Pump technology
Cavitation damage and cavitation reduction in high performance turbopumps and inducers
INDUCER↗
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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.
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Strain-rate hardening enhances fatigue resistance of AlSi10Mg alloy at 350°C
The high cycle fatigue behavior of laser powder bed fusion processed AlSi10Mg has been investigated at 350 °C (T/T m ∼ 0.7). The alloy exhibited a fatigue strength of 30 MPa defined by runout after 10 7 cycles at a conventional loading frequency of 20 Hz, corresponding to a notable fatigue strength to ultimate tensile strength ratio of 0.73. The surprising fatigue resistance was attributed to the strain-rate hardening effect at high fatigue loading frequency relative to tensile loading rates at 350 °C. The strain-rate hardening effect was validated by performing ultrasonic fatigue tests (20 kHz loading frequency) with three orders of magnitude higher strain-rates than those at conventional loading frequency. The higher strain-rates in ultrasonic fatigue increased the magnitude of strain-rate hardening resulting in longer AlSi10Mg fatigue lives compared to fatigue at conventional frequency, thus confirming the strain-rate hardening effect. The fatigue crack initiation mechanism was strain-rate dependent. Post-mortem microstructural examination revealed intergranular cavitation inside clusters of fine equiaxed grains. The cavities interlinked with each other to initiate near-surface fatigue cracks at conventional frequency. Cavitation occurred to a lesser extent at the ultrasonic frequency. As a result, fatigue cracks initiated at pre-existing processing defects near the surface in ultrasonic fatigue samples. Finally, this investigation underscores the role of fine grain clusters in promoting high-temperature fatigue crack initiation and indicates a possible trade-off between printability via grain refinement and high-temperature fatigue resistance of additively manufactured alloys.
Additive manufacturing↗
Plasma-Bubble Imaging and Spectroscopy (Final Report)
The aim of this research was to capture time- and space-resolved behavior of breakdown initiation and development in water with gas bubbles injected between the electrodes when excited with microsecond voltage pulses. The results were directly compared to our previous results from a PCRF collaboration on the development of an electrical discharge in a gas bubble immersed in liquids with different conductivities when excited by nanosecond voltage pulses. For nanosecond regimes, cavitation seems to play a major role in plasma breakdown for low conductivities and discharge initiates at an electrode. On microsecond timescales, where cavitation does not play a role, it has been hypothesized that breakdown in water occurs first in bubbles on or near the electrodes, pre-existing or formed thermally.
70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
Manufacturability and performance response of developed Ni-based alloys for reactor environments
Under the Advanced Materials and Manufacturing Technologies program, two Ni-based alloys fabricated by laser powder bed fusion (LPBF) at Oak Ridge National Laboratory and by laser powder directed energy deposition (LP-DED) at Idaho National Laboratory have been evaluated: γ′-strengthened Haynes 282 and solution-strengthened Inconel 625. Printing defects were observed in the LPBF 282 alloy fabricated using a Renishaw AM250 machine, likely due to particle spattering during printing. For both the LPBF and LP-DED 282 alloys, annealing at 1,180°C for 1 h resulted in partial recrystallization and a bimodal grain distribution, and subsequent aging for 4 h at 800°C led to the formation of a high density of nano-size γ′-strengthening precipitates. Creep testing performed at 750°C revealed lower creep life and ductility for the LPBF and LP-DED 282 compared with wrought 282. X-ray computed tomography combined with optical and scanning electron microscopy microstructural characterization revealed crack formation in the LPBF 282 alloy during creep testing, initiated either from printing defects or from creep cavitation at grain boundaries. Creep cavitation and cracking at grain boundaries were also observed for the LP-DED 282 alloy, and optimization of the printing strategies and postheat treatments will be needed to fabricate high-performance 282 components for high-temperature nuclear applications.
36 MATERIALS SCIENCE↗
Manufacturability and performance response of developed Ni-based alloys for reactor environments
Under the Advanced Materials and Manufacturing Technologies program, two Ni-based alloys fabricated by laser powder bed fusion (LPBF) at ORNL and laser powder directed energy deposition (LP-DED) at INL have been evaluated: γ′-strengthened Haynes 282 and solution-strengthened Inconel 625. Printing defects were observed in the LPBF 282 alloy fabricated using a Renishaw AM250 machine, likely due to particle spattering during printing. For both the LPBF and LP-DED 282 alloys, annealing at 1,180°C for 1 h resulted in partial recrystallization and a bimodal grain distribution, while subsequent aging for 4 h at 800°C led to the formation of a high density of nano size γ′-strengthening precipitates. Creep testing performed at 750°C revealed lower creep life and ductility for the LPBF and LP-DED 282 compared with wrought 282. X-ray computed tomography combined with optical and scanning electron microscopy microstructural characterization revealed crack formation in the LPBF 282 alloy during creep testing, initiated either from printing defects or from creep cavitation at grain boundaries. Creep cavitation and cracking at grain boundaries were also observed for the LP-DED 282 alloy, and optimization of the printing strategies and post heat treatments will be needed to fabricate high performance 282 components for high temperature nuclear applications.
