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NASA NTRS1981

Abrasive drill for resilient materials

Resilient materials normally present problem in obtaining accurate and uniform hole size and position. Tool is fabricated from stiff metal rod such as tungsten or carbon steel that has diameter slightly smaller than required hole. Piercing/centering point is ground on one end of rod. Rod is then plasma-sprayed (flame-sprayed) with suitable hard abrasive coating. High-speed, slow-feed operation of tool is necessary for accurate holes, and this can be done with drill press, hard drill, or similar machines.

Koch, A. J.↗

NASA NTRS2010

Analysis of Flame Deflector Spray Nozzles in Rocket Engine Test Stands

The development of a unified tightly coupled multi-phase computational framework is described for the analysis and design of cooling spray nozzle configurations on the flame deflector in rocket engine test stands. An Eulerian formulation is used to model the disperse phase and is coupled to the gas-phase equations through momentum and heat transfer as well as phase change. The phase change formulation is modeled according to a modified form of the Hertz-Knudsen equation. Various simple test cases are presented to verify the validity of the numerical framework. The ability of the methodology to accurately predict the temperature load on the flame deflector is demonstrated though application to an actual sub-scale test facility. The CFD simulation was able to reproduce the result of the test-firing, showing that the spray nozzle configuration provided insufficient amount of cooling.

Sachdev, Jai S.↗

NASA NTRS1937

Fuel Spray and Flame Formation in a Compression-Ignition Engine Employing Air Flow

The effects of air flow on fuel spray and flame formation in a high-speed compression-ignition engine have been investigated by means of the NACA combustion apparatus. The process was studied by examining high-speed motion pictures taken at the rate of 2,200 frames a second. The combustion chamber was of the flat-disk type used in previous experiments with this apparatus. The air flow was produced by a rectangular displacer mounted on top of the engine piston. Three fuel-injection nozzles were tested: a 0.020-inch single-orifice nozzle, a 6-orifice nozzle, and a slit nozzle. The air velocity within the combustion chamber was estimated to reach a value of 425 feet a second. The results show that in no case was the form of the fuel spray completely destroyed by the air jet although in some cases the direction of the spray was changed and the spray envelope was carried away by the moving air. The distribution of the fuel in the combustion chamber of a compression-ignition engine can be regulated to some extent by the design of the combustion chamber, by the design of the fuel-injection nozzle, and by the use of air flow.

Rothrock, A M↗

NASA NTRS1937

Effects of Air-Fuel Spray and Flame Formation in a Compression-Ignition Engine

High-speed motion pictures were taken at the rate of 2,500 frames per second of the fuel spray and flame formation in the combustion chamber of the NACA combustion apparatus. The compression ratio was 13.2 and the speed 1,500 revolutions per minute. An optical indicator was used to record the time-pressure relationship in the combustion chamber. The air-fuel ratio was varied from 10.4 to 365. The results showed that as the air-fuel ratio was increased definite stratification of the charge occurred in the combustion chamber even though moderate air flow existed. The results also showed the rate of vapor diffusion to be relatively slow.

Rothrock, A M↗

NASA NTRS1997

High-Temperature Extensometry and PdCr Temperature-Compensated Wire Resistance Strain Gages Compared

