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At least 73 records · Page 4

Forward Skirt Structural Testing on the Space Launch System (SLS) Program

Structural testing was performed to evaluate heritage forward skirts from the Space Shuttle program for use on the Space Launch System (SLS) program. One forward skirt is located in each solid rocket booster. Heritage forward skirts are aluminum 2219 welded structures. Loads are applied at the forward skirt thrust post and ball assembly. Testing was needed because SLS ascent loads are roughly 40% higher than Space Shuttle loads. Testing objectives were to determine margins of safety, demonstrate reliability, and validate analytical models. Two forward skirts were structurally tested using the test configuration. The test stand applied loads to the thrust post. Four hydraulic actuators were used to apply axial load and two hydraulic actuators were used to apply radial and tangential loads. The first test was referred to as FSTA-1 (Forward Skirt Structural Test Article) and was performed in April/May 2014. The purpose of FSTA-1 was to verify the ultimate capability of the forward skirt subjected to ascent ultimate loads. Testing consisted of two liftoff load cases taken to 100% limit load followed by an ascent load case taken to 110% limit load. The forward skirt was unloaded to no load after each test case. Lastly, the forward skirt was tested to 140% limit and then to failure using the ascent loads. The second test was referred to as FSTA-2 and performed in July/August of 2014. The purpose of FSTA-2 was to verify the ultimate capability of the forward skirt subjected to liftoff ultimate loads. Testing consisted of six liftoff load cases taken to 100% limit load followed by the six liftoff cases taken to 140% limit load. Two ascent load cases were then tested to 100% limit load. The forward skirt was unloaded to no load after each test case. Lastly, the forward skirt was tested to 140% limit and then to failure using the ascent loads. The forward skirts on FSTA-1 and FSTA-2 successfully carried all applied liftoff and ascent load cases. Both FSTA-1 and FSTA-2 were tested to failure by increasing the ascent loads. Failure occurred in the forward skirt thrust post radius. The forward skirts on FSTA-1 and FSTA-2 had nearly identical failure modes. FSTA-1 failed at 1.72 times limit load and FSTA-2 failed at 1.62 times limit load. This difference is primarily attributed to variation in material properties in the thrust post region. Test data were obtained from strain gages, deflection gages, ARAMIS digital strain measurement, acoustic emissions, and high-speed video. Strain gage data and ARAMIS strain were compared to finite element (FE) analysis predictions. Both the forward skirt and tooling were modeled. This allows the analysis to simulate the loading as close as possible to actual test configuration. FSTA-1 and FSTA-2 were instrumented with over 200 strain gages to ensure all possible failure modes could be captured. However, it turned out that three gages provided critical strain data. One was located in the post bore and two on the post radius. More gages were not specified due to space limitations and the desire to not interfere with the use of the ARAMIS system on the post radius. Measured strains were compared to analysis results for the load cycle to failure. Note that FSTA-1 gages were lost before failure was reached. FSTA-2 gages made it to the failure load but one of the radius gages was lost before testing began. This gage was not replaced because of the time and cost associated with disassembly of the test structure. Correlation to analysis was excellent for FSTA-1. FSTA-2 was not quite as good because there was more residual strain from previous load cycles. FSTA-2 was loaded and unloaded with 12 liftoff cases and two ascent cases before taking the skirt to failure. FSTA-1 only had two liftoff cases and one ascent case before taking the skirt to failure. The ARAMIS system was used to determine strain at the post radius by processing digital images of a speckled paint pattern. Digital cameras recorded images of the speckled paint pattern. ARAMIS strain results for FSTA-2 just prior to failure. Note a high strain location develops near the left side. This high strain compares well to analysis prediction for both FSTA-1 and FSTA-2. The strain at this location was also plotted versus limit load. Both FSTA-1 and FSTA-2 had excellent correlation between ARAMIS and analysis strains. Acoustic emission (AE) sensors were used to monitor for damage formation that may occur during testing (e.g., crack formation and growth or propagation). AE was very important because after disassembly of FSTA-1, a crack was observed in the ball fitting radius. The ball fitting did not crack on FSTA-2. AE data was used to reconstruct when the crack occurred. The AE energy versus time plot for FSTA. The energy increased considerably at 850 seconds (152% limit load), indicating a crack could have formed at this point. The only visual evidence found that could have corresponded to this was the crack that initiated in the ball fitting. The cracks in the forward skirt aluminum structures would likely have been lower energy due to a lower modulus and all that were found after failure correlated to occurring after the initial crack in the post radius. This was verified by high-speed cameras used to record the failure.

