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Boundary effects on Marangoni-Rayleigh and morphological instabilities

Effects of boundaries (vertical sides) on the Marangoni-Rayleigh problem are reviewed. Spectral crowding and a dimensional singularity when Rayleigh effects are neglected are discussed. In the unbounded case, there is a unique Ma with unique eigenfunction for fixed Ra but infinite Ra for fixed Ma. These infinite values of Ra correspond to vertical cellular modes. In the bounded case, there is infinite Ma for a fixed Ra. The stress free side wall case gives double infinite of Ra for fixed Ma and wave number. Clearly, a dimensional singularity occurs for the Marangoni problem when the side walls go to infinity and a fixed Ra is considered. There is no direct analogy regarding this singularity in the morphological instability problem. Results on the behavior of Mac, Rac with boundary conditions also show only marginal connection to the morphological stability problem.

Narayanan, R.↗

Operando synchrotron X-ray analysis of melt pool dynamics in an Al-Sn immiscible alloy

The melt flow in an Al-50vol.% Sn immiscible alloy, produced by single-track laser melting of Al and Sn elemental powders, was studied in real time. High-speed synchrotron X-ray imaging was used to track Al and Sn liquids’ movements, and also to examine elemental distributions in the laser tracks, complimented by electron microscopy after solidification. Key aspects, including melt pool geometry, keyhole instability, and flow dynamics (flow pattern and velocity), were examined using digital image analysis. Relatively deeper melt pools formed at 400 W and 300 mm/s exhibited greater stability, with smooth surfaces, consistent outward flow, and minor vortices near the keyhole. In contrast, shallower pools produced at higher scanning speeds (>500 mm/s) demonstrated greater instability with increased surface waviness, and stronger velocity fluctuations, leading to numerous micro-vortices and increased Al-Sn heterogeneity. Velocity scale estimations, supported by experimental observations, examined the roles of vapour pressure, Marangoni effect, buoyancy, inertial, and surface tension forces in the flow. The results revealed that vapour pressure and mechanical waves dominated at high scanning speeds (shallow pools), while Marangoni forces were equally significant in deep pools at lower speeds (300 mm/s). Buoyancy was found to have minimal impact in both cases. Furthermore, the interaction between inertial and surface tension forces played a critical role in determining the degree of waviness of the pools’ surfaces. These findings offer valuable insights into melt pool dynamics during laser processing of immiscible alloys and other metallic systems using elemental powders, and provide guidance for developing high-fidelity computational fluid dynamics models.

immiscible alloys↗

Combustion of two-component miscible droplets in reduced gravity

This research focuses on the combustion of binary miscible droplets initially in the mm size range. Experiments are performed using the NASA Lewis 2.2 sec drop tower in Cleveland, Ohio, where mixtures of alkanes and/or alcohols are studied. The fuel components are selected to have significantly different volatilities. Initial oxygen mole fractions from about 0.15-0.5 and initial pressures from 0.2-2 atm are employed. Different inerts are used (He, CO2, Ar, N2) to change burning rates and sooting behaviors. Objectives are to observe the following: (1) Transient droplet diameters (including three-staged combustion behaviors and microexplosion; (2) Transient flow behaviors (sudden flame contraction, luminosity, extinction); and (3) Behaviors of observable soot particles. theoretical and computational research in support of this program has also been undertaken. This research includes analytical studies to determine the effects of small but nonzero gravitational levels on droplet gasification, analytical studies of hydrodynamic stability of spherically-symmetrical droplet gasification (to address the question as to whether spherically-symmetrical droplet gasification may be destabilized from capillary, i.e., Marangoni effects), and computational modeling of effects of capillary stresses on droplet gasification.

Shaw, Benjamin D.↗

Effect of surface tension on the onset of convection in a double-diffusive layer

The effect of surface tension on the stability of a double-diffusive layer is considered using linear stability analysis. The surface tension is assumed to vary linearly with temperature and solute concentration. The eigenvalue problem is solved by the Galerkin method. Results show that the predicted stability boundary based on Marangoni effects alone is completely altered in the presence of buoyancy effects induced by low gravity levels (about 10 exp -5 g). At reduced gravity levels, salt-finger instability may onset in the overstable mode due to the stabilizing effect of surface tension. Fluid properties in terms of the Prandtl and the Lewis numbers have a profound effect on the stability conditions; opposite stability characteristics are found in salt solutions and in molten metals.

