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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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At least 415 records · Page 23
All sourcesNASA NTRSDOE OSTI
NASA NTRS2008

Friction Stir Welding

Friction stir welding (FSW) is a solid state welding process invented in 1991 at The Welding Institute in the United Kingdom. A weld is made in the FSW process by translating a rotating pin along a weld seam so as to stir the sides of the seam together. FSW avoids deleterious effects inherent in melting and promises to be an important welding process for any industries where welds of optimal quality are demanded. This article provides an introduction to the FSW process. The chief concern is the physical effect of the tool on the weld metal: how weld seam bonding takes place, what kind of weld structure is generated, potential problems, possible defects for example, and implications for process parameters and tool design. Weld properties are determined by structure, and the structure of friction stir welds is determined by the weld metal flow field in the vicinity of the weld tool. Metal flow in the vicinity of the weld tool is explained through a simple kinematic flow model that decomposes the flow field into three basic component flows: a uniform translation, a rotating solid cylinder, and a ring vortex encircling the tool. The flow components, superposed to construct the flow model, can be related to particular aspects of weld process parameters and tool design; they provide a bridge to an understanding of a complex-at-first-glance weld structure. Torques and forces are also discussed. Some simple mathematical models of structural aspects, torques, and forces are included.

Nunes, Arthur C., Jr.↗
NASA NTRS1978

Unsteady vortical and entropic distortions of potential flows round arbitrary obstacles

The analysis concerns the alterations produced when small amplitude disturbances, including entropy and vorticity disturbances, are imposed on steady potential flows. For the most general nonacoustic incident distortion field that can be imposed on the uniform upstream flow, it is shown that the perturbation velocity at any point of the resulting unsteady compressible and vortical flow consists of a part that is a known function of the imposed upstream distortion field and the mean flow variables and a potential part that can be found by solving a linear inhomogeneous wave equation with a dipole-type source term whose strength is a known function of the imposed upstream distortion field. The theory is applied to the unsteady flow past a corner, and a closed-form analytical solution is found.

Goldstein, M. E.↗
NASA NTRS1983

Ship waves and lee waves

Dynamics analogous to those of surface ship waves on water of finite depth are noted for the three-dimensional trapped lee wave modes produced by an isolated obstacle in a stratified fluid. This vertical trapping of wave energy is modeled by uniform upstream flow and stratification, bounded above by a rigid lid, and by a semiinfinite fluid of uniform stability whose wind velocity increases exponentially with height, representing the atmosphere. While formal asymptotic solutions are produced, limited quantitative usefulness is obtained through them because of the limitations of the approximations and the infinity of modes in the solution. Time-dependent numerical models are accordingly developed for both surface ship waves and internal and atmospheric ship waves, yielding a variety of results.

Sharman, R. D.↗
DOE OSTI2022

Optimization of flow in additively manufactured porous columns with graded permeability

Chemical engineering systems often involve a functional porous medium, such as in catalyzed reactive flows, fluid purifiers, and chromatographic separations. Ideally, the flow rates throughout the porous medium are uniform, and all portions of the medium contribute efficiently to its function. The permeability is a property of a porous medium that depends on pore geometry and relates flow rate to pressure drop. Additive manufacturing techniques raise the possibilities that permeability can be arbitrarily specified in three dimensions, and that a broader range of permeabilities can be achieved than by traditional manufacturing methods. Using numerical optimization methods, we show that designs with spatially varying permeability can achieve greater flow uniformity than designs with uniform permeability. We consider geometries involving hemispherical regions that distribute flow, as in many glass chromatography columns. By several measures, significant improvements in flow uniformity can be obtained by modifying permeability only near the inlet and outlet.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2021

Hanford Waste Treatment Plant LAB Facility Stack Effluent Monitoring: Sampling Probe Location Qualification Evaluation