Lohrer, J. D.↗

Phase Contrast X‐Ray Imaging of the Collapse of an Engineered Void in Single‐Crystal HMX

Abstract Imaging the collapse of a single void that creates a hot spot initiation site in an otherwise defect‐free explosive is challenging given the spatial and temporal scales involved in explosive systems. This work presents our attempt to examine a single hot spot mode (void collapse) in single‐crystal octahydro‐l,3,5,7‐tetranitro‐l,3,5,7‐tetrazocine (HMX) embedded in Sylgard. The hot spot heating mechanisms involved with pore collapse include adiabatic heating, jetting, and viscoplastic dissipation. Quantifying the dynamics of a pore collapse is a crucial step to understanding which mechanisms dominate during ignition events. Our experiments were conducted with a single‐stage, light‐gas gun at Argonne National Laboratory's Advanced Photon Source, applying the phase contrast imaging technique while collecting high‐speed video. The details of HMX single crystal production, defect (pore) engineering, and sample construction, along with experimental results are presented here. These results demonstrate that detailed collapse dynamics can be obtained from homogeneous, single‐crystal explosives with this approach. Qualitative comparisons are made with simulation data which show good agreement in the transition between a quasi‐symmetric pore collapse and an asymmetric collapse with jetting across the pore as measured with normalized pore area and pore circularity.

42 ENGINEERING↗

Safe passage of American Eels through a novel hydropower turbine

Abstract Objective Study the effects of downstream passage through a novel turbine designed for fish safety, the Restoration Hydro Turbine (RHT), on American Eels Anguilla rostrata in a recirculating turbine test facility. Methods A 55‐cm‐diameter RHT was operated under 10 m of hydraulic head and 667 revolutions/min. In total, 131 eels were passed through the turbine and 43 eels were used as experimental controls (length = 33.9–65.5 cm). High‐speed video of passage through the runner region was captured for 89% of turbine‐passed eels, and injury and behavioral effects were recorded immediately before and after passage, as well as after a 48‐h holding period. A subset of 37 eels was additionally examined with X‐ray imaging for internal injuries. Result The 48‐h survival rate for both treatment and control groups was 100%, with no major internal or external injuries present after the holding period. Conclusion This is a substantial improvement over eel survival rates through conventional Kaplan and Francis turbines, which may range from 40% to 95%, and suggests that hydropower turbines designed for safe downstream fish passage could be implemented without major impacts to eels.

59 BASIC BIOLOGICAL SCIENCES↗

New electric force and charge exchange modules in discrete element model enables particle dynamics simulation in electric field

Discrete element modeling (DEM) is an important technique for particle dynamics simulation. The field of metal additive manufacturing often utilizes DEM to simulate the rheological behaviors of powder. Standard contact and short-range interactions are sufficient in most cases but insufficient to describe the particle dynamics with the influence of an electric field. Modeling such a system requires additional physics to describe the particle–field interactions. The relevant physics has been experimentally understood but is not yet available in DEM. Here, we develop a charge exchange and an electric force module. The electric force module governs particle response to the electric field, while the charge exchange module enables particles to acquire proper charge during contact with charged geometries. We validate the modules against analytical calculations and high-speed videos of electrostatic powder deposition experiments. Notably, the model struggles to capture the initial particle levitation. We later deploy a modified electric field, as supported by static electric field simulation, to better approximate the electric field penetration into the powder layer. This modification improves the model’s capability of simulating realistic particle levitation. The results highlight the challenges of modeling particle behaviors in the electric field while demonstrating the feasibility of obtaining quantitative results, which are difficult to measure experimentally.

charge exchange↗

Effect of PVD-coated chromium on the subcooled flow boiling performance of nuclear reactor cladding materials

