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DOE OSTI2024

Direct mechanistic connection between acoustic signals and melt pool morphology during laser powder bed fusion

Various nondestructive diagnostic techniques have been proposed for in situ process monitoring of laser powder bed fusion (LPBF), including melt pool pyrometry, whole-layer optical imaging, acoustic emission, atomic emission spectroscopy, high speed melt pool imaging, and thermionic emission. Correlations between these in situ monitoring signals and defect formation have been demonstrated with acoustic signals having been shown to predict pore formation with especially high confidence in recent machine learning studies. Here, in this work, time-resolved acoustic data are collected in both the conduction and keyhole welding regimes of LPBF-processed Ti-6Al-4V alloy. A non-dimensionalized Strouhal number analysis, used in whistle aeroacoustics, is applied to demonstrate that the acoustic signals recorded in the keyhole regimes can be directly associated with the vapor depression morphology. This mechanistic understanding developed from whistle aeroacoustics shows that acoustic monitoring during the LPBF process can provide a direct probe into the vapor depression dynamics and defect occurrence, especially in the keyhole regimes relevant to printing and defect formation.

36 MATERIALS SCIENCE↗

NASA NTRS1978

Initial results of a porous plug nozzle for supersonic jet noise suppression

As part of a continuing study of possible methods of jet noise reduction, some tests have been made on a porous plug type noise suppressor. Very little information exists on the aeroacoustic performance of jet nozzles having porous elements designed to eliminate the shock wave in the exhaust stream and by so doing to eliminate the shock associated noise and screech. Some initial results on the aeroacoustic performance of a model porous plug type jet noise suppressor are presented. Included are shadowgraph pictures of the flow exhausting from the porous plug nozzle with the comparable acoustic far-field spectra and cross correlations which illustrate the benefits of the test device.

Maestrello, L.↗

NASA NTRS1982

Aerodynamic prediction I

The aerodynamic prediction methodology which is needed for rotor noise calculations is presented. Airloads and wakes, dynamic stall, compressible flow, and random loads are reviewed. The aerodynamics/acoustics interface is defined when the noise or measurements are considered. The classical approach involving a distinct separation of aerodynamic sources and acoustic propagation is the basis of most rotor noise calculations. Aeroacoustics of rotors involve unique features which are not encountered in other aerodynamic problems of rotors: (1) acoustics problems ultimately require only an order of magnitude estimate of the sound pressure field, consequently remarkably good noise predictions are obtained from very simple aerodynamic analyses; (2) aeroacoustics introduce an interest in the higher frequency aerodynamics, the deterministic aerodynamic phenomena are still low frequency, however, the high frequency noise comes from the acoustic propagation; and (3) the aerodynamic phenomena on rotors that are only of interest due to the noise they produce, are the random aerodynamic pressures on the blades.

Johnson, W.↗

NASA NTRS1984

Results of the AFRSI detailed-environment test of the 0.035-scale SSV pressure-loads model 84-0 in the Ames 11x11 ft. TWT and the Lewis 8x6 ft. and 10x10 ft. SWT (OA-310A, B, C), volume 1

Detailed orbiter aerodynamic and aeroacoustic pressure data were obtained in a three-part experimental investigation (OA-310A, B and C). The tests were conducted in three NASA facilities: OA-310A in the Ames 11x11-foot Transonic Wind Tunnel; OA-310B in the Lewis 8x6-foot Supersonic Wind Tunnel; and OA-310C in the Lewis 10x10-foot Supersonic Wind Tunnel. Test data were obtained to support analysis of the Space Transportation System (STS)-6 advanced flexible reusable surface insulation (AFRSI) anomaly using the 0.035-scale space shuttle vehicle pressure-loads Model 84-0. Data were obtained in the areas of the orbiter where AFRSI is to be applied to OV-099 and OV-103. Emphasis was placed on acquiring detailed aeroacoustic data and time-averaged pressure distributions on five affected areas: (1) canopy; (2) side of fuselage; (3) upper surface of wing; (4) OMS pods; and (5) vertical tail. Data were obtained at nominal ascent and entry atmospheric flight trajectory conditions between M=0.6 through M-3.5. Sample plotted data are given. aba M.G.