The WTP LAB stack monitor locations were qualified using scale model stacks to mitigate the risk of identifying that sampling locations do not meet the qualification criteria on the full-scale stack. As required by the ANSI/HPS N13.1-1999 standard, the scale model and its sampling location were geometrically similar to the actual stack and the Reynolds numbers for both the actual and model stacks were >10,000. An additional criterion is that the DV of the full-scale stack must be between 1/6 DV and 6 DV of the scale model stack tests. Verification tests of the LAB stacks were performed at normal operating conditions. The maximum 6 DV value from the scale model testing determines the maximum conditions for which the full-scale stack may be operated and remain in compliance with the stack verification criterion. The remaining criteria for the stack verification to be considered valid involve the flow angle and velocity uniformity results. First, the flow angle at the full-scale stack must be = 20°. Second, the velocity uniformity at the full-scale stack must be = 20% COV. Finally, the velocity uniformity results for the actual and scale model stacks must agree within 5% COV. In general, these criteria were met through the full-scale stack tests at the LAB facility. Some specific items for each scale model and full-scale stack comparison should be noted in assessing the validity of the verification tests. The LB-C2 scale model stacks were performed with single fan operations at then-minimum flow conditions. These conditions resulted in DV values that were too low to meet the DV range criterion, and therefore are unable to be used in qualifying single fan operations on the full-scale stack. However, the single fan operations demonstrated COV values for velocity uniformity as well as flow angles that were comparable to the dual-fan operations at high flows. Overall, the test conditions and test results were within the range of acceptable values based on current design flow rates. Single fan operations are expected to only occur infrequently for maintenance needs and is therefore not a planned operating condition at this time. The LB-S1 scale model stacks were performed at three fan combinations, and in each combination, at least one test was performed at the then-minimum flow conditions as well as at then-maximum flow conditions. While the then-minimum flow conditions result in a DV range that is lower than the verification test DV value, and therefore does not meet the criterion, these tests are un-necessary for the verification test acceptance. The normal and maximum flow conditions from the scale model stack tests meet the DV range criterion, and the velocity uniformity test results compare favorably with the full-scale stack results. The LB-S2 scale model stacks were performed at nominally the same maximum flow condition; however, the 6 DV value for Fan A operation was slightly lower than the full-scale stack test DV. The COV values from the scale model stacks were comparable between the Fan A and Fan B results, and the overall test conditions are within the range of acceptable values. The stack verification is therefore considered acceptable for both Fan A and Fan B operations. The verification tests were performed at flows that were appreciably higher than the design conditions, and further elevated flow rates would be beyond the range of acceptable DV. Based on these stack verification test results, the three LAB filtered exhaust stacks meet the qualification criteria provided in the ANSI/HPS N13.1-1999 standard. Further changes to the system configuration or operating conditions that are outside the bounds described in this and the scale model test reports (Glissmeyer, Flaherty, and Piepel (2001), Glissmeyer and Geeting (2013)) may require additional tests and additional analyses to determine compliance with the standard.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
NASA NTRS1982

Experimental performance of the regenerator for the Chrysler upgraded automotive gas turbine engine

Automobile gas turbine engine regenerator performance was studied in a regenerator test facility that provided a satisfactory simulation of the actual engine operating environment but with independent control of airflow and gas flow. Velocity and temperature distributions were measured immediately downstream of both the core high-pressure-side outlet and the core low-pressure-side outlet. For the original engine housing, the regenerator temperature effectiveness was 1 to 2 percent higher than the design value, and the heat transfer effectiveness was 2 to 4 percent lower than the design value over the range of test conditions simulating 50 to 100 percent of gas generator speed. Recalculating the design values to account for seal leakage decreased the design heat transfer effectiveness to values consistent with those measured herein. A baffle installed in the engine housing high-pressure-side inlet provided more uniform velocities out of the regenerator but did not improve the effectiveness. A housing designed to provide more uniform axial flow to the regenerator was also tested. Although temperature uniformity was improved, the effectiveness values were not improved. Neither did 50-percent flow blockage (90 degree segment) applied to the high-pressure-side inlet change the effectiveness significantly.