A detailed experimental evaluation is underway at the NASA Lewis Research Center to compare and contrast the performance of the PdCr/Pt dual-element temperature-compensated wire resistance strain gage with that of conventional high-temperature extensometry. The advanced PdCr gage, developed by researchers at Lewis, exhibits desirable properties and a relatively small and repeatable apparent strain to 800 C. This gage represents a significant advance in technology because existing commercial resistance strain gages are not reliable for quasi-static strain measurements above approx. 400 C. Various thermal and mechanical loading spectra are being applied by a high-temperature thermomechanical uniaxial testing system to evaluate the two strain-measurement systems. This is being done not only to compare and contrast the two strain sensors, but also to investigate the applicability of the PdCr strain gage to the coupon-level specimen testing environment typically employed when the high-temperature mechanical behavior of structural materials is characterized. Strain measurement capabilities to 800 C are being investigated with a nickel-base superalloy, Inconel 100 (IN 100), substrate material and application to TMC's is being examined with the model system, SCS-6/Ti-15-3. Furthermore, two gage application techniques are being investigated in the comparison study: namely, flame-sprayed and spot welding. The apparent strain responses of both the weldable and flame-sprayed PdCr wire strain gages were found to be cyclically repeatable on both IN 100 and SCS-6/Ti-15-3 [0]_8. In general, each gage exhibited some uniqueness with respect to apparent strain behavior. Gages mounted on the IN 100 specimens tended to show a repeatable apparent strain within the first few cycles, because the thermal response of IN 100 was stable. This was not the case, however, for the TMC specimens, which typically required several thermal cycles to stabilize the thermal strain response. Thus, progressive changes in the apparent strain behavior were corroborated by the extensometer, which unlike the mounted gage can distinguish quantitative changes in the material's thermal strain response. One specimen was instrumented with both a fixed and floating gage. From the difference in output of these two gages, the thermal expansion strains were calculated. These data, which are given in the figure, show excellent agreement with the values measured by the high-temperature extensometry.

Source record↗

NASA NTRS2000

A Validation Summary of the NCC Turbulent Reacting/non-reacting Spray Computations

This pper provides a validation summary of the spray computations performed as a part of the NCC (National Combustion Code) development activity. NCC is being developed with the aim of advancing the current prediction tools used in the design of advanced technology combustors based on the multidimensional computational methods. The solution procedure combines the novelty of the application of the scalar Monte Carlo PDF (Probability Density Function) method to the modeling of turbulent spray flames with the ability to perform the computations on unstructured grids with parallel computing. The calculation procedure was applied to predict the flow properties of three different spray cases. One is a nonswirling unconfined reacting spray, the second is a nonswirling unconfined nonreacting spray, and the third is a confined swirl-stabilized spray flame. The comparisons involving both gas-phase and droplet velocities, droplet size distributions, and gas-phase temperatures show reasonable agreement with the available experimental data. The comparisons involve both the results obtained from the use of the Monte Carlo PDF method as well as those obtained from the conventional computational fluid dynamics (CFD) solution. Detailed comparisons in the case of a reacting nonswirling spray clearly highlight the importance of chemistry/turbulence interactions in the modeling of reacting sprays. The results from the PDF and non-PDF methods were found to be markedly different and the PDF solution is closer to the reported experimental data. The PDF computations predict that most of the combustion occurs in a predominantly diffusion-flame environment. However, the non-PDF solution predicts incorrectly that the combustion occurs in a predominantly vaporization-controlled regime. The Monte Carlo temperature distribution shows that the functional form of the PDF for the temperature fluctuations varies substantially from point to point. The results also bring to the fore some of the deficiencies associated with the use of assumed-shape PDF methods in spray computations.

Raju, M. S.↗

NASA NTRS1993

Welding Wires To Thin Thermocouple Films

Parallel-gap resistance welding yields joints surviving temperatures of about 1,000 degrees C. Much faster than thermocompression bonding. Also exceeds conductive-paste bonding and sputtering thin films through porous flame-sprayed insulation on prewelded lead wires. Introduces no foreign material into thermocouple circuit and does not require careful control of thickness of flame-sprayed material.

Holanda, Raymond↗

NASA NTRS1973

Method of making pressure tight seal for super alloy

A procedure for forming a pressure tight seal along two edges of super alloy sheets is presented. The procedure consists of flame spraying a powdered aluminum-nickel composition on the joint. The use of frozen carbon dioxide and carbon dioxide gas to maintain a low temperature environment during the flame spraying is described.