Marshall, B. A.↗

NASA NTRS1986

A comparison of the acoustic and aerodynamic measurements of a model rotor tested in two anechoic wind tunnels

Two aeroacoustic facilities--the CEPRA 19 in France and the DNW in the Netherlands--are compared. The two facilities have unique acoustic characteristics that make them appropriate for acoustic testing of model-scale helicopter rotors. An identical pressure-instrumented model-scale rotor was tested in each facility and acoustic test results are compared with full-scale-rotor test results. Blade surface pressures measured in both tunnels were used to correlated nominal rotor operating conditions in each tunnel, and also used to assess the steadiness of the rotor in each tunnel's flow. In-the-flow rotor acoustic signatures at moderate forward speeds (35-50 m/sec) are presented for each facility and discussed in relation to the differences in tunnel geometries and aeroacoustic characteristics. Both reports are presented in appendices to this paper. ;.);

Boxwell, D. A.↗

NASA NTRS1986

A comparison of the acoustic and aerodynamic measurements of a model rotor tested in two anechoic wind tunnels

Two aeroacoustic facilities - the CEPRA 19 in France and the DNW in the Netherlands - are compared. The two facilities have unique acoustic characteristics that make them appropriate for acoustic testing of model-scale helicopter rotors. An identical pressure-instrumented model-scale rotor was tested in each facility and acoustic test results are compared with full-scale-rotor test results. Blade surface pressures measured in both tunnels were used to correlated nominal rotor operating conditions in each tunnel, and also used to assess the steadiness of the rotor in each tunnel's flow. In-the-flow rotor acoustic signatures at moderate forward speeds (35-50 m/sec) are presented for each facility and discussed in relation to the differences in tunnel geometries and aeroacoustic characteristics. Both reports are presented in appendices to this paper.

Boxwell, D. A.↗

NASA NTRS1988

Research investigation of helicopter main rotor/tail rotor interaction noise

Acoustic measurements were obtained in a Langley 14 x 22 foot Subsonic Wind Tunnel to study the aeroacoustic interaction of 1/5th scale main rotor, tail rotor, and fuselage models. An extensive aeroacoustic data base was acquired for main rotor, tail rotor, fuselage aerodynamic interaction for moderate forward speed flight conditions. The details of the rotor models, experimental design and procedure, aerodynamic and acoustic data acquisition and reduction are presented. The model was initially operated in trim for selected fuselage angle of attack, main rotor tip-path-plane angle, and main rotor thrust combinations. The effects of repositioning the tail rotor in the main rotor wake and the corresponding tail rotor countertorque requirements were determined. Each rotor was subsequently tested in isolation at the thrust and angle of attack combinations for trim. The acoustic data indicated that the noise was primarily dominated by the main rotor, especially for moderate speed main rotor blade-vortex interaction conditions. The tail rotor noise increased when the main rotor was removed indicating that tail rotor inflow was improved with the main rotor present.

Fitzgerald, J.↗

NASA NTRS1989

Prediction of the spectrum of atmospheric microburst noise in the range 2-20 Hz - Preliminary results

An engineering estimate of the spectrum of atmospheric microburst noise radiation in the range 2-20 Hz is developed. This prediction is obtained via a marriage of standard aeroacoustic theory with a numerical computation of the relevant fluid dynamics. The 'computational aeroacoustics' technique applied here to the interpretation of atmospheric noise measurements is illustrative of a methodology that can now be employed in a wide class of problems.

