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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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All sourcesNASA NTRSDOE OSTI
NASA NTRS1993

Turbulence modeling of free shear layers for high performance aircraft

In many flowfield computations, accuracy of the turbulence model employed is frequently a limiting factor in the overall accuracy of the computation. This is particularly true for complex flowfields such as those around full aircraft configurations. Free shear layers such as wakes, impinging jets (in V/STOL applications), and mixing layers over cavities are often part of these flowfields. Although flowfields have been computed for full aircraft, the memory and CPU requirements for these computations are often excessive. Additional computer power is required for multidisciplinary computations such as coupled fluid dynamics and conduction heat transfer analysis. Massively parallel computers show promise in alleviating this situation, and the purpose of this effort was to adapt and optimize CFD codes to these new machines. The objective of this research effort was to compute the flowfield and heat transfer for a two-dimensional jet impinging normally on a cool plate. The results of this research effort were summarized in an AIAA paper titled 'Parallel Implementation of the k-epsilon Turbulence Model'. Appendix A contains the full paper.

Sondak, Douglas↗
NASA NTRS1982

Flow distributions and discharge coefficient effects for jet array impingement with initial crossflow

To model the impingement cooled mid-chord region of gas turbine airfoils in cases where an initial crossflow is present, the paper presents experimentally determined flow distributions for jet arrays with ten spanwise rows of holes, which range from uniform to highly nonuniform. The jet flow after impingement is constrained to exit in a single direction along the channel formed by the jet orifice plate and the impingement surface. The streamwise distributions and crossflow velocities are presented for ratios of the initial crossflow rate to the total jet flow rate ranging from zero to unity. For crossflow to jet velocity ratios greater than a value somewhat less than unity, jet orifice discharge coefficients do not remain constant, but decrease significantly, showing a secondary dependence on z/d, where z is the channel height and d is the jet hole diameter.

Florschuetz, L. W.↗
NASA NTRS1993

Fluid flow and heat convection studies for actively cooled airframes

This report details progress made on the jet impingement - liquid crystal - digital imaging experiment. With the design phase complete, the experiment is currently in the construction phase. In order to reach this phase two design related issues were resolved. The first issue was to determine NASP leading edge active cooling design parameters. Meetings were arranged with personnel at SAIC International, Torrance, CA in order to obtain recent publications that characterized expected leading edge heat fluxes as well as other details of NASP operating conditions. The information in these publications was used to estimate minimum and maximum jet Reynolds numbers needed to accomplish the required leading edge cooling, and to determine the parameters of the experiment. The details of this analysis are shown in Appendix A. One of the concerns for the NASP design is that of thermal stress due to large surface temperature gradients. Using a series of circular jets to cool the leading edge will cause a non-uniform temperature distribution and potentially large thermal stresses. Therefore it was decided to explore the feasibility of using a slot jet to cool the leading edge. The literature contains many investigations into circular jet heat transfer but few investigations of slot jet heat transfer. The first experiments will be done on circular jets impinging on a fiat plate and results compared to previously published data to establish the accuracy of the method. Subsequent experiments will be slot jets impinging on full scale models of the NASP leading edge. Table 1 shows the range of parameters to be explored. Next a preliminary design of the experiment was done. Previous papers which used a similar experimental technique were studied and elements of those experiments adapted to the jet impingement study. Trade-off studies were conducted to determine which design was the least expensive, easy to construct, and easy to use. Once the final design was settled, vendors were contacted to verify that equipment could be obtained to meet our specifications. Much of the equipment required to complete the construction of the experiment has been ordered or received. The material status list is shown in Appendix B.

