responsible for regulating the diameter of the vessel (1) and therefore, blood flow. In a fully developed blood vessel, the endothelial cells make- up the majority of cells in the intimal layer while the mesenchymal cells make-up the majority of cells in the medial and adventitial layers. Within the medial layer of a mature vessel, cells are organized into multiple circular layers of alternating bands of connective tissue and cells. The cell layer is composed of a mixture of mesenchymal cells that have not developed into smooth muscle cells and fully developed smooth muscle cells (2). The assembly and organization of complex tissues is directed in part by a signaling system composed of proteins on the cell surface called adhesion molecules. Adhesion molecules enable cells to recognize each other as well as the composition of the connective tissue in which they reside (3). It was hypothesized that the different cell types that compose the vascular wall possess different adhesion molecules that enable them to recognize each other and through this recognition system, form the complex layered organization of the vascular wall. In other words, the layered organization is an intrinsic property of the cells. If this hypothesis is correct then the different cells that make up the vessel wall, when mixed together, should organize themselves into a layered structure resembling an intact blood vessel. Experiments described below were designed to test this hypothesis.

Seidel, Charles L.↗

DOE OSTI2022

Global gyrokinetic study of shaping effects on electromagnetic modes at NSTX aspect ratio with ad hoc parallel magnetic perturbation effects

Plasma shaping may have a stronger effect on global turbulence in tight-aspect-ratio tokamaks than in conventional-aspect-ratio tokamaks due to the higher toroidicity and more acute poloidal asymmetry in the magnetic field. In addition, previous local gyrokinetic studies have shown that it is necessary to include parallel magnetic field perturbations in order to accurately compute growth rates of electromagnetic modes in tight-aspect-ratio tokamaks. In this work, the effects of elongation and triangularity on global, ion-scale, linear electromagnetic modes are studied at National Spherical Torus Experiment (NSTX) aspect ratio and high plasma β using the global gyrokinetic particle-in-cell code XGC. The effects of compressional magnetic perturbations are approximated via a well-known modification to the particle drifts that was developed for flux-tube simulations [Joiner et al., Phys. Plasmas 17, 072104 (2010)], without proof of its validity in a global simulation, with the gyrokinetic codes GENE and GEM being used for local verification and global cross-verification. Magnetic equilibria are re-constructed for each distinct plasma profile that is used. Coulomb collision effects are not considered. Within the limitations imposed by the present study, it is found that linear growth rates of electromagnetic modes (collisionless microtearing modes and kinetic ballooning modes) are significantly reduced in a high-elongation and high-triangularity NSTX-like geometry compared to a circular NSTX-like geometry. For example, growth rates of kinetic ballooning modes at high- β are reduced to the level of that of collisionless trapped electron modes.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

NASA NTRS1977

Simultaneous in situ magnetospheric and ionospheric detection of detached plasmas

On January 19, 1972, in situ measurements by Explorer 45, orbiting in the magnetosphere near the equatorial plane, and ISIS 2, in a circular polar orbit at 1400 km, simultaneously detected patches of enhanced ionization outside the main body of the plasmasphere. The magnetospheric plasma region extended between (geomagnetic latitude) L values 3.4-4.8 and the ionospheric electron density enhancement extended between L values 3.6-4.4. The two plasma features were detected near 22 hours magnetic local time (MLT). Based on a number of observations, it is inferred that the plasma density enhancement persisted for more than 5 hours and extended over at least 2 hours in MLT near L = 5. These results provide experimental evidence that some detached magnetospheric plasma regions are signatures of a flux tube containing enhanced ionization throughout a volume extending from the topside ionosphere out to the equator.

Miller, N. J.↗

NASA NTRS1992

Fluid mechanics experiments in oscillatory flow. Volume 1: Report

Results of a fluid mechanics measurement program in oscillating flow within a circular duct are presented. The program began with a survey of transition behavior over a range of oscillation frequency and magnitude and continued with a detailed study at a single operating point. Such measurements were made in support of Stirling engine development. Values of three dimensionless parameters, Re(sub max), Re(sub w), and A(sub R), embody the velocity amplitude, frequency of oscillation and mean fluid displacement of the cycle, respectively. Measurements were first made over a range of these parameters which included operating points of all Stirling engines. Next, a case was studied with values of these parameters that are representative of the heat exchanger tubes in the heater section of NASA's Stirling cycle Space Power Research Engine (SPRE). Measurements were taken of the axial and radial components of ensemble-averaged velocity and rms-velocity fluctuation and the dominant Reynolds shear stress, at various radial positions for each of four axial stations. In each run, transition from laminar to turbulent flow, and its reverse, were identified and sufficient data was gathered to propose the transition mechanism. Models of laminar and turbulent boundary layers were used to process the data into wall coordinates and to evaluate skin friction coefficients. Such data aids in validating computational models and is useful in comparing oscillatory flow characteristics to those of fully-developed steady flow. Data were taken with a contoured entry to each end of the test section and with flush square inlets so that the effects of test section inlet geometry on transition and turbulence are documented. Volume 1 contains the text of the report including figures and supporting appendices. Volume 2 contains data reduction program listings and tabulated data (including its graphical presentation).