Winter, J. M.↗
NASA NTRS1991

Time-dependent aerodynamic analysis of ducted and unducted propfans at angle of attack

A three-dimensional unsteady aerodynamic analysis is described for predicting the time-dependent flow about ducted and unducted propfans operating at angle of attack. Although the freestream is assumed to be uniform, the flow relative to the rotating blades varies with circumferential position, resulting in an inherent unsteadiness due to the nonaxial inflow. The time-dependent Euler equations are solved utilizing a Runge-Kutta time-stepping scheme. The analysis is based on a finite-volume discretization employing a multiple-block grid network. To permit the use of large calculation time steps, an implicit residual smoothing scheme previously tested for unsteady flow calculations in two dimensions is extended to three spatial dimensions. For unducted propfans, a single H-type grid block is used for each blade passage to determine the time-periodic flowfield. For ducted propfans (ultra-high bypass fans) a body-centered C-type grid is wrapped about the cowl to improve the accuracy of the analysis in the high gradient flow region near the cowl leading edge. Numerical results are compared with available data for both ducted and unducted propfans operating at angle of attack.

Hall, Edward J.↗
NASA NTRS1976

Effects of mean flow on duct mode optimum suppression rates

The nature of the solution to the convected acoustic wave equation and associated boundary conditions for rectangular ducts containing uniform mean flow is examined in terms of the complex mapping between the wall admittance and characteristic mode eigenvalues. It is shown that the Cremer optimum suppression criteria must be modified to account for the effects of flow below certain critical values of the nondimensional frequency parameter of duct height divided by sound wavelength. The implications of these results on the design of low frequency suppressors are considered.

Kraft, R. E.↗
DOE OSTI2023

Effect of PBX prill size on the compressive properties of PBX 9502

Plastic-Bonded Explosive (PBX) prills are agglomerates a few millimeters in diameter composed of High Explosive crystals non-uniformly distributed in and surrounded by a polymer binder. When pressed at elevated temperatures at or above the binder melt temperature the polymer flows to uniformly coat the HE crystals to create a well-consolidated compaction. In reality it does so imperfectly, such that x-ray tomographic scans often look like a collection of prills mashed together. It is speculated that the larger the prill, the more non-uniform the binder distribution, but this has never been proven. Even if that were not so, the larger the prill the farther binder must flow toward the middle to homogenize during pressing. Thus, the degree of homogenization depends in part on prill size. The degree to which binder flows during pressing in turn affects the void distribution within pressed charges, which one suspects will affect shock sensitivity and material strength. In this paper we explore, for ~30 PBX 9502 formulation batches using the same TATB powder lot, how prill size affects the compressive mechanical properties.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Effect of PBX Prill Size on the Compressive Properties of PBX 9502

Plastic-Bonded Explosive (PBX) prills are agglomerates a few millimeters in diameter composed of High Explosive crystals non-uniformly distributed in and surrounded by a polymer binder. When pressed at elevated temperatures at or above the binder melt temperature the polymer flows to uniformly coat the HE crystals to create a well-consolidated compaction. In reality it does so imperfectly, such that x-ray tomographic scans often look like a collection of prills mashed together. It is speculated that the larger the prill, the more non-uniform the binder distribution, but this has never been proven. Even if that were not so, the larger the prill the farther binder must flow toward the middle to homogenize during pressing. Thus, the degree of homogenization depends in part on prill size. The degree to which binder flows during pressing in turn affects the void distribution within pressed charges, which one suspects will affect shock sensitivity and material strength. In this paper we explore, for ~30 PBX 9502 formulation batches using the same TATB powder lot, how prill size effects the compressive mechanical properties.

36 MATERIALS SCIENCE↗
NASA NTRS2003

Task II: Three-dimensional Rotating Stall Inception and Effects of Rotating Tip Clearance Asymmetry in Axial Compressors

