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DOE OSTI2020

A Phenomenological Model for Cavitation

A phenomenological model of cavitation is presented, based on observations that both large relative negative pressures and large negative time derivatives of pressure are required for cavitation onset. We simulated two cavitation experiments to generate cavitation scaling parameters for relative pressure drop and rate of pressure drop. Our results show the model, while simple, is effective at reproducing results from laboratory experiments of cavitation. The parameters were then used in conjunction with a human surrogate computational model to predict, at any position within the head, the probability of intracranial cavitation caused by exposure to a blast event. The results suggest that the magnitude of blast overpressure observed in field data is sufficient to cause intracranial cavitation. Our analysis indicates that the helmeted head, when compared to the unhelmeted head configuration, results in a decrease but not elimination of cavitation exposure. When density functions of cavitation probability versus cumulative brain volume are combined with an injury severity model, the results show helmet efficacy at low and moderate risk levels. However, the convergence of unhelmeted and helmeted probability density functions at high-to-excessive risk thresholds indicates the helmet offers diminishing protection at elevated exposure levels, relative to the unhelmeted baseline. Future investigation and collaboration with neuroscience subject matter experts are needed to contextualize the current computational results. While the present work contributes specific and quantified predictions of intracranial cavitation location and severity, more research is required to apply our results to clinical settings with population-based brain injury subjects and controls. The relationship between our intracranial cavitation predictions with their anticipated clinical sequelae remains a topic in need of exploration.

60 APPLIED LIFE SCIENCES↗

NASA NTRS2010

J-2X Turbopump Cavitation Diagnostics

The J-2X is the upper stage engine currently being designed by Pratt & Whitney Rocketdyne (PWR) for the Ares I Crew Launch Vehicle (CLV). Propellant supply requirements for the J-2X are defined by the Ares Upper Stage to J-2X Interface Control Document (ICD). Supply conditions outside ICD defined start or run boxes can induce turbopump cavitation leading to interruption of J-2X propellant flow during hot fire operation. In severe cases, cavitation can lead to uncontained engine failure with the potential to cause a vehicle catastrophic event. Turbopump and engine system performance models supported by system design information and test data are required to predict existence, severity, and consequences of a cavitation event. A cavitation model for each of the J-2X fuel and oxidizer turbopumps was developed using data from pump water flow test facilities at Pratt & Whitney Rocketdyne (PWR) and Marshall Space Flight Center (MSFC) together with data from Powerpack 1A testing at Stennis Space Center (SSC) and from heritage systems. These component models were implemented within the PWR J-2X Real Time Model (RTM) to provide a foundation for predicting system level effects following turbopump cavitation. The RTM serves as a general failure simulation platform supporting estimation of J-2X redline system effectiveness. A study to compare cavitation induced conditions with component level structural limit thresholds throughout the engine was performed using the RTM. Results provided insight into system level turbopump cavitation effects and redline system effectiveness in preventing structural limit violations. A need to better understand structural limits and redline system failure mitigation potential in the event of fuel side cavitation was indicated. This paper examines study results, efforts to mature J-2X turbopump cavitation models and structural limits, and issues with engine redline detection of cavitation and the use of vehicle-side abort triggers to augment the engine redline system.

Santi, I. Michael↗

DOE OSTI2017

Investigations of effect of phase change mass transfer rate on cavitation process with homogeneous relaxation model

The super high fuel injection pressure and micro size of nozzle orifice has been an important development trend for the fuel injection system. Accordingly, cavitation transient process, fuel compressibility, amount of noncondensable gas in the fuel and cavitation erosion have attracted more attention. Based on the fact of cavitation in itself is a kind of thermodynamic phase change process, this paper takes the perspective of the cavitation phase change mass transfer process to analyze above mentioned phenomenon. The two-phase cavitating turbulent flow simulations with VOF approach coupled with HRM cavitation model and U-RANS of standard k-ε turbulence model were performed for investigations of cavitation phase change mass transfer process. It is concluded the mass transfer time scale coefficient in the Homogenous Relaxation Model (HRM) representing mass transfer rate should tend to be as small as possible in a condition that ensured the solver stable. At very fast mass transfer rate, the phase change occurs at very thin interface between liquid and vapor phase and condensation occurs more focused and then will contribute predictably to a more serious cavitation erosion. Both the initial non-condensable gas in fuel and the fuel compressibility can accelerate the cavitation mass transfer process.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗

DOE OSTI2020

Water Energy Resource Innovation on the Cavitation Characteristics

The main purpose of this study is to numerically correlate the amount of generated vapor over a hydrofoil to the lift and drag coefficients acting on it. As such, cavitation characteristics were investigated of a hydrofoil in the cavitating, sub-cavitating, and non-cavitating flows for different angles of attacks (AoA) with the high upstream flow velocity. The hydrofoil was tested in a square water tunnel with water entering the tunnel at various velocities for each AoA ranges from 9.1 m/s to 12.2 m/s. It was found that lift and drag forces acting on the hydrofoil follow the trend of the experimental data quite closely. While the cavitation can be identified by a unique number (averaged vapor volume fraction), the work done created an inverse correlation between this number and the cavitation number at the same angle of attack. The lift force declines with the increase in the vapor content on the hydrofoil surface, meanwhile the drag force peaks at certain vapor volume fraction, and then, a huge reduction occurs with the considerable decrease in the corresponding cavitation number. A fourth-order correlation generated between the lift to drag (L/D) and the cavitation number (σ). It was found the lift-to-drag ratio decreases by the formation of the cavitation over the hydrofoil, thus causing a drop in the efficiency of the turbomachines.

42 ENGINEERING↗

DOE OSTI2020

ASSESSING FUEL PROPERTY EFFECTS ON CAVITATION AND EROSION PROPENSITY USING A COMPUTATIONAL FUEL SCREENING TOOL

To advance compression ignition combustion strategies, researchers have evaluated fuel property effects and their impact on achieving higher efficiencies and lower emissions levels relative to current capabilities. Within the Department of Energy's Co-Optima initiative, there has been a recent focus on understanding the influence of fuel properties on fuel injection performance. To help identify candidate fuels that can meet desired injector performance metrics, a computational fuel screening tool is under development that can link fuel properties with the tendency of a given fuel to cavitate and lead to cavitation-induced erosion. In the initial development of this tool, five liquid fuel properties were selected to represent candidate fuels, namely density, viscosity, vapor pressure, surface tension, and heat of vaporization. A design of experiments methodology was employed to generate a set of pseudo fuel cases, which can represent the main effects and interactions among the fuel properties and be related to cavitation erosion predictions. Large eddy simulations were performed using a mixture modeling approach to predict the cavitation and erosion propensity of these pseudo-fuels in terms of the mean fuel vapor mole fraction and stored impact energy from repeated cloud collapse events. The low order regression models generated from this study revealed the importance of liquid fuel density on cavitation formation, whereas liquid viscosity was found to have a strong negative correlation with erosion severity. The surrogate models were then used in the fuel screening tool to rank the cavitation and erosion tendency of four candidate single-component fuels: methyl decanoate, isooctane, ethanol and n-dodecane. While the fuel screening tool was not able to quantitatively predict the cavitation and erosion response metrics, the tool was able to accurately rank the relative cavitation and erosion propensity of the four fuels. Overall, ethanol and iso-octane were observed to produce the highest levels of cavitation and erosion, respectively.

cavitation-induced erosion↗

DOE OSTI2019

Friction stir processing of dual certified 304/304L austenitic stainless steel for improved cavitation erosion resistance

Cavitation phenomenon is known to be prevalent in equipment in hydraulic environments. Understanding cavitation and improving the cavitation resistance of commonly used materials is of interest for both scientific and economic reasons. In this study, friction stir processing was employed to modify commercial dual certified AISI 304/304L austenitic stainless steel plates. The cavitation erosion resistance of the processed plates was evaluated and compared to that of the unprocessed steel. A temperature control algorithm was employed to maintain a target tool temperature during the processing. The cross sections of the processed nuggets were evaluated using optical microscopy, scanning electron microscopy and Vickers hardness testing. Cavitation testing was performed conforming to ASTM G134 on specimens cut out of the nuggets of the commercially unprocessed and the processed 304/304L steel. The tool temperature was found to affect the microstructure and the cavitation performance. Friction stir processed steel showed 3 times better cavitation resistance than the unprocessed 304/304L. Surface cavitation patterns and cavitation rates were characterized and the mechanisms of material removal were discussed.

Jiang, Xiujuan↗

NASA NTRS1990

Current research in cavitating fluid films

A review of the current research of cavitation in fluid films is presented. Phenomena and experimental observations include gaseous cavitation, vapor cavitation, and gas entrainment. Cavitation in flooded, starved, and dynamically loaded journal bearings, as well as squeeze films are reviewed. Observations of cavitation damage in bearings and the possibility of cavitation between parallel plates with microasperities were discussed. The transcavity fluid transport process, meniscus motion and geometry or form of the film during rupture, and reformation were summarized. Performance effects were related to heat transfer models in the cavitated region and hysteresis influence on rotor dynamics coefficients. A number of cavitation algorithms was presented together with solution procedures using the finite difference and finite element methods. Although Newtonian fluids were assumed in most of the discussions, the effect of non-Newtonian fluids on cavitation was also discussed.