Chen, C. F.↗

A New Theory of Nucleate Pool Boiling in Arbitrary Gravity

Heat transfer rates specific to nucleate pool boiling under various conditions are determined by the dynamics of vapour bubbles that are originated and grow at nucleation sites of a superheated surface. A new dynamic theory of these bubbles has been recently developed on the basis of the thermodynamics of irreversible processes. In contrast to other existing models based on empirically postulated equations for bubble growth and motion, this theory does not contain unwarrantable assumptions, and both the equations are rigorously derived within the framework of a unified approach. The conclusions of the theory are drastically different from those of the conventional models. The bubbles are shown to detach themselves under combined action of buoyancy and a surface tension force that is proven to add to buoyancy in bubble detachment, but not the other way round as is commonly presumed. The theory ensures a sound understanding of a number of so far unexplained phenomena, such as effect caused by gravity level and surface tension on the bubble growth rate and dependence of the bubble characteristics at detachment on the liquid thermophysical parameters and relevant temperature differences. The theoretical predictions are shown to be in a satisfactory qualitative and quantitative agreement with observations. When being applied to heat transfer at nucleate pool boiling, this bubble dynamic theory offers an opportunity to considerably improve the main formulae that are generally used to correlate experimental findings and to design boiling heat removal in various industrial applications. Moreover, the theory makes possible to pose and study a great deal of new problems of essential impact in practice. Two such problems are considered in detail. One problem concerns the development of a principally novel physical model for the first crisis of boiling. This model allows for evaluating critical boiling heat fluxes under various conditions, and in particular at different gravity levels, with a good agreement with experimental evidence. The other problem bears upon equilibrium shapes of a detached bubble near a heated surface in exceedingly low gravity. In low gravity or in weightlessness, the bubble can remain in the close vicinity of the surface for a long time, and its shape is greatly affected by the Marangoni effect due to both temperature and possible surfactant concentration being nonuniform along the interface. The bubble performs at these conditions like a heat pipe, with evaporation at the bubble lower boundary and condensation at its upper boundary, and ultimately ensures a substantial increase in heat removal as compared with that in normal gravity. Some other problems relevant to nucleate pool and forced convection boiling heat transfer are also discussed.

Buyevich, Y. A.↗

3D Characterization of the Columnar-to-Equiaxed Transition in Additively Manufactured Inconel 718

Additive manufacturing (AM) provides enormous processing flexibility, enabling novel part geometries and optimized designs. Access to a local heat source further permits the potential for local microstructure control on the scale of individual melt pools, which can enable local control of part properties. In order to design tailored processing strategies for target microstructures, models predicting the columnar-to-equiaxed transition must be extended to the high solidification velocities and complex thermal histories present in AM. Here, we combine 3D characterization with advanced modeling techniques to develop a more complete understanding of the solidification process and evolution of microstructure during electron beam melting (EBM) of Inconel 718. Full calibration of existing microstructure prediction models demonstrates the differences between AM processes and more conventional welding techniques, underlying the need for accurate determination of key parameters that can only be measured directly in 3D. The ability to combine multisensor data in a consistent 3D framework via data fusion algorithms is essential to fully leverage these advanced characterization approaches. Thermal modeling provides insight on microstructure development within isolated solidification events and demonstrates the role of Marangoni effects on controlling solidification behavior.