Little, R. E.↗

NASA NTRS1937

Effect of Nozzle Design on Fuel Spray and Flame Formation in a High-Speed Compression-Ignition Engine

Fuel was injected from different type of injection nozzles into the combustion chamber of the NACA combustion apparatus, operated as a compression-ignition engine. High speed motion pictures were taken of the fuel sprays and combustion. Single-orifice nozzles of 0.008, 0.020, and 0.040 inch diameter, and multiorifice nozzles having 2, 6, and 16 orifices were tested. Nozzles having impinging jets and slit orifices were also included. The photographs indicate that the rate of vapor diffusion from the spray is comparatively slow and that this slow rate of diffusion for combustion chambers with little or no air flow prevents the compression-ignition engine from giving the high performance inherent in the high compression ratios. The sprays from the multiorifice nozzles destroyed the air movement to a greater extent than did those from single orifice nozzles. It is concluded that high performance cannot be realized until the methods of distributing the fuel are improved by means of the injection-nozzle design, air flow, or both.

Rothrock, A M↗

NASA NTRS1977

Reliability analysis of forty-five strain-gage systems mounted on the first fan stage of a YF-100 engine

The reliability of 45 state-of-the-art strain gage systems under full scale engine testing was investigated. The flame spray process was used to install 23 systems on the first fan rotor of a YF-100 engine; the others were epoxy cemented. A total of 56 percent of the systems failed in 11 hours of engine operation. Flame spray system failures were primarily due to high gage resistance, probably caused by high stress levels. Epoxy system failures were principally erosion failures, but only on the concave side of the blade. Lead-wire failures between the blade-to-disk jump and the control room could not be analyzed.

Holanda, R.↗

NASA NTRS1992

Palladium-chromium static strain gages for high temperatures

An electrical resistance strain gage that can provide accurate static strain measurement to a temperature of 1500 F or above is being developed both in fine wire and thin film forms. The gage is designed to be temperature compensated on any substrate material. It has a dual element: the gage element is a special alloy, palladium-13wt percent chromium (PdCr), and the compensator element is platinum (Pt). Earlier results of a PdCr based wire gage indicated that the apparent strain of this gage can be minimized and the repeatability of the apparent strain can be improved by prestabilizing the gage on the substrate for a long period of time. However, this kind of prestabilization is not practical in many applications and therefore the development of a wire gage which is prestabilized before installation on the substrate is desirable. This paper will present our recent progress in the development of a prestabilized wire gage which can provide meaningful strain data for the first thermal cycle. A weldable PdCr gage is also being developed for field testing where conventional flame-spraying installation can not be applied. This weldable gage is narrower than a previously reported gage, thereby allowing the gage to be more resistant to buckling under compressive loads. Some preliminary results of a prestabilized wire gage flame-sprayed directly on IN100, an engine material, and a weldable gage spot-welded on IN100 and SCS-6/(beta)21-S Titanium Matrix Composite (TMC), a National Aero-Space Plane (NASP) structure material, will be reported. Progress on the development of a weldable thin film gage will also be addressed. The measurement technique and procedures and the lead wire effect will be discussed.

Lei, Jih-Fen↗

NASA NTRS1979

Measurement in multiphase reacting flows

A survey is presented of diagnostic techniques and measurements made in multiphase reacting flows. The special problems encountered by the presence of liquid droplets, soot and solid particles in high temperature chemically reacting turbulent environments are outlined. The principal measurement techniques that have been tested in spray flames are spark photography, laser anemometry, thermocouples and suction probes. Spark photography provides measurement of drop size, drop size distribution, drop velocity, and angle of flight. Photographs are analysed automatically by image analysers. Photographic techniques are reliable, inexpensive and proved. Laser anemometers have been developed for simultaneous measurement of velocity and size of individual particles in sprays under conditions of vaporization and combustion. Particle/gas velocity differentials, particle Reynolds numbers, local drag coefficients and direct measurement of vaporization rates can be made by laser anemometry. Gas temperature in sprays is determined by direct in situ measurement of time constants immediately prior to measurement with compensation and signal analysis by micro-processors. Gas concentration is measured by suction probes and gas phase chromatography. Measurements of particle size, particle velocity, gas temperature, and gas concentration made in airblast and pressure atomised liquid spray flames are presented.