Here we elucidate the separate effect of a thin Cr coating deposited by physical vapor deposition (PVD) on the subcooled flow boiling performance of zircaloy-4. First, we run flow boiling experiments on prototypical zircaloy-4 surfaces mimicking the scratch pattern and surface roughness of nuclear reactor claddings. Then, we PVD-coat a 0.3 µm thick chromium layer on the same exact surface and repeat the same flow boiling investigations. All experiments are run using deionized water at atmospheric pressure, flowing on a 1 × 3 cm 2 rectangular cross section channel at a rate of 1000 kg/m 2 /s and a subcooling of 10 K. We measure the average temperature of the boiling surface at increasing surface heat fluxes, covering a wide range of heat transfer regimes, from single-phase forced convection to the boiling crisis. We also record high-speed videos of the boiling process, which we postprocess to measure bubble nucleation site density, growth time, departure diameter and frequency. The surface analysis reveals that, while the chromium coating does not seem change the surface roughness and morphology, it improves surface wettability. However, it decreases the critical heat flux. The chromium coating causes an increase of nucleation temperature, bubble departure diameter and growth time, and a reduction of the nucleation site density. The concurrence of these observations indicates that a size reduction of the nucleation sites, conformally covered by the chromium coating, may be the cause of the boiling performance deterioration. We confirm this hypothesis repeating the same analysis on a FeCrAl sample prepared and tested using the same protocol as the zircaloy-4 sample, but with a different initial surface texture.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

Flow pattern and void fraction characterization in nitrogen/water flows through a diamond-type triply periodic minimal surface lattice

Here, this study presents, to the authors knowledge, the first experimental investigation on the void fraction and flow patterns in two-phase flows through a diamond-type Triply Periodic Minimal Surface (TPMS) lattice. An additively manufactured TPMS structure was tested under upward co-current flow of a water/nitrogen mixture. Superficial velocities varied for a total of 42 test conditions (gas: 0.01–2.4 m/s; liquid: 0.01–2.4 m/s; mass flux: 20–2370 kg/m 2 ·s). High-speed video and X-ray imaging enabled time-averaged void fraction measurements and identified six distinct flow regimes which were used to develop a flow pattern map. Comparison of the void fraction data with correlations from literature demonstrated the Rouhani and Axelsson (1970) [49] correlation modified by Steiner (1993) [52] provided the best agreement, which was improved with empirically fit coefficients. This approach predicted the void fraction with errors < ±20% for 64% of the data, with a mean absolute percent deviation (MAPD) of 23%. The measured frictional pressure drop was compared to correlations from literature which captured the observed trends but did not provide good accuracy. The best agreement was found after optimizing the empirical coefficients of the Muller-Steinhagen & Heck (1986) [56] correlation; this approach captured 33% of the data within ±20% with a MAPD of 46% over the full range and captured 71% of the data within ±20% a MAPD of 13.3% at mass fluxes >1100 kg/m 2 -s. These results provide foundational insight into TPMS two-phase flow behavior and inform modeling and design of advanced heat exchange components incorporating TPMS geometries.

42 - ENGINEERING↗

Influence of strain-rate on the response of elastomeric architected materials

Architected materials have shown substantial promise in impact mitigation and protective applications, and there has accordingly been great interest in better characterizing their response at elevated strain rates due to impact. There remains ambiguity regarding the contribution of inertial and material responses to strain rate sensitivity, and, in particular, when these effects begin to gain dominance in the impact response of an architected material. The response of soft polymer architected materials as a function of strain rate, in particular, has been little investigated. We characterize the experimental impact response of four soft polymer architected lattice geometries across varying strain rates in the intermediate strain rate regime (∼10 3 s −1 ) using split-Hopkinson pressure bar loading and high speed video characterization of the resulting deformation fields. In conclusion, our results highlight the interplay of influence between constituent material, lattice geometry, length scale, and strain rate in determining the onset of significant inertia effects.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗

Parameters of the Lightning Attachment Processes in a Negative Cloud-To-Ground Stroke Observed on a Microsecond Timescale

We present time-correlated ultra-high-speed video camera and electromagnetic field measurements of the attachment processes in a natural negative cloud-to-ground stroke. The video camera frame exposure time and pixel resolution were 740 ns and 0.91 m/pixel, respectively. The common streamer zone (CSZ) was first observed 2.52 µs preceding the first frame showing the return stroke (RS) in progress, when the upward and downward leader-tips were 9.8 m apart. In the next frame, the two leaders were observed to have propagated toward each other within the CSZ, with their tips being 0.91 m apart. Our observations show with unprecedented precision/clarity that (a) the slow front in the field waveform is associated with the CSZ, and (b) the “proper” start of the RS is marked by the onset of the fast transition in the field waveform which occurs at the completion of the attachment processes (when the upward and downward leaders have merged).