22 GENERAL STUDIES OF NUCLEAR REACTORS↗
Design of a High-Pressure Fuel System for Use with Dimethyl Ether
The paper documents the modeling and experimental work on a common rail fuel injection system for Dimethyl Ether, a potential diesel substitute with a low carbon intensity signature. The DME fuel system is deployed on a light duty 2.2L compression ignition engine. The paper describes the injector optimization to shift to higher flows to account for the lower heating value and density of the DME when compared to diesel. The type of the injection system used for the DME application is an advanced rendering of the Common rail noted for a one-piece piston-needle injector construction and a solenoid driven spill valve featuring a pressure balanced poppet. A dedicated high-pressure fuel pump designed to pressurize DME is used. The design results in a fast acting open and close injection event, reduced leakage, with reduced cavitation in the fuel injector volume. Design parameters for system optimization included fill and spill orifices, needle lift, bias spring, and injector hole size. The design model provides good correlation of the instantaneous rates of injection with experiments across a wide range of pressure and injection timings. Proposed performance milestones for the design included similar DME injection duration to the diesel counterpart for same fuel energy injected into the cylinder to retain high engine cycle efficiency. Here, the dedicated DME design provided reduced hydraulic delays of 50%. Tests demonstrated sustained operation at pressures of 1000 bar, with capability to reach 1500bar. Durability tests showed no cavitation-deterioration over a 200-hour test cycle by means of spray imaging and hardware inspection.
De Ojeda, William [WM International Engineering, L↗
Calculation of incompressible fluid flow through cambered blades
Conformal mapping technique yields linear, approximate solutions for calculating flow of an incompressible fluid through staggered array of cambered blades for the cases of flow with partial cavitation and supercavitation. Lift and drag coefficients, cavitation number, cavity shape, and exit flow conditions can be determined.
Hsu, C. C.↗
An experimental investigation of two-phase liquid oxygen pumping
The results of an experimental program to explore the feasibility of pumping two-phase oxygen (liquid and gas) at the pump inlet are reported. Twenty-one cavitation tests were run on a standard J-2 oxygen pump at the MSFC Components Test Laboratory. All tests were run with liquid oxygen 5 to 10 K above the normal boiling point temperature. During ten tests run at approximately at the pump inlet were noted before complete pump performance 50 percent of the nominal operating speed, two phase conditions were achieved. Vapor volumes of 40 to 50 percent at the pump inlet were noted before complete pump performance loss. The experimental results compared to predictions. Nine cavitation tests run at the nominal pump speed over a 5 K temperature range showed progressively lower net positive suction head (NPSH) requirements as temperature was increased. Two-phase operation was not achieved. The temperature varying NPSH data were used to calculate thermodynamic effects on NPSH, and the results were compared to existing data.
Gross, L. A.↗
The dynamic liquid squeeze film.
Experiments were conducted during which plane circular surfaces bounding a liquid squeeze film were subjected to impulsive loads. Pressure measurements within the liquid film and the boundary motion were recorded. These experimental results were compared with theoretical analyses which predict the bonding strength of dynamic squeeze films. The data show that the fluid inertia contributes significantly to the value of the bonding strength. It was also found that, for high loading rates, the liquid squeeze film can resist tensile loads. When in tension, liquid cavitation was observed. A photographic study was conducted which indicated that the inception of cavitation is directly related to the squeeze film liquid viscosity and inversely related to the film thickness.
Riepe, R.↗
Process to restore obliterated serial numbers on metal surfaces
Metal smeared into grooves of serial numbers by grinding or filing can be cleaned out by process called cavitation. Ultrasonic vibrator generates very high frequency vibrations in water which create millions of microscopic bubbles. Cavitation bubbles impact metal surface at thousands of pounds per square inch pressure. Metal particles filling grooves are broken away.
Young, S. G.↗
Design and application of squeeze film dampers for turbomachinery stabilization
The steady-state transient response of the squeeze film damper bearing was investigated. Both the steady-state and transient equations for the hydrodynamic bearing forces are derived; the steady-state equations were used to determine the damper equivalent stiffness and damping coefficients. These coefficients are used to find the damper configuration which will provide the optimum support characteristics based on a stability analysis of the rotor-bearing system. The effects of end seals and cavitated fluid film are included. The transient analysis of rotor-bearing systems was conducted by coupling the damping and rotor equations and integrating forward in time. The effects of unbalance, cavitation, and retainer springs are included. Methods of determining the stability of a rotor-bearing system under the influence of aerodynamic forces and internal shaft friction are discussed.
Gunter, E. J.↗
A vortex venturi for reverting antimisting fuel properties
The level of degradation of antimisting fuel polymers such as FM-9 which must be accomplished in order to use antimisting fuel in existing engines may require the use of cavitation. The hydrodynamic shear produced by the collapse of vapor bubbles is capable of producing more splitting of polymeric molecules than mechanically-induced shear. A program has been carried out to investigate the possibility of using a cavitating venturi with rotating flow as a fuel reverter. This investigation included the effects of a swirl-inducing twisted tape upstream of the throat, inlet pressure, recovery pressure ratio and a pintle for varying throat area. A correlation of the data was produced, system concepts for using the vortex venturi were investigated and problem areas were delineated.