Chigier, N. A.↗

NASA NTRS1974

Development of sputtered techniques for thrust chambers, task 1

Filler materials proposed for use in the sputter fabrication regeneratively cooled thrust chambers were evaluated. Low melting castable alloys, CERROBEND. CERROCAST, and CERROTRU, slurry applied SERMETEL 481 and flame-sprayed aluminum were investigated as filler materials. Sputter deposition from a cylindrical cathode inverted magnestron was used to apply an OFHC copper closeout layer to filled OFHC copper ribbed-wall cylindrical substrates. The sputtered closeout layer structure was evaluated with respect to filler material contamination, predeposition machining and finishing operations, and deposition parameters. The application of aluminum by flame-spraying resulted in excessiver filler porosity. Though the outgassing from this porosity was found to be detrimental to the closeout layer structure, bond strengths in excess of 10,500 psi were achieved. Removal of the aluminum from the grooves was readily accomplished by leaching in a 7.0 molar solution of sodium hydroxide at 353 K. Of the other filler materials evaluated, CERROTRU was found to be the most suitable material with respect to completely filling the ribbed-wall cylinders and vacuum system compatibility. However, bond contamination resulted in low closeout layer bond strength with the CERROTRU filler. CERROBEND, CERROCAST, and SERMETEL 481 were found to be unacceptable as filler materials.

Mullaly, J. R.↗

NASA NTRS1959

Measurements of Total Hemispherical Emissivity of Several Stably Oxidized Metals and Some Refractory Oxide Coatings

A description of the apparatus and methods used for obtaining total hemispherical emissivity is presented, and data for several stably oxidized metals are included. The metals which were tested included type 347 stainless steel, tungsten, and Haynes alloys B, C, X, and 25. No values of emissivity were obtained for tungsten or Haynes alloy B because of the nature of the oxides produced. The refractory oxide coatings tested were flame-sprayed alumina and zirconia. The results of the investigation indicate that strongly adherent, oxidized surfaces of a high stable emissivity can be produced on type 347 stainless steel for which the total hemispherical emissivity varied from 0.87 to 0.91 for temperatures from 600 F to 2,000 F. For this same temperature range, the Haynes alloys tested showed values of total hemispherical emissivity from 0.90 to 0.96 for alloy C, from 0.85 to 0.88 for alloy X, and from 0.85 to 0.89 for alloy 25. Haynes alloy B and tungsten formed nonadherent oxides at elevated temperatures and, therefore, stable emissivities were not obtained. The results obtained for the flame-sprayed ceramics (alumina and zirconia) showed considerably higher values of total emissivity than those measured for coatings applied by other methods. Emissivity values ranging from 0.69 to 0.44 for aluminum oxide and from 0.62 to 0.44 for zirconium oxide were measured for temperatures from 800 F to 2,000 F.

Wade, William R.↗

NASA NTRS1986

Analysis of coaxial spray combustion flames and related numerical issues

An approach to the simulation of strongly coupled multiphase flows in combustion hardware is sketched and its unique requirements highlighted. An example of a successful application to a coaxial injector flame is presented. Furthermore, several numerical issues that tend to interact with the physics of the problem are discussed with special regard to their potential impact on the choices of numerical parameters by the analyst. These include the issues of stability, numerical diffusivity, stiffness, and boundary conditions. The theme of this paper focuses on the intriguing relationships among the grid, the solution algorithm, and the actual physical mechanisms themselves.