The effects of two types of flow non-uniformity on stall inception behavior were assessed with linearized stability analyses of two compressor flow models. Response to rotating tip clearance asymmetries induced by a whirling rotor shaft or rotor height variations were investigated with a two-dimensional flow model. A 3-D compressor model was also developed to study the stability of both full-span and part-span rotating stall modes in annular geometries with radial flow variations. The studies focussed on (1) understanding what compressor designs were sensitive to these types of circumferential and spanwise flow non-uniformities, and (2) situations where 2-D stability theories were inadequate because of 3-D flow effects. Rotating tip clearance non-uniformity caused the greatest performance loss for shafts whirling at the rotating stall frequency. A whirling shaft displacement of 1 percent chord caused the stalling mass flow to rise by as much as 10 percent and the peak pressure rise to decrease by 6 percent. These changes were an order of magnitude larger than for equivalent-sized stationary or rotor-locked clearance asymmetries. Spanwise flow non-uniformity always destabilized the compressor, so that 2-D models over-predicted that stall margin compared to 3-D theory. The difference increased for compressors with larger spanwise variations of characteristic slope and reduced characteristic curvature near the peak. Differences between 2-D and 3-D stall point predictions were generally unacceptable (2 - 4 percent of flow coefficient) for single-stage configurations, but were less than 1 percent for multistage compressors. 2-D analyses predicted the wrong stall mode for specific cases of radial inlet flow distortion, mismatching and annulus area contraction, where higher-order radial modes led to stall. The stability behavior of flows with circumferential or radial non-uniformity was unified through a single stability criterion. The stall point for both cases was set by the integral around the annulus of the pressure rise characteristic slope, weighted by the amplitude of the mode shape. For the case of steady circumferential variations, this criterion reduced to the integrated mean slope (IMS) condition associated with steady inlet distortions. The rotating tip clearance asymmetry model was also used to demonstrate the feasibility of actively controlling the shaft position to suppress rotating stall. In axisymmetric mean flow, this method only stabilized the first harmonic mode, increasing the operating range until surge or higher harmonic modes became unstable.

Suder, Kenneth↗
NASA NTRS2001

Comparison of Two Acoustic Waveguide Methods for Determining Liner Impedance

Acoustic measurements taken in a flow impedance tube are used to assess the relative accuracy of two waveguide methods for impedance eduction in the presence of grazing flow. The aeroacoustic environment is assumed to contain forward and backward-traveling acoustic waves, consisting of multiple modes, and uniform mean flow. Both methods require a measurement of the complex acoustic pressure profile over the length of the test liner. The Single Mode Method assumes that the sound pressure level and phase decay-rates of a single progressive mode can be extracted from this measured complex acoustic pressure profile. No a priori assumptions are made in the Finite Element. Method regarding the modal or reflection content in the measured acoustic pressure profile. The integrity of each method is initially demonstrated by how well their no-flow impedances match those acquired in a normal incidence impedance tube. These tests were conducted using ceramic tubular and conventional perforate liners. Ceramic tubular liners were included because of their impedance insensitivity to mean flow effects. Conversely, the conventional perforate liner was included because its impedance is known to be sensitive to mean flow velocity effects. Excellent comparisons between impedance values educed with the two waveguide methods in the absence of mean flow and the corresponding values educed with the normal incident impedance tube were observed. The two methods are then compared for mean flow Mach numbers up to 0.5, and are shown to give consistent results for both types of test liners. The quality of the results indicates that the Single Mode Method should be used when the measured acoustic pressure profile is clearly dominated by a single progressive mode, and the Finite Element Method should be used for all other cases.

Jones, Michael G.↗
NASA NTRS1987

Computational analysis and preliminary redesign of the nozzle contour of the Langley hypersonic CF4 tunnel

A computational analysis, modification, and preliminary redesign study was performed on the nozzle contour of the Langley Hypersonic CF4 Tunnel. This study showed that the existing nozzle was contoured incorrectly for the design operating condition, and this error was shown to produce the measured disturbances in the exit flow field. A modified contour was designed for the current nozzle downstream of the maximum turning point that would provide a uniform exit flow. New nozzle contours were also designed for an exit Mach number and Reynolds number combination which matches that attainable in the Langley 20-Inch Mach 6 Tunnel. Two nozzle contours were designed: one having the same exit radius but a larger mass flow rate than that of the existing CF4 Tunnel, and the other having the same mass flow rate but a smaller exit radius than that of the existing CF4 Tunnel.