Mills, A. F.↗
NASA NTRS1983

Gear Lubrication and Cooling Experiment and Analysis

A gear tooth temperature analysis was performed using a finite element method combined with a calculated heat input, a calculated oil jet impingement depth, and estimated heat transfer coefficients for the different parts of the gear tooth that are oil cooled and air cooled. Experimental measurements of gear tooth average surface temperature and gear tooth instantaneous surface temperature were made with a fast response, infrared, radiometric microscope. Increasing oil pressure has a significant effect on both average surface temperature and peak surface temperature at loads above 1895 N/cm(1083 lb/in) and speeds of 10,000 and 7500 rpm. Both increasing speed (from 5000 to 10,000 rpm) at constant speed cause a significant rise in the average surface temperature and in the instantaneous peak surface temperatures on the gear teeth. The oil jet pressure required to provide the best cooling for gears is the pressure required to obtain full gear tooth impingement. Calculated results for gear tooth temperatures were close to experimental results for various oil jet impingement depths for identical operating conditions.

Townsend, D. P.↗
NASA NTRS1976

Measurements of mean flow and acoustic power for a subsonic jet impinging normal to a large rigid surface

An experimental study was made to measure the mean flow field and acoustic power of a subsonic jet impinging normal to a large rigid surface. A 6.25 cm diameter, circular cool air jet was used at heights of 20, 10, and 5 jet diameters above the surface. The jet exit Mach number was varied from 0.28 to 0.93. Impact and static pressure surveys were made in directions both axial and lateral to the jet axis and also parallel and perpendicular to the surface. Acoustic power was calculated from microphone measurements made during each test run using a diffuse field calibration for the test facility. Results indicate that the flow field for jet impingement is characterized mainly by a strong rise in static pressure in the impingement region near the surface and by boundary layer development in the wall jet region. Acoustic power measurements generally followed a U(8) law for both the free jet and jet impingement although there was some variation especially at high Mach number and for close impingement distances. Overall noise levels increased with decreasing jet-to-surface height. Normalized power spectra correlated well for all cases when the Strouhal number was greater than 0.2; the correlation was poor when the Strouhal number was low.

Schloth, A. P.↗
NASA NTRS1981

Heat transfer from a row of impinging jets to concave cylindrical surfaces

Starting from the first principles, and with one experimentally obtained parameter, an expression for stagnation heat transfer is derived, applicable to round, impinging jets. The results obtained with a row of air jets impinging on an electrically-heated surface in a small-scale setup characteristic of a typical turbine blade have been found compatible with the average heat transfer from a geometrically similar, steam-heated surface scaled up ten times, and comparable with the results of other investigators. These findings were linked to the flow fields likely to exist in the gas turbine blades, internally cooled by a row of round jets or a single jet of equivalent width. The magnitude of heat-transfer coefficients obtained here with impinging jets approaches that normally associated with forced convection of water and evaporative cooling.

Hrycak, P.↗
DOE OSTI2023

Integrated Traction Drive Thermal Management: Keystone Project 3

The presentation represents a report of accomplishments during FY 2022 and is prepared for 2022 DOE VTO Annual Merit Review. The project goal is facilitation of achieving DOE 2025 target of 33 kW/L system power density for an electric traction drive through support of other EDT consortium members in design and development of thermal management systems for their respective integrated drive concepts. Namely, identifying pathways enabling high-performance, compact, and reliable integrated electric drives. Specific objectives are: 1) Research and evaluation of motor-integrated power electronics packaging technologies and thermal management approaches. 2) Development of thermal management system and its sub-components to enable integrated electric drive DOE power density targets in collaboration with project partners. 3) Supporting activities of DOE's Electric Drive Technologies (EDT) consortium members, Oak Ridge National Laboratory (ORNL) and University of Wisconsin research teams in thermal management component design and thermal modeling of their integrated traction drives. 4) Identifying candidate driveline fluids suitable for direct cooling of traction-drive components and high-voltage power electronics and evaluate their convective cooling performance.