Polonsky, Andrew↗

Spot pattern welding scanning strategy for sensor embedding and residual stress reduction in laser-foil-printing additive manufacturing

Here, this paper aims to present spot pattern welding (SPW) as a scanning strategy for laser-foil-printing (LFP) additive manufacturing (AM) in place of the previously used continuous pattern welding (CPW) (line-raster scanning). The SPW strategy involves generating a sequence of overlapping spot welds on the metal foil, allowing the laser to form dense and uniform weld beads. This in turn reduces thermal gradients, promotes material consolidation and helps mitigate process-related risks such as thermal cracking, porosity, keyholing and Marangoni effects. 304L stainless steel (SS) feedstock is used to fabricate test specimens using the LFP system. Imaging techniques are used to examine the melt pool dimensions and layer bonding. In addition, the parts are evaluated for residual stresses, mechanical strength and grain size. Compared to CPW, SPW provides a more reliable heating/cooling relationship that is less dependent on part geometry. The overlapping spot welds distribute heat more evenly, minimizing the risk of elevated temperatures during the AM process. In addition, the resulting dense and uniform weld beads contribute to lower residual stresses in the printed part. To the best of the authors’ knowledge, this is the first study to thoroughly investigate SPW as a scanning strategy using the LFP process. In general, SPW presents a promising strategy for securing embedded sensors into LFP parts while minimizing residual stresses.

36 MATERIALS SCIENCE↗

Use of thermocapillary migration in a controllable heat valve

In accordance with the Marangoni effect, immiscible droplets in a host fluid in which a temperature gradient exists move in the direction of increasing temperature. It is proposed that this thermocapillary migration could be used to construct a 'liquid wick' that would return the condensed vapor at the condenser end of a heat pipe back to the evaporator, thus completing the fluid circuit. The droplets would be formed by capillary pressure forcing the condensate through a perforated diaphragm whose temperature would control the droplet flux, and hence the heat flux between the two ends of the heat pipe, thus making it a controllable heat valve.

Schmid, L. A.↗

Directional Solidification of Monotectic and Hypermonotectic Aluminum-indium Alloys Under Micron-g

The objective of this program is to analyze the mechanisms involved in the composite solid structure formation obtained from a miscibility gap alloy under microgravity. The metallic system aluminum-indium was chosen for its low critical temperature, broad miscibility gap, and rather well-known thermodynamic properties. The experiment was performed aboard the Salyut-7 spacecraft. The theories of capture of particulates by an advancing front were not able to explain the observations made on SPAR and Salyut-7 experiments. A new model was developed based on the filtration theory considering the globules population: the solid/liquid interface is like a filter of negligible thickness for the globules and its efficiency is limited by a pressure barrier measured for Al-In alloys by ground based experiments. The Materials Experiment Assembly (MEA)-3 experiment was consequently adjusted to take into account the new model. The behavior of the globules in an interacting population on the solid front is, of course, an essential factor in the theory. The theory is at present being completed by results obtained by the Laboratoire d'Aerothermique of Meudon. The hydrodynamic and thermal interactions between pairs of globules placed in a temperature gradient have been calculated showing a large reduction of the Marangoni effect compared to the isolated globule. Physico-chemical properties of metallic liquid interface are currently being investigated.

Potard, C.↗

Stable localized patterns in thin liquid films

We study a 2-D nonlinear evolution equation which describes the 3-D spatiotemporal behavior of the air-liquid interface of a thin liquid film lying on the underside of a cooled horizontal plate. We show that the Marangoni effect can stabilize the destabilizing effect of gravity (the Rayleigh-Taylor instability) allowing for the existence of stable localized axisymmetric solutions for a wide range of parameter values. Various properties of these structures are discussed.

Deissler, Robert J.↗

Stable localized patterns in thin liquid films

A two-dimensional nonlinear evolution equation is studied which describes the three-dimensional spatiotemporal behavior of the air-liquid interface of a thin liquid film lying on the underside of a cooled horizontal plate. It is shown that the equation has a Liapunov functional, and this fact is exploited to demonstrate that the Marangoni effect can stabilize the destabilizing effect of gravity (the Rayleigh-Taylor instability), allowing for the existence of stable localized axisymmetric solutions for a wide range of parameter values. Various properties of these structures are discussed.