Szetela, E. J.↗
Study of journal bearing dynamics using 3-dimensional motion picture graphics
Computer generated motion pictures of three dimensional graphics are being used to analyze journal bearings under dynamically loaded conditions. The motion pictures simultaneously present the motion of the journal and the pressures predicted within the fluid film of the bearing as they evolve in time. The correct prediction of these fluid film pressures can be complicated by the development of cavitation within the fluid. The numerical model that is used predicts the formation of the cavitation bubble and its growth, downstream movement, and subsequent collapse. A complete physical picture is created in the motion picture as the journal traverses through the entire dynamic cycle.
Brewe, D. E.↗
Analysis of a two row hydrostatic journal bearing with variable properties, inertia effects and surface roughness
A computer algorithm for simulation of hydrostatic journal bearing pressure-flow behavior has been generated. The effects taken into account are inertia, cavitation, variable properties (isothermal bearing) and roughness. The program has been specifically tailored for simulation of the hybrid bearing of the cryogenic turbopumps of the main shuttle engine. Due to the high pressure (515 psia) of the supply line no cavitation has been found. The influence of the roughness effects have been found to become important only when the surface-roughness order of magnitude is comparable with that of the bearing clearance itself. Pocket edge inertia and variable properties have been found to have quite an important influence upon the pocket pressure, field pressure distribution and lubricant mass flow.
Braun, M. J.↗
Toughening mechanisms in elastomer-modified epoxies. I - Mechanical studies. II - Microscopy studies
Tensile dilatometry at constant displacement rates is presently used to ascertain whether voiding, crazing or shear banding are the deformation mechanisms at work in the toughening of brittle epoxies through the addition of an elastomeric phase. The results obtained for epoxies toughened by various levels of several types of carbonyl-terminated butadiene nitrile liquid rubber indicate that, at low strain rates, the rubber particles simply enhance shear deformation; at sufficiently high strain rates, the particles cavitate and promote further shear deformation. Examinations of these materials are conducted by means of SEM, TEM, and optical microscopy in the second part of this study. Toughening is hypothesized to involve cavitation's relieving of triaxial tension at the crack tip, as well as shear band formation, which creates a plastic zone.
Yee, A. F.↗
Characterization of a centrifugal pump in He II
As part of an effort to determine the feasibility of helium transfer in space, a centrifugal pump was tested in He II at a variety of flow rates, pump speeds, and fluid temperatures. The pump, which has a straight bladed impeller 6.86 cm in diameter, generated a maximum pressure rise of 15 kPa and a maximum flow rate of 22 g/s for the conditions of the test. Pump performance seems to be independent of fluid temperature and is in good agreement with the values predicted by the manufacturer. Over the range of flow coefficients, the measured maximum efficiency is around 50 percent. Cavitation is observed in the pump and is thought to be highly dependent on the local heating of the helium in the pump. Preliminary measurements of the noise spectra of the pump suggest a possible mechanism to predict the onset of cavitation.
Weisend, J. G., II↗
Space Cryogenics Workshop, University of Wisconsin, Madison, June 22, 23, 1987
Papers are presented on liquid helium servicing from the Space Station, performance estimates in the Superfluid Helium On-Orbit Transfer Flight Experiment, an analytical study of He II flow characteristics in the SHOOT transfer line, a Dewar to Dewar model for superfluid helium transfer, and mechanical pumps for superfluid helium transfer in space. Attention is also given to the cavitation characteristics of a small centrifugal pump in He I and He II, turbulent flow pressure drop in various He II transfer system components, slip effects associated with Knudsen transport phenomena in porous media, and an integrated fountain effect pump device for fluid management at low gravity. Other papers are on liquid/vapor phase separation in He-4 using electric fields, an enclosed capillary device for low-gravity management of He II, cavitation in flowing superfluid helium, the long-term performance of the passive thermal control systems of the IRAS spacecraft, and a novel approach to supercritical helium flight cryostat support structures.
Source record↗
Enclosed capillary device for low gravity management of He II
To transfer He II in space, a large tank must be drained at low gravity. This paper describes and analyzes an enclosed gallery device designed for collecting and delivering He II to a pump. The device allows most of the liquid to move about in the tank while it maintains a liquid flow to the pump. Only the liquid in the screen-covered gallery channels and in the upper and lower receivers is contained. The device operates by providing surface tension dominated liquid paths from all locations within the tank to the lower receiver, which houses the pump. Since the fluid pressure in the channels may be below the saturated vapor pressure, an analysis of He II cavitation is performed to determine if cavitation will occur. The effect of heat dissipation from the pump is examined to determine if it may result in nucleation of boiling. It is concluded that this enclosed device can meet the requirements for transfer of He II under the predicted adverse accelerations that will be encountered on-orbit.
Frank, D. J.↗