ADVANCED PROPULSION SYSTEMS↗
NASA NTRS1983

Heat transfer characteristics for jet array impingement with initial crossflow

Two-dimensional arrays of circular air jets impinging on a heat transfer surface parallel to the jet orifice plate are considered. The jet flow, after impingement, is constrained to exit in a single direction along the channel formed by the jet orifice plate and the heat transfer surface. In addition to the crossflow which originates from the jets following impingement, an initial crossflow is present which approaches the array through an upstream extension of the channel. The temperature of the initial crossflow air may differ from the jet air temperature. The configurations considered are intended to model the impingement cooled midchord region of gas turbine airfoils in cases where an initial crossflow is also present. Nusselt numbers and dimensionless adiabatic wall temperatures resolved to one streamwise jet hole spacing were experimentally determined for ratios of the initial crossflow rate to the total jet flow rate ranging from zero to unity. These are presented and discussed relative to the flow and geometric parameters.

Florschuetz, L. W.↗
NASA NTRS1980

Multiple jet impingement heat transfer characteristic: Experimental investigation of in-line and staggered arrays with crossflow

Heat transfer characteristics were obtained for configurations designed to model the impingement cooled midchord region of air cooled gas turbine airfoils. The configurations tested were inline and staggered two-dimensional arrays of circular jets with ten spanwise rows of holes. The cooling air was constrained to exit in the chordwise direction along the channel formed by the jet orifice plate and the heat transfer surface. Tests were run for chordwise jet hole spacings of five, ten, and fifteen hole diameters; spanwise spacings of four, six, and eight diameters; and channel heights of one, two, three, and six diameters. Mean jet Reynolds numbers ranged from 5000 to 50,000. The thermal boundary condition at the heat transfer test surface was isothermal. Tests were run for sets of geometrically similar configurations of different sizes. Mean and chordwise resolved Nusselt numbers were determined utilizing a specially constructed test surface which was segmented in the chordwise direction.

Florschuetz, L. W.↗
NASA NTRS1983

Jet array impingement heat transfer characteristics

Two dimensional arrays of circular air jets impinging on a heat transfer surface parallel to the jet orifice plate are considered. The jet flow, after impingement, is constrained to exit in a single direction along the channel formed by the jet orifice plate and the heat transfer surface. In addition to the crossflow which originates from the jets following impingement, an initial crossflow is present which approaches the array through an upstream extension of the channel. The configurations considered are intended to model the impingement cooled midchord region of gas turbine airfoils in cases where an initial crossflow is also present. A major objective is determination of the effect of initial crossflow air temperature relative to jet array air temperature on impingement surface heat fluxes.

Florschuetz, L. W.↗
NASA NTRS1982

Jet array impingement flow distributions and heat transfer characteristics: Effects of initial crossflow and nonuniform array geometry

Flow distributions and heat transfer characteristics for two-dimensional arrays of circular air jets impinging on a surface parallel to the jet orifice plate were determined. The configurations considered were intended to model those of interest in current and contemplated gas turbine airfoil midchord cooling applications. The geometry of the airfoil applications considered dictates that all of the jet flow, after impingement, exit in the chordwise (i.e., streamwise) direction toward the trailing edge. Experimental results for the effect of an initial crossflow on both flow distributions and heat transfer characteristics for a number of the prior uniform array geometries. The effects of nonuniform array geometries on flow distributions and heat transfer characteristics for noninitial crossflow configurations are discussed.

Florschuetz, L. W.↗
DOE OSTI2025

Overall Cooling Effectiveness of Internally Cooled Additively Manufactured Blades

Power generation gas turbine blades must utilize highly effective cooling schemes to withstand moderate heat loads for long operating times. Prior work indicates that gas turbines in the 5-10 MW range primarily utilize internal cooling to prevent further increase of aerodynamic losses that result from film cooling, but few studies focus solely on internal cooling. In this study, three additively manufactured internal cooling designs were tested in the 50 percent span section of the National Experimental Turbine (NExT) blade: a baseline cooling design with pin-fin arrays and rib turbulators, a double wall design with impingement jets and serpentine channels, and an incremental impingement design. The designs were tested in a high-speed linear cascade at exit Reynolds numbers ranging from 700,000 to 1,400,000 at an exit Mach of 0.8. In addition, freestream turbulence and build angle effects on cooling performance were studied.