Hardin, Jay C.↗

NASA NTRS1993

Numerical Simulation of a High Mach Number Jet Flow

The recent efforts to develop accurate numerical schemes for transition and turbulent flows are motivated, among other factors, by the need for accurate prediction of flow noise. The success of developing high speed civil transport plane (HSCT) is contingent upon our understanding and suppression of the jet exhaust noise. The radiated sound can be directly obtained by solving the full (time-dependent) compressible Navier-Stokes equations. However, this requires computational storage that is beyond currently available machines. This difficulty can be overcome by limiting the solution domain to the near field where the jet is nonlinear and then use acoustic analogy (e.g., Lighthill) to relate the far-field noise to the near-field sources. The later requires obtaining the time-dependent flow field. The other difficulty in aeroacoustics computations is that at high Reynolds numbers the turbulent flow has a large range of scales. Direct numerical simulations (DNS) cannot obtain all the scales of motion at high Reynolds number of technological interest. However, it is believed that the large scale structure is more efficient than the small-scale structure in radiating noise. Thus, one can model the small scales and calculate the acoustically active scales. The large scale structure in the noise-producing initial region of the jet can be viewed as a wavelike nature, the net radiated sound is the net cancellation after integration over space. As such, aeroacoustics computations are highly sensitive to errors in computing the sound sources. It is therefore essential to use a high-order numerical scheme to predict the flow field. The present paper presents the first step in a ongoing effort to predict jet noise. The emphasis here is in accurate prediction of the unsteady flow field. We solve the full time-dependent Navier-Stokes equations by a high order finite difference method. Time accurate spatial simulations of both plane and axisymmetric jet are presented. Jet Mach numbers of 1.5 and 2.1 are considered. Reynolds number in the simulations was about a million. Our numerical model is based on the 2-4 scheme by Gottlieb & Turkel. Bayliss et al. applied the 2-4 scheme in boundary layer computations. This scheme was also used by Ragab and Sheen to study the nonlinear development of supersonic instability waves in a mixing layer. In this study, we present two dimensional direct simulation results for both plane and axisymmetric jets. These results are compared with linear theory predictions. These computations were made for near nozzle exit region and velocity in spanwise/azimuthal direction was assumed to be zero.

Hayder, M. Ehtesham↗

NASA NTRS1993

In-flight near- and far-field acoustic data measured on the Propfan Test Assessment (PTA) testbed and with an adjacent aircraft

Flight tests to define the far-field tone source at cruise conditions were completed on the full-scale SR-7L advanced turboprop that was installed on the left wing of a Gulfstream 2 aircraft. This program, designated Propfan Test Assessment (PTA), involved aeroacoustic testing of the propeller over a range of test conditions. These measurements defined source levels for input into long-distance propagation models to predict en route noise. In-flight data were taken for seven test cases. Near-field acoustic data were taken on the Gulfstream fuselage and on a microphone boom that was mounted on the Gulfstream wing outboard of the propeller. Far-field acoustic data were taken by an acoustically instrumented Learjet that flew in formation with the Gulfstream. These flight tests were flown from El Paso, Texas, and from the NASA Lewis Research Center. A comprehensive listing of the aeroacoustic results from these flight tests which may be used for future analysis are presented.

Woodward, Richard P.↗

NASA NTRS1993

User's manual for UCAP: Unified Counter-Rotation Aero-Acoustics Program

This is the user's manual for the Unified Counter-rotation Aeroacoustics Program (UCAP), the counter-rotation derivative of the UAAP (Unified Aero-Acoustic Program). The purpose of this program is to predict steady and unsteady air loading on the blades and the noise produced by a counter-rotation Prop-Fan. The aerodynamic method is based on linear potential theory with corrections for nonlinearity associated with axial flux induction, vortex lift on the blades, and rotor-to-rotor interference. The theory for acoustics and the theory for individual blade loading and wakes are derived in Unified Aeroacoustics Analysis for High Speed Turboprop Aerodynamics and Noise, Volume 1 (NASA CR-4329). This user's manual also includes a brief explanation of the theory used for the modelling of counter-rotation.