Liang, P. Y.↗

NASA NTRS2003

Gravity Effects Observed In Partially Premixed Flames

Partially premixed flames (PPFs) contain a rich premixed fuel air mixture in a pocket or stream, and, for complete combustion to occur, they require the transport of oxidizer from an appropriately oxidizer-rich (or fuel-lean) mixture that is present in another pocket or stream. Partial oxidation reactions occur in fuel-rich portions of the mixture and any remaining unburned fuel and/or intermediate species are consumed in the oxidizer-rich portions. Partial premixing, therefore, represents that condition when the equivalence ratio (phi) in one portion of the flowfield is greater than unity, and in another section its value is less than unity. In general, for combustion to occur efficiently, the global equivalence ratio is in the range fuel-lean to stoichiometric. These flames can be established by design by placing a fuel-rich mixture in contact with a fuel-lean mixture, but they also occur otherwise in many practical systems, which include nonpremixed lifted flames, turbulent nonpremixed combustion, spray flames, and unwanted fires. Other practical applications of PPFs are reported elsewhere. Although extensive experimental studies have been conducted on premixed and nonpremixed flames under microgravity, there is a absence of previous experimental work on burner stabilized PPFs in this regard. Previous numerical studies by our group employing a detailed numerical model showed gravity effects to be significant on the PPF structure. We report on the results of microgravity experiments conducted on two-dimensional (established on a Wolfhard-Parker slot burner) and axisymmetric flames (on a coannular burner) that were investigated in a self-contained multipurpose rig. Thermocouple and radiometer data were also used to characterize the thermal transport in the flame.

Puri, Ishwar K.↗

NASA NTRS1997

Formation and Combustion of Unconfined Drop Clusters in Microgravity

Single-drop and droplet array studies have become common methods to isolate and investigate the effects of any of the complexities that enter into the drop combustion process. Microgravity environments are required to allow larger drops to be studied while minimizing or eliminating the confounding effects of buoyancy. Based on the results from current isolated drop, drop array, and spray studies funded through the Microgravity Science and Applications Division, it has become clear that even with the effects of buoyancy removed, the extrapolation of results from droplet array studies to spray flames is difficult. The problem occurs because even the simplest spray systems introduce complexities of multi-disperse drop sizes and drop-drop interactions, coupled with more complicated fluid dynamics. Not only do these features make the interpretation of experimental data difficult, they also make the problem very difficult to analyze computationally. Group combustion models, in which the interaction between droplets is treated on a statistical manner, have become a popular method to investigate the behavior of large numbers of interacting droplets, particularly through the work of Ryan et al. and Bellan and co-workers. While these models idealize the actual spray systems to a point where they can be treated computationally, the experimental analogy to these models is difficult to achieve because it requires the formation and Combustion of drop clusters without the effects of buoyancy. Therefore, even though these models have provided useful and insightful information, the verification of the results by direct comparison with experimental data is still lacking.

Liu, S.↗

NASA NTRS1984

Flame propagation in heterogeneous mixtures of fuel drops and air

Photographic methods are used to measure flame speeds in flowing mixtures of fuel props and air at atmospheric pressure. The fuels employed include a conventional fuel oil plus various blends JP 7 with stocks containing single-ring and mullti-ring aromatics. The results for stoichiometric mixtures show that flame propagation cannot occur in mixtures containing mean drop sizes larger than 300 to 400 microns, depending on the fuel type. For smaller drop sizes, down to around 60 microns, flame speed is inversely proportional to drop size, indicating that evaporation rates are limiting to flame speed. Below around 60 microns, the curves of flame speed versus mean drop size flatten out, thereby demonstrating that for finely atomized sprays flame speeds are much less dependent on evaporation rates, and are governed primarily by mixing and/or chemical reaction rates. The fuels exhibiting the highest flame speeds are those containing multi-ring aromatics. This is attributed to the higher radiative heat flux emanating from their soot-bearing flames which enhances the rate of evaporation of the fuel drops approaching the flame front.

Myers, G. D.↗