gas turbine blades↗
NASA NTRS1990

Experimental studies of shock wave/wall jet interaction in hypersonic flow

The interaction between a planar shock wave and a wall jet produced by slot cooling in turbulent hypersonic flow was experimentally studied. Detailed distributions of heat transfer and pressure are obtained in the incident shock/wall jet interaction region for a series of shock strengths and impingement positions for two nozzle heights. The major result is that the cooling film could be readily dispersed by relatively weak incident shocks such that the peak heating in the recompression region was not significantly reduced by even the largest levels of film cooling. Regions of boundary layer separation were induced in the film cooling layer, the size of which first increased and then decreased with increasing film cooling. The size of the separated regions and magnitude of the recompression heating were not strongly influenced by the thickness of the cooling film or point of shock impingement relative to the exit plane of the nozzles.

Holden, Michael S.↗
NASA NTRS1992

Numerical evaluation of single central jet for turbine disk cooling

The cooling arrangement of the Space Shuttle Main Engine High Pressure Oxidizer Turbopump (HPOTP) incorporates two jet rings, each of which produces 19 high-velocity coolant jets. At some operating conditions, the frequency of excitation associated with the 19 jets coincides with the natural frequency of the turbine blades, contributing to fatigue cracking of blade shanks. In this paper, an alternate turbine disk cooling arrangement, applicable to disk faces of zero hub radius, is evaluated, which consists of a single coolant jet impinging at the center of the turbine disk. Results of the CFD analysis show that replacing the jet ring with a single central coolant jet in the HPOTP leads to an acceptable thermal environment at the disk rim. Based on the predictions of flow and temperature fields for operating conditions, the single central jet cooling system was recommended for implementation into the development program of the Technology Test Bed Engine at NASA Marshall Space Flight Center.

Subbaraman, M. R.↗
DOE OSTI2023

Automotive Silicon Carbide Power Module Cooling With A Novel Modular Manifold And Embedded Heat Sink

The next generation of integrated power electronics packages will implement wide-bandgap devices with ultrahigh device heat fluxes. Although jet impingement has received attention for power electronics thermal management, it is not used in commercial electric vehicles (EVs) because of the associated pressure drop and reliability concerns. Here, in this paper, we present a modular thermal management system designed for automotive power electronics. The system achieves superior thermal performance to benchmarked EVs, while adhering to reliability standards and with low pumping power. The system utilizes a low-cost and lightweight plastic manifold to generate jets over an optimized heat sink, which is embedded in the direct-bonded-copper (DBC) substrate. The embedded heat sink concept leverages additive manufacturing to add elliptical pin fins to the DBC substrate. The heat sink geometry is optimized for submerged jet impingement using a unit-cell model and an exhaustive search algorithm. The model predictions are validated using unit-cell experiments. A full-scale power module model is then used to compare the DBC-embedded heat sink against direct DBC cooling and baseplate-integrated heat sinks for single-sided (SS) and double-sided (DS) cooling concepts. Using the SS and DS DBC-embedded cooling concepts, the models predict a thermal resistance that represents a reduction of 75% and 85% compared to the 2015 BMW i3, respectively, for the same water-ethylene glycol inverter flow rate. We have shown that an inverter with a 100-kilo-Watt-per-liter power density is achievable with the proposed design.