Deissler, Robert J.↗

Ground based studies of thermocapillary flows in levitated drops

Analytical studies along with ground-based experiments are presently being carried out in connection with thermocapillary phenomena associated with drops and bubbles in a containerless environment. The effort here focuses on the thermal and the fluid phenomena associated with the local heating of acoustically levitated drops, both at 1-g and at low-g. In particular, the Marangoni effect on drops under conditions of local spot-heating and other types of heating are being studied. With the experiments conducted to date, fairly stable acoustic levitation of drops has been achieved and successful flow visualization by light scattering from smoke particles has been carried out. The results include situations with and without heating. As a preliminary qualitative interpretation of these experimental results, we consider the external flow pattern as a superposition of three discrete circulation cells operating on different spatial scales. The observations of the flow fields also indicate the existence of a steady state torque induced by the streaming flows. The theoretical studies have been concentrated on the analysis of streaming flows in a gaseous medium with the presence of a spherical particle undergoing periodic heating. A matched asymptotic analysis was carried out for small parameters derived from approximations in the high frequency range. The heating frequency being 'in tune' with the acoustic frequency results in a nonzero time-averaged thermal field. This leads to a steady heat flow across the equatorial plane of the sphere.

Sadhal, Satwindar Singh↗

A Theory of Oscillating Edge Flames

It has been known for some years that when a near-limit flame spreads over a liquid pool of fuel, the edge of the flame can oscillate relative to a frame moving with the mean speed. Each period of oscillation is characterized by long intervals of modest motion during which the edge gases radiate like those of a diffusion flame, punctuated by bursts of rapid advance during which the edge gases radiate like those in a deflagration. Substantial resources have been brought to bear on this issue within the microgravity program, both experimental and numerical. It is also known that when a near-asphyxiated candle-flame burns at zero gravity, the edge of the (hemispherical) flame can oscillate violently prior to extinction. Thus a web-surfer, turning to the NASA web-site at http://microgravity.msfc.nasa.gov, and following the trail combustion science/experiments/experimental results/candle flame, will find photographs and a description of candle burning experiments carried out on board both the Space-shuttle and the Russian space station Mir. A brief report can also be found in the proceedings of the Fourth Workshop. And recently, in a third microgravity program, the leading edge of the flame supported by injection of ethane through the porous surface of a plate over which air is blown has been found to oscillate when conditions are close to blow-off. A number of important points can be made with respect to these observations: It is the edge itself which oscillates, advancing and retreating, not the diffusion flame that trails behind the edge; oscillations only occur under near limit conditions; in each case the Lewis number of the fuel is significantly larger than 1; and because of the edge curvature, the heat losses from the reacting edge structure are larger than those from the trailing diffusion flame. We propose a general theory for these oscillations, invoking Occam's 'Law of Parsimony' in an expanded form, to wit: The same mechanism is responsible for the oscillations in all three experiments; and no new mechanism is invoked (Occam's original 'Razor'). Such a strategy eliminates Marangoni effects as the source, for these are absent in the second and third experiments. And it eliminates arguments that point to numerically predicted gas eddies as the source, a new mechanism, unelucidated. Indeed, we hypothesize that the essential driving mechanism for the instability is a combination of large Lewis number and heat losses from the reacting structure near the flame edge. Instabilities driven by these mechanisms are commonplace in 1D configurations. Chemical reactor theory, for example, leads to system responses which mimic the response of the candle flame - steady flame, oscillations, extinction. In a combustion context, oscillating instabilities were first reported for diffusion flames in a theoretical study by Kirkby and Schmitz, and here also the instabilities are associated with near-extinction conditions, large Lewis numbers, and heat losses. And deflagrations will oscillate if the Lewis number is large enough, oscillations that are exacerbated when heat losses are present, whether global or to a surface.

Buckmaster, J.↗

Critical Heat Flux in Pool Boiling on Metal-Graphite Composite Surfaces

A study is conducted on high heat-flux pool boiling of pentane on micro-configured composite surfaces. The boiling surfaces are copper-graphite (Cu-Gr) and aluminum-graphite (Al-Gr) composites with a fiber volume concentration of 50%. The micro-graphite fibers embedded in the matrix contribute to a substantial enhancement in boiling heat-transfer performance. Correlation equations are obtained for both the isolated and coalesced bubble regimes, utilizing a mathematical model based on a metal-graphite, two-tier configuration with the aid of experimental data. A new model to predict the critical heat flux (CHF) on the composites is proposed to explain the fundamental aspects of the boiling phenomena. Three different factors affecting the CHF are considered in the model. Two of them are expected to become the main agents driving vapor volume detachment under microgravity conditions, using the metal-graphite composite surfaces as the heating surface and using liquids with an unusual Marangoni effect as the working fluid.