Thompson, R. A.↗
DOE OSTI2021

The role of gas flow distributions on CO 2 mineralization within monolithic cemented composites: coupled CFD-factorial design approach

The carbonation kinetics of monolithic cementing composites are strongly affected by gas transport which is, in turn, influenced by microstructural resistances and the presence of liquid water within pore networks. The non-uniform gas flow distribution within the CO 2 mineralization reactor can impart mass transfer resistance in the monolith microstructure, which affects the uptake of CO 2 (“carbonation”) of the cementing composites. This paper demonstrates how the gas spatial distribution (velocity and flow rate; quantified by CFD analysis) and processing conditions (temperature, relative humidity, and flow rate; quantified by factorial design) affect drying and carbonation, and in turn, the engineering properties of a representative ‘monolithic’ carbonate-cemented concrete component (i.e., herein concrete masonry unit: CMUs, also known as concrete block). It is shown that the gas flow distribution affects drying front penetration and results in moisture and carbonation gradients within the monolith. Particularly, variations in drying kinetics caused by non-uniformity of the contacting gas velocity impose gradients in moisture saturation, which results in increasing microstructural resistance to CO 2 transport. The resultant non-uniform carbonate-mineral formation (i.e., carbonate cementation), if not controlled, can produce gradients in mechanical properties and may alter failure patterns upon loading. Finally, these insights inform the optimal design of gas flow distribution systems and processing conditions within CO 2 mineralization reactors for the manufacturing of low-CO 2 concrete components using CO 2 -dilute industrial flue gas streams.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
NASA NTRS1981

An experimental investigation of a large delta P settling chamber for a supersonic pilot quiet tunnel

The mean streamwise flow distributions and turbulence levels across the chamber were measured with a hot wire anemometer downstream of a series of porous Rigimesh plates which were shown to be an effective means of reducing the chamber acoustic disturbance levels due to upstream pipe and valve systems. Tests made with various types of flow conditioners downstream of the porous plates showed that a series of screens was the most effective means of achieving the objective of a uniform mean flow distribution with reduced vorticity levels downstream of the porous components. Frequency spectra obtained across the series of screens show that they reduce vorticity over a wide frequency range for several different initial upstream vorticity conditions. Improvements in the mechanical installation of the porous plates and damping screens and the use of porous plates with more uniform porosity should reduce the freestream velocity fluctuations to the minimum acoustic levels of about 0.5 percent.

Piatt, M.↗
NASA NTRS1976

Monte Carlo calculations of diatomic molecule gas flows including rotational mode excitation

The direct simulation Monte Carlo method was used to solve the Boltzmann equation for flows of an internally excited nonequilibrium gas, namely, of rotationally excited homonuclear diatomic nitrogen. The semi-classical transition probability model of Itikawa was investigated for its ability to simulate flow fields far from equilibrium. The behavior of diatomic nitrogen was examined for several different nonequilibrium initial states that are subjected to uniform mean flow without boundary interactions. A sample of 1000 model molecules was observed as the gas relaxed to a steady state starting from three specified initial states. The initial states considered are: (1) complete equilibrium, (2) nonequilibrium, equipartition (all rotational energy states are assigned the mean energy level obtained at equilibrium with a Boltzmann distribution at the translational temperature), and (3) nonequipartition (the mean rotational energy is different from the equilibrium mean value with respect to the translational energy states). In all cases investigated the present model satisfactorily simulated the principal features of the relaxation effects in nonequilibrium flow of diatomic molecules.

Yoshikawa, K. K.↗
NASA NTRS1985

Experimental evaluation of an advanced Space Shuttle main engine hot-gas manifold design concept

This study, using an extensively modified, full-scale space shuttle main engine (SSME) hot-gas manifold (HGM), established a detailed aerodynamic data base to support development of an advanced, three-dimensional, fluid-dynamic analysis computer model. In addition, the advanced SSME hot-gas manifold design used in this study demonstrated improved flow environment (uniformity) in the fuel side turbine exit and transfer duct exit regions. Major modifications were incorporated in the full-scale HGM flow test article model using two large transfer ducts on the fuel turbine side of the HGM in place of the three small transfer ducts in the present design. Other model features included an increases in the flow areas downstream of the 180-degree turn and in the fishbowl regions.

Pelaccio, D. G.↗