Culver, E. M.↗

NASA NTRS1994

A method for obtaining a statistically stationary turbulent free shear flow

The long-term goal of the current research is the study of Large-Eddy Simulation (LES) as a tool for aeroacoustics. New algorithms and developments in computer hardware are making possible a new generation of tools for aeroacoustic predictions, which rely on the physics of the flow rather than empirical knowledge. LES, in conjunction with an acoustic analogy, holds the promise of predicting the statistics of noise radiated to the far-field of a turbulent flow. LES's predictive ability will be tested through extensive comparison of acoustic predictions based on a Direct Numerical Simulation (DNS) and LES of the same flow, as well as a priori testing of DNS results. The method presented here is aimed at allowing simulation of a turbulent flow field that is both simple and amenable to acoustic predictions. A free shear flow is homogeneous in both the streamwise and spanwise directions and which is statistically stationary will be simulated using equations based on the Navier-Stokes equations with a small number of added terms. Studying a free shear flow eliminates the need to consider flow-surface interactions as an acoustic source. The homogeneous directions and the flow's statistically stationary nature greatly simplify the application of an acoustic analogy.

Timson, Stephen F.↗

NASA NTRS1995

Investigation of dispersion-relation-preserving scheme and spectral analysis methods for acoustic waves

Important characteristics of the aeroacoustic wave propagation are mostly encoded in their dispersion relations. Hence, a computational aeroacoustic (CAA) algorithm, which reasonably preserves these relations, was investigated. It was derived using an optimization procedure to ensure, that the numerical derivatives preserved the wave number and angular frequency of the differential terms in the linearized, 2-D Euler equations. Then, simulations were performed to validate the scheme and a compatible set of discretized boundary conditions. The computational results were found to agree favorably with the exact solutions. The boundary conditions were transparent to the outgoing waves, except when the disturbance source was close to a boundary. The time-domain data generated by such CAA solutions were often intractable until their spectra was analyzed. Therefore, the relative merits of three different methods were included in the study. For simple, periodic waves, the periodogram method produced better estimates of the steep-sloped spectra than the Blackman-Tukey method. Also, for this problem, the Hanning window was more effective when used with the weighted-overlapped-segment-averaging and Blackman-Tukey methods gave better results than the periodogram method. Finally, it was demonstrated that the representation of time domain-data was significantly dependent on the particular spectral analysis method employed.

Vanel, Florence O.↗

NASA NTRS1996

Numerical Algorithms for Acoustic Integrals - The Devil is in the Details

The accurate prediction of the aeroacoustic field generated by aerospace vehicles or nonaerospace machinery is necessary for designers to control and reduce source noise. Powerful computational aeroacoustic methods, based on various acoustic analogies (primarily the Lighthill acoustic analogy) and Kirchhoff methods, have been developed for prediction of noise from complicated sources, such as rotating blades. Both methods ultimately predict the noise through a numerical evaluation of an integral formulation. In this paper, we consider three generic acoustic formulations and several numerical algorithms that have been used to compute the solutions to these formulations. Algorithms for retarded-time formulations are the most efficient and robust, but they are difficult to implement for supersonic-source motion. Collapsing-sphere and emission-surface formulations are good alternatives when supersonic-source motion is present, but the numerical implementations of these formulations are more computationally demanding. New algorithms - which utilize solution adaptation to provide a specified error level - are needed.

Brentner, Kenneth S.↗

NASA NTRS1996

Introduction to computational aero-acoustics

Computational aeroacoustics (CAA) is introduced, by presenting its definition, advantages, applications, and initial challenges. The effects of Mach number and Reynolds number on CAA are considered. The CAA method combines the methods of aeroacoustics and computational fluid dynamics.