Zhang, Nengli↗

Enhancements of Nucleate Boiling Under Microgravity Conditions

This paper presents two means for enhancing nucleate boiling and critical heat flux under microgravity conditions: using micro-configured metal-graphite composites as the boiling surface and dilute aqueous solutions of long-chain alcohols as the working fluid. In the former, thermocapillary force induced by temperature difference between the graphite-fiber tips and the metal matrix plays an important role in bubble detachment. Thus boiling-heat transfer performance does not deteriorate in a reduced-gravity environment. In the latter cases, the surface tension-temperature gradient of the long-chain alcohol solutions turns positive as the temperature exceeds a certain value. Consequently, the Marangoni effect does not impede, but rather aids in bubble departure from the heating surface. This feature is most favorable in microgravity. As a result, the bubble size of departure is substantially reduced at higher frequencies. Based on the existing experimental data, and a two-tier theoretical model, correlation formulas are derived for nucleate boiling on the copper-graphite and aluminum-graphite composite surfaces, in both the isolated and coalesced bubble regimes. In addition, performance equations for nucleate boiling and critical heat flux in dilute aqueous solutions of long-chain alcohols are obtained.

Zhang, Nengli↗

Heat pipe systems using new working fluids

The performance of a heat pipe system is greatly improved by the use of a dilute aqueous solution of about 0.0005 and about 0.005 moles per liter of a long chain alcohol as the working fluid. The surface tension-temperature gradient of the long-chain alcohol solutions turns positive as the temperature exceeds a certain value, for example about 40.degree. C. for n-heptanol solutions. Consequently, the Marangoni effect does not impede, but rather aids in bubble departure from the heating surface. Thus, the bubble size at departure is substantially reduced at higher frequencies and, therefore, increases the boiling limit of heat pipes. This feature is useful in microgravity conditions. In addition to microgravity applications, the heat pipe system may be used for commercial, residential and vehicular air conditioning systems, micro heat pipes for electronic devices, refrigeration and heat exchangers, and chemistry and cryogenics.

Chao, David F.↗

Ball Bearings Equipped for In Situ Lubrication on Demand

In situ systems that provide fresh lubricants to ball/race contacts on demand have been developed to prolong the operational lives of ball bearings. These systems were originally intended to be incorporated into ball bearings in mechanisms that are required to operate in outer space for years, in conditions in which lubricants tend to deteriorate and/or evaporate. These systems may also be useful for similarly prolonging bearing lifetimes on Earth. Reservoirs have been among the means used previously to resupply lubricants. Lubricant- resupply reservoirs are bulky and add complexity to bearing assemblies. In addition, such a reservoir cannot be turned on or off as needed: it supplies lubricant continuously, often leading to an excess of lubricant in the bearing. A lubricator of the present type includes a porous ring cartridge attached to the inner or the outer ring of a ball bearing (see Figure 1). Oil is stored in the porous cartridge and is released by heating the cartridge: Because the thermal expansion of the oil exceeds that of the cartridge, heating causes the ejection of some oil. A metal film can be deposited on a face of the cartridge to serve as an electrical-resistance heater. The heater can be activated in response to a measured increase in torque that signals depletion of oil from the bearing/race contacts. Because the oil has low surface tension and readily wets the bearing-ring material, it spreads over the bearing ring and eventually reaches the ball/race contacts. The Marangoni effect (a surface-tension gradient associated with a temperature gradient) is utilized to enhance the desired transfer of lubricant to the ball/race contacts during heating. For a test, a ball bearing designed for use at low speed was assembled without lubricant and equipped with a porous-ring lubricator, the resistance heater of which consumed a power of less than 1 W when triggered on by a torque-measuring device. In the test, a load of 20 lb (.89 N) was applied and the bearing was turned at a rate of 200 RPM. The lubricator control was turned on at the beginning of the test, turned off for about 800 seconds, then turned on again. As shown in Figure 2, the controlled lubricator stabilized the torque in a low range, starting immediately after initial turn-on and immediately after resumption of the lubricator control.

Marchetti, Mario↗