Brewe, D. E.↗

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.↗

DOE OSTI2016

One-way-coupling simulation of cavitation accompanied by high-speed droplet impact

Erosion due to high-speed droplet impact is a crucial issue in industrial applications. The erosion is caused by the water-hammer loading on material surfaces and possibly by the reloading from collapsing cavitation bubbles that appear within the droplet. Here, we simulate the dynamics of cavitation bubbles accompanied by high-speed droplet impact against a deformable wall in order to see whether the bubble collapse is violent enough to give rise to cavitation erosion on the wall. The evolution of pressure waves in a single water (or gelatin) droplet to collide with a deformable wall at speed up to 110 m/s is inferred from simulations of multicomponent Euler flow where phase changes are not permitted. Then, we examine the dynamics of cavitation bubbles nucleated from micron/submicron-sized gas bubble nuclei that are supposed to exist inside the droplet. For simplicity, we perform Rayleigh–Plesset-type calculations in a one-way-coupling manner, namely, the bubble dynamics are determined according to the pressure variation obtained from the Euler flow simulation. In the simulation, the preexisting bubble nuclei whose size is either micron or submicron show large growth to submillimeters because tension inside the droplet is obtained through interaction of the pressure waves and the droplet interface; this supports the possibility of having cavitation due to the droplet impact. It is also found, in particular, for the case of cavitation arising from very small nuclei such as nanobubbles, that radiated pressure from the cavitation bubble collapse can overwhelm the water-hammer pressure directly created by the impact. Hence, cavitation may need to be accounted for when it comes to discussing erosion in the droplet impact problem.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗

NASA NTRSDate not supplied

Cavitation Effects on the Structural Dynamics of Turbomachinery Components

The structural integrity of inducer and impeller blades in rocket engine turbomachinery must be evaluated in the face of complex excitation mechanisms including fluctuating pressures due to cavitation. Cavitation occurs when the local fluid pressure drops below the vapor pressure, causing the formation of vapor-filled bubbles. Cavitation can exist to various extents within the typical operating range of rocket engine turbopumps. Despite recent progress towards reducing uncertainties in structural dynamic models of turbomachinery components, the extent to which pump cavitation affects the structural dynamic properties (i.e., natural frequencies, damping, and mode shapes) of inducer and impeller blades remains largely unknown. To study the structural dynamic effects of cavitating flows, experiments are conducted in a high-speed water tunnel. The test article is a low aspect ratio cantilevered plate, thus mimicing a single inducer blade that is unwrapped from its hub. The test article is oriented at zero angle of attack and has a triangular trip at its leading edge to induce cavitation. To change the extent of cavitation, the static pressure of the water tunnel is controlled. A high-speed camera is used to quantify the coverage of the cavitation sheet.

Fluid-Structure Interaction↗

NASA NTRSDate not supplied

Cavitation Effects on the Structural Dynamics of Turbomachinery Components

The structural integrity of inducer and impeller blades in rocket engine turbo machinery must be evaluated in the face of complex excitation mechanisms including fluctuating pressures due to cavitation. Cavitation occurs when the local fluid pressure drops below the vapor pressure, causing the formation of vapor-filled bubbles. Cavitation can exist to various extents within the typical operating range of rocket engine turbo pumps. Despite recent progress towards reducing uncertainties in structural dynamic models of turbo machinery components, the extent to which pump cavitation affects the structural dynamic properties (i.e., natural frequencies, damping, and mode shapes) of inducer and impeller blades remains largely unknown. To study the structural dynamic effects of cavitating flows, experiments are conducted in a high-speed water tunnel. The test article is a low aspect ratio cantilevered plate, thus mimicing a single inducer blade that is unwrapped from its hub. The test article is oriented at zero angle of attack and has a triangular trip at its leading edge to induce cavitation. To change the extent of cavitation, the static pressure of the water tunnel is controlled. A high-speed camera is used to quantify the coverage of the cavitation sheet.

Structural Dynamics↗

NASA NTRS1982

High-speed motion picture camera experiments of cavitation in dynamically loaded journal bearings

A high-speed camera was used to investigate cavitation in dynamically loaded journal bearings. The length-diameter ratio of the bearing, the speeds of the shaft and bearing, the surface material of the shaft, and the static and dynamic eccentricity of the bearing were varied. The results reveal not only the appearance of gas cavitation, but also the development of previously unsuspected vapor cavitation. It was found that gas cavitation increases with time until, after many hundreds of pressure cycles, there is a constant amount of gas kept in the cavitation zone of the bearing. The gas can have pressures of many times the atmospheric pressure. Vapor cavitation bubbles, on the other hand, collapse at pressures lower than the atmospheric pressure and cannot be transported through a high-pressure zone, nor does the amount of vapor cavitation in a bearing increase with time. Analysis is given to support the experimental findings for both gas and vapor cavitation.