Hardin, Jay C.↗

NASA NTRS1996

Turbulent Inflow Measurements

In the present research, tilt rotor aeroacoustics have been studied experimentally and computationally. Experimental measurements were made on a 1/12.5 scale model. A dimensional analysis showed that the model was a good aeroacoustic approximation to the full-scale aircraft, and scale factors were derived to extrapolate the model measurements to the full-scale XV-15. The experimental measurements included helium bubble flow visualization, silk tuft flow visualization, 2-component hot wire anemometry, 7-hole pressure probe measurements, vorticity measurements, and outdoor far field acoustic measurements. The hot wire measurements were used to estimate the turbulence statistics of the flow field into the rotors, such as length scales, velocity scales, dissipation, and turbulence intermittency. To date, these flow measurements are the only ones in existence for a hovering tilt rotor. Several different configurations of the model were tested: (1) standard configurations (single isolated rotor, two rotors without the aircraft, standard tilt rotor configuration); (2) flow control devices (the 'plate', the 'diagonal fences'); (3) basic configuration changes (increasing the rotor/rotor spacing, reducing the rotor plane/wing clearance, operating the rotors out of phase). Also, an approximation to Sikorsky's Variable Diameter Tilt Rotor (VDTR) configuration was tested, and some flow measurements were made on a semi-span configuration of the model. Acoustic predictions were made using LOWSON.M, a Mathematica code. This hover prediction code, from HOVER.FOR, used blade element theory for the aerodynamics, and Prandtl's Vortex theory to model the wake, along with empirical formulas for the effects of Reynolds number, Mach number, and stall. Aerodynamic models were developed from 7-hole pressure probe measurements of the mean velocity into the model rotors. LOWSON.M modeled a rotor blade as a single force and source/sink combination separated in the chordwise direction, at an effective blade radius. Spanwise, Mach-weighted integrals were used to find the equivalent forces and equivalent source strengths.

George, Albert R.↗

NASA NTRS1997

A Three-Dimensional Linearized Unsteady Euler Analysis for Turbomachinery Blade Rows

A three-dimensional, linearized, Euler analysis is being developed to provide an efficient unsteady aerodynamic analysis that can be used to predict the aeroelastic and aeroacoustic responses of axial-flow turbo-machinery blading.The field equations and boundary conditions needed to describe nonlinear and linearized inviscid unsteady flows through a blade row operating within a cylindrical annular duct are presented. A numerical model for linearized inviscid unsteady flows, which couples a near-field, implicit, wave-split, finite volume analysis to a far-field eigenanalysis, is also described. The linearized aerodynamic and numerical models have been implemented into a three-dimensional linearized unsteady flow code, called LINFLUX. This code has been applied to selected, benchmark, unsteady, subsonic flows to establish its accuracy and to demonstrate its current capabilities. The unsteady flows considered, have been chosen to allow convenient comparisons between the LINFLUX results and those of well-known, two-dimensional, unsteady flow codes. Detailed numerical results for a helical fan and a three-dimensional version of the 10th Standard Cascade indicate that important progress has been made towards the development of a reliable and useful, three-dimensional, prediction capability that can be used in aeroelastic and aeroacoustic design studies.

Montgomery, Matthew D.↗

NASA NTRS1997

Computational Considerations for the Simulation of Discontinuous Flows

The numerical study of aeroacoustic problems places stringent demands on the choice of a computational algorithm, because it requires the ability to propagate disturbances of small amplitude and short wavelength. The demands are particularly high when shock waves are involved, because the chosen algorithm must also resolve discontinuities in the solution. In a previous work the capabilities and deficiencies of shock-capturing methods for aeroacoustic problems were demonstrated using a high-order essentially nonoscillatory (ENO) numerical method. It was shown that first-order results are obtained when simulating time-dependent flows with discontinuities. The present study reaffirms this conclusion by comparing the ENO results with those obtained using a conventional linear scheme. A sixth-order-accurate compact implicit finite difference scheme is used to investigate various discontinuous flows. The design order of accuracy is achieved in the smooth regions of a steady-state, quasi-one-dimensional Euler test case, as well as in the time-dependent Burgers' equation. However, in the unsteady Euler sound-shock interaction, first-order results are obtained downstream of the shock. A comparison is made between the linear and nonlinear results, noting the advantages of each method. A discontinuous linear model problem is then used to identify the cause of the first-order results. Here, the nature of the solution error is quantified as being predominantly a numerical phase shift, and a post-processing procedure is demonstrated which increases the solution accuracy downstream of the discontinuity to second-order.

Carpenter Mark H.↗