Seume, J.↗

NASA NTRS2009

A Computational and Experimental Study of Resonators in Three Dimensions

In a previous work by the present authors, a computational and experimental investigation of the acoustic properties of two-dimensional slit resonators was carried out. The present paper reports the results of a study extending the previous work to three dimensions. This investigation has two basic objectives. The first is to validate the computed results from direct numerical simulations of the flow and acoustic fields of slit resonators in three dimensions by comparing with experimental measurements in a normal incidence impedance tube. The second objective is to study the flow physics of resonant liners responsible for sound wave dissipation. Extensive comparisons are provided between computed and measured acoustic liner properties with both discrete frequency and broadband sound sources. Good agreements are found over a wide range of frequencies and sound pressure levels. Direct numerical simulation confirms the previous finding in two dimensions that vortex shedding is the dominant dissipation mechanism at high sound pressure intensity. However, it is observed that the behavior of the shed vortices in three dimensions is quite different from those of two dimensions. In three dimensions, the shed vortices tend to evolve into ring (circular in plan form) vortices, even though the slit resonator opening from which the vortices are shed has an aspect ratio of 2.5. Under the excitation of discrete frequency sound, the shed vortices align themselves into two regularly spaced vortex trains moving away from the resonator opening in opposite directions. This is different from the chaotic shedding of vortices found in two-dimensional simulations. The effect of slit aspect ratio at a fixed porosity is briefly studied. For the range of liners considered in this investigation, it is found that the absorption coefficient of a liner increases when the open area of the single slit is subdivided into multiple, smaller slits.

Tam, C. K. W.↗

DOE OSTI2023

Final Report on Development of Microwave Resonant Cavity Transducer for Fluid Flow Sensing: Development of Microwave Cavity Flow Meter for Advanced Reactor High Temperature Fluids

We are investigating a microwave resonant cavity transducer for flow sensing in the vessel of a high temperature fluid advanced reactor (AR), such as a molten salt cooled reactor (MSCR) or a sodium fast reactor (SFR). This transducer is a hollow metallic cylindrical cavity, with one of the flat walls of the cylinder flexible enough to undergo microscopic deflection due to dynamic fluid pressure. Membrane deflection leads to a shift in the microwave resonant frequency, which can be detected with a spectrum analyzer. We have developed a continuum electromechanics model of the microwave resonant cavity transducer performance. The deflection of the membrane is calculated using equations from the theory of plates and shells for deflection of radially constrained thin circular disk under uniform load. The microwave frequency shift is calculated using the equations from the microwave cavity perturbation theory. The transducer model was validated with proof-of-concept experimental data of water flow sensing with a Brass 360 right circular cylinder with 22.2mm diameter and 203µm thick wall. The cavity was excited through a subwavelength hole in TE 011 mode with resonant frequency f ≈ 17.8GHz. Subsequently, we have performed a preliminary proof-of-principle test of flow sensing in high temperature liquid sodium in environment. For this test, we have developed a cylindrical resonator with the same dimensions as for the Brass 360 cavity. The resonator for high temperature liquid sodium test was machined from stainless steel 316 and electroplated with silver on the interior surfaces. We have also developed and insertion probe consisting of a 50cm WR-42 brass waveguide enclosed in a protective SS316 tube. The cavity was excited through a subwavelength hole on the side of the wall of the cylinder in the TE 011 mode with resonant frequency f ≈ 17.8GHz. The liquid sodium setup consists of a cylindrical vessel with a center feed line, where a transducer inserted through the top cap of the vessel measures velocity of the impinging liquid jet. The sodium flow sensing study was performed in a liquid sodium vessel at 340°C temperature and ambient pressure. The flow rate was changed by varying sodium pump power, and a frequency shift of several hundred kHz was observed. The transducer was removed after 70 days of testing. No visual damage was observed, and the electromagnetic response remained the same. As a calibration experiment, we have assembled a water vessel with a center feed, and with dimensions similar to those of the liquid sodium setup. Water flow sensing was performed before and after liquid sodium test. The responses in both cases are similar and agree with COMSOL computer simulations. Because long-term (multi-year) experimental tests of transducer resilience to harsh environment are not practical, we have developed a probabilistic model of creep to estimate transducer resilience to the harsh environment. The probabilistic model considers diffusion creep under the condition of high temperature and low stress, where the stress and temperature are allowed to be random variables with Gaussian distributions. Using the probabilistic model, we estimate inelastic membrane deflections due to creep for several temperature ranges. We conclude that for temperatures less than 650°C, creep has negligible long-term effect on the transducer performance.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