Jacobson, B. O.↗

NASA NTRS1983

High-speed motion picture camera experiments of cavitation in dynamically loaded journal bearings

Hamrock, B. J.↗

NASA NTRSDate not supplied

Cavitation Effects on the Structural Dynamics of Turbomachinery Components

The structural integrity of inducer and impeller blades in rocket engine turbomachinery must be evaluated in the face of complex excitation mechanisms including fluctuating pressures due to cavitation. Cavitation occurs when the local fluid pressure drops below the vapor pressure, causing the formation of vapor-filled bubbles. Cavitation can exist to various extents within the typical operating range of rocket engine turbopumps. Despite recent progress towards reducing uncertainties in structural dynamic models of turbomachinery components, the extent to which pump cavitation affects the structural dynamic properties (i.e., natural frequencies, damping, and mode shapes) of inducer and impeller blades remains largely unknown. To study the structural dynamic effects of cavitating flows, experiments are conducted in a high-speed water tunnel. The test articles mimic a single inducer blade that is unwrapped from the hub, thus resembling a low aspect ratio cantilevered plate. To induce cavitation, the plates are oriented at a non-zero angle of attack and have rough strips near their leading edges. To control the extent of cavitation, the static pressure of the water tunnel is controlled between roughly 0.5 and 1.5 atm. A high-speed camera is used to quantify the coverage of the cavitations heet. The sheet coverage is then correlated to changes in fluid-added mass and hydroelstic damping. In addition, a corresponding two-way coupled CFD/FE model is under development for test/analysis correlation.

Ben Davis↗

DOE OSTI2016

Released air during vapor and air cavitation

Cavitation today is a very important problem that is solved by means of experimental and mathematical methods. The article deals with the generation of cavitation in convergent divergent nozzle of rectangular cross section. Measurement of pressure, flow rate, temperature, amount of dissolved air in the liquid and visualization of cavitation area using high-speed camera was performed for different flow rates. The measurement results were generalized by dimensionless analysis, which allows easy detection of cavitation in the nozzle. For numerical simulation the multiphase mathematical model of cavitation consisting of water and vapor was created. During verification the disagreement with the measurements for higher flow rates was proved, therefore the model was extended to multiphase mathematical model (water, vapor and air), due to release of dissolved air. For the mathematical modeling the multiphase turbulence RNG k-ε model for low Reynolds number flow with vapor and air cavitation was used. Subsequently the sizes of the cavitation area were verified. In article the inlet pressure and loss coefficient depending on the amount of air added to the mathematical model are evaluated. On the basis of the approach it may be create a methodology to estimate the amount of released air added at the inlet to the modeled area.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗

NASA NTRS1983

A study of pump cavitation damage

The cavitation assessment for the space shuttle main engine high pressure oxidizer turbopump is documented. A model of the flow through the pump was developed. Initially, a computational procedure was used to analyze the flow through the inlet casing including the prediction of wakes downstream of the casing vanes. From these flow calculations, cavitation patterns on the inducer blades were approximated and the damage rate estimated. The model correlates the heavy damage on the housing and over the inducer with unsteady blade surface cavitation. The unsteady blade surface cavitation is due to the large incidence changes caused by the wakes of the upstream vanes. Very high cavitation damage rates are associated with this type of cavitation. Design recommendations for reducing the unsteady cavitation include removing the set of vanes closest to the inducer and modifying the remaining vanes.

Brophy, M. C.↗

NASA NTRS1985

An analysis of pump cavitation damage

Brophy, M. C.↗

NASA NTRS1993

Current Status in Cavitation Modeling

Cavitation is a common problem for many engineering devices in which the main working fluid is in liquid state. In turbomachinery applications, cavitation generally occurs on the inlet side of pumps. The deleterious effects of cavitation include: lowered performance, load asymmetry, erosion and pitting of blade surfaces, vibration and noise, and reduction of the overall machine life. Cavitation models in use today range from rather crude approximations to sophisticated bubble dynamics models. Details about bubble inception, growth and collapse are relevant to the prediction of blade erosion, but are not necessary to predict the performance of pumps. An engineering model of cavitation is proposed to predict the extent of cavitation and performance. The vapor volume fraction is used as an indicator variable to quantify cavitation. A two-phase flow approach is employed with the assumption of the thermal equilibrium between liquid and vapor. At present velocity slip between the two phases is selected. Preliminary analyses of 2D flows shows qualitatively correct results.

Singhal, Ashok K.↗