33 ADVANCED PROPULSION SYSTEMS↗
NASA NTRS1998

Design, Operation, and Modeling of a Vertical APCVD Reactor for Silicon Carbide Film Growth

An atmospheric pressure chemical vapor deposition (APCVD) reactor utilizing a unique vertical geometry which enables 3C-SiC films to be grown on two, 4-inch diameter Si wafers has been constructed. Contrary to expectations, 3C-SiC films grown in this reactor are thickest at the downstream end of the substrates. To better understand the reason for the thickness distribution on the wafers, an axisymmetric finite-element model of the gas flow in the reactor was constructed. The model uses the ANSYS53 Flowtran package and includes compressible and temperature-dependent fluid properties in laminar or turbulent flow. It does not include reaction chemistry or unsteady flow. The ANSYS53 results predict that the cool, inlet fluid falls through the inlet pipe and the warm, diffuser region like a jet. This jet impinges on top of the susceptor and gets diverted to the reactor side walls, where it flows to the bottom of the reactor, turns, and slowly rises along the face of the susceptor. This may explain why the SiC films are thickest at the downstream side of the wafers, as gas containing fresh reactants first passes over this region. Modeling results are presented for both one atmosphere and one half atmosphere reactor pressure.

DeAnna, Russell G.↗
NASA NTRS1993

Local heat transfer measurement with liquid crystals on rotating surfaces including non-axisymmetric cases

An overview and summary of test methods and results are given for the problem of measuring local heat transfer on rotating surfaces that model gas turbine engine disks. Disk cavity situations generically similar to those encountered in the high pressure stage disk cooling are considered, with cooling air supplied both at or near the wheel centerline as well as through single or multiple jets impinging outboard on the wheel near the blade attachment region. In some situations provision has been made for ingestion into the disk-cavity from the gas path region radially outboard of the disk. Local heat transfer rates in all cases are determined from the color display from a thin coating of encapsulated liquid crystals sprayed onto the disk, in conjunction with use of a video camera and computer vision system. For cases with axisymmetric disk surfaces, the coated surfaces are illuminated and viewed continuously, and detailed radial distributions of local Nusselt number are obtained. For non-axisymmetric disk surfaces, such as encountered in the vicinity of bolt heads, the disk is illuminated with stroboscopic light, and a method has been developed and used to synchronize the computer frame grabber with the illumination.

Metzger, D. E.↗
DOE OSTI2022

CFD simulations of electric motor end ring cooling for improved thermal management

Proper thermal management of an electric motor for vehicle applications extends its operating range. One cooling approach is to impinge Automatic Transmission Fluid (ATF) onto the rotor end ring. Increased ATF coverage correlates to enhanced heat transfer. Computational Fluid Dynamics (CFD) analytical tools provide a mechanism to assess motor thermal management prior to hardware fabrication. The complexity of the fluid flow (e.g., jet atomization, interface tracking, wall impingement) and heat transfer makes these simulations challenging. Computational costs are high when solving these flows on high-speed rotating meshes. Typically, a Volume-of Fluid (VOF) technique (i.e., two-fluid system) is used to resolve ATF dynamics within this rotating framework. Suitable numerical resolution of the relevant physics for thin films under strong inertial forces at high rotor speeds is computationally expensive, further increasing the run times. In this work, a numerical study of rotor-ring cooling by ATF is presented using a patent automated Cartesian cut-cell based method coupled with Automatic Mesh Refinement (AMR). This approach automatically creates the Cartesian mesh on-the-fly and can effectively handle complex rotating geometries by adaptively refining the mesh based on local gradients in the flow field which results in better resolution of the air-ATF interface. A Single non-inertial Reference Frame (SRF) approach is used to account for the rotating geometry and to further improve the overall computational efficiency. Quasi-steady state conditions are targeted in the analysis of the results. Important physics such as ATF jet structure, velocity detail near the air-jet interface, ATF coverage/accumulation on the ring surface, and cooling capacity are presented for a low-resolution Reynolds averaged Navier-Stokes (RANS), high-resolution RANS, and high-resolution Large-Eddy Simulation (LES) models. Computations are scaled over hundreds of cores on a supercomputer to maximize turnaround time. Each numerical approach is shown to capture the general trajectory of the oil jet prior to surface impingement. The high-resolution LES simulation, however, is superior in capturing small scale details and heat transfer between the free jet and surrounding air.

42 ENGINEERING↗