NASA NTRS1989

An experimental study of near wall flow parameters in the blade end-wall corner region

The near wall flow parameters in the blade end-wall corner region is investigated. The blade end-wall corner region was simulated by mounting an airfoil section (NACA 65-015 base profile) symmetric blades on both sides of the flat plate with semi-circular leading edge. The initial 7 cm from the leading edge of the flat plate was roughened by gluing No. 4 floor sanding paper to artificially increase the boundary layer thickness on the flat plate. The initial flow conditions of the boundary layer upstream of the corner region are expected to dictate the behavior of flow inside the corner region. Therefore, an experimental investigation was extended to study the combined effect of initial roughness and increased level of free stream turbulence on the development of a 2-D turbulent boundary layer in the absence of the blade. The measurement techniques employed in the present investigation included, the conventional pitot and pitot-static probes, wall taps, the Preston tube, piezoresistive transducer and the normal sensor hot-wire probe. The pitot and pitot-static probes were used to obtain mean velocity profile measurements within the boundary layer. The measurements of mean surface static pressure were obtained with the surface static tube and the conventional wall tap method. The wall shear vector measurements were made with a specially constructed Preston tube. The flush mounted piezoresistive type pressure transducer were employed to measure the wall pressure fluctuation field. The velocity fluctuation measurements, used in obtaining the wall pressure-velocity correlation data, were made with normal single sensor hot-wire probe. At different streamwise stations, in the blade end-wall corner region, the mean values of surface static pressure varied more on the end-wall surface in the corner region were mainly caused by the changes in the curvature of the streamlines. The magnitude of the wall shear stress in the blade end-wall corner region increased significantly in the close vicinity of the corner line. The maximum value of the wall shear stress and its location from the corner line, on both the surfaces forming the corner region, were observed to change along the corner. These observed changes in the maximum values of the wall shear stress and its location from the corner line could be associated with the stretching and attenuation of the horseshoe vortex. The wall shear stress vectors in the blade end-wall corner region were observed to be more skewed on the end-wall surface as compared to that on the blade surface. The differences in the wall shear stress directions obtained with the Preston tube and flow visualization method were within the range in which the Preston tube was found to be insensitive to the yaw angle.

Bhargava, Rakesh K.↗

NASA NTRS1998

Galileo Direction Finding of Jovian Radio Emissions

The Galileo spacecraft, in orbit about Jupiter, has observed distinct spin modulation of plasma wave emissions near the Ganymede (G1 and G2) encounters in the frequency range from about 100 kHz to approximately 6 MHz. Assuming circularly polarized, transverse electromagnetic radiation, we have used the spin modulation of the sweep-frequency receivers of the electric dipole antenna over many spins to estimate the source location in the spin plane of the spacecraft. Hectometric (HOM) and decametric (DAM) emission is observed by Galileo as a general and continuous background with frequent bursts that last tens of minutes and can be separated by minutes or hours. We have analyzed HOM and DAM emissions observed near Jupiter just after the GI and G2 encounters, including two HOM/DAM "arc" signatures observed after the G2 encounter. These latter appear to be low-frequency extensions of DAM arcs, with source regions along either the Io or the Ganymede flux tube. While the uncertainties associated with the data analysis do not allow a precise source location, the HOM/DAM emission observed near the G1 and G2 encounters is consistent with a gyroresonant source region, but it is necessary to require refraction due to the Io torus to understand the results. To explain emission from apparent source regions above a gyroresonant source region, wave refraction from asymmetries in the Io plasma torus that extend along magnetic field lines is postulated. Alternatively, if such torus density asymmetries do not exist, emission with sources above a gyroresonant source region would require another free-energy source such as energetic plasma beams in the presence of density gradients or temperature anisotropies.

Menietti, J. D.↗