54 ENVIRONMENTAL SCIENCES↗

Shock tube experiments on the three-layer Richtmyer–Meshkov instability

Here, a vertical shock tube is used for experiments on the three-layer Richtmyer–Meshkov instability. Two closely spaced membrane-less interfaces are formed by the flow of two different sects of three gases: one with air above CO 2 above SF 6 and the other with helium above air above SF 6 . The lightest of the three gases enters the shock tube at the top of the driven section and flows downward. Conversely, the heaviest gas enters at the bottom of the shock tube and flows upward while the intermediate density gas enters at the middle through porous plates. All three gases are allowed to escape through holes at the layer location, leaving an approximately 30-mm layer of intermediate-density gas suspended between the lightest gas from above and the heaviest gas from below. A single-mode, two-dimensional initial perturbation is then imposed on the lower interface by oscillating the shock tube in the horizontal direction. The flow is visualized by seeding the intermediate gas with particles and illuminating it with a pulsed laser. Image sequences are then captured using high-speed video cameras. Perturbation amplitude measurements are made from the three-layer system and compared with measurements from 2, two-layer systems. It is observed that the presence of the upper, initially flat interface produces a decrease in growth of instability amplitude in the nonlinear phase over an equivalent single-interface configuration.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗

Analysis of the Shattered Pellet Injection Fragment Plumes Generated by Machine Specific Shatter Tube Designs

Shattered pellet injector systems have been installed on DIII-D, JET, and KSTAR and used to experimentally determine the effectiveness of the shattered pellet injection (SPI) process in mitigating the deleterious effects of a tokamak plasma disruption. Pellets are fired, and before entering the plasma, strike a bent tube known as a shatter tube causing the pellet to shatter. The process of pellet fragmentation is a chaotic process that can be described in terms of fragment size distribution through a statistical model that incorporates the effects of the pellet material and impact characteristics. In addition to the fragment size distribution, the shatter plume has other characteristics of interest, such as a fragment velocity distribution and temporal mass evolution. The fragment velocity distribution is important because it is needed to accurately model the spread and location of the ablation and the deposition of impurities in the plasma over time. The temporal mass evolution is necessary to determine the time-resolved delivery of mass to the plasma.Due to installation constraints, the shatter tube currently installed on JET has a unique geometry with a modest S-bend followed by a 20-deg bend at the end of the tube. The DIII-D and KSTAR shatter tube design is a simple tube bent through an angle of 20 deg followed by a straight section. The resulting shatter sprays from the JET shatter tube and a 20-deg miter bend shatter tube were experimentally characterized for various pellet materials and speeds. Laboratory testing of these shatter tubes allows for the use of fast cameras to capture the fragment spray traveling through a large vacuum chamber. These high-speed videos of the shatter plumes allow the fragment size distribution, temporal mass evolution, and velocity distribution of the fragments within the plume to be determined. Overall, this paper presents a comparison of the unique geometry of the JET shatter tube to the miter bend geometries used for shattering and some insight into the variables that may be adjusted to produce the optimal shatter spray. The impact of entrained propellant gas on the resulting shatter spray was examined during testing.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

Comparison of juvenile white sturgeon blade strike survival through a conventional and a novel hydropower turbine

Hydropower is a globally important renewable energy source with profound impacts on aquatic organisms, including direct injury and mortality to fish that move through hydropower facilities. While it is expected that the characteristics of turbine design and operation influence the type, frequency, and magnitude of injuries suffered by entrained fish, few direct comparisons exist to illustrate differences in fish survival outcomes for conventional and novel turbine designs. This study evaluated blade strike-associated injury and mortality rates for juvenile white sturgeon (Acipenser transmontanus) passed through a model-scale turbine equipped with a runner having conventional blade profiles (thin, straight leading edges) and the same turbine equipped with a runner designed for improved fish survival (thick, slanted leading edges). In both trials, head and turbine runner rotational speeds were matched to produce five blade peripheral speeds between 15.0 and 27.6 m/s. High-speed video was captured for all turbine passage events. Fish were assessed for injuries following passage, and mortalities were assessed immediately after passage and after 48 h. Conventional runner passage resulted in 42% to 78% survival after 48 h, with approximately one-third of all tested fish killed by severing. Under the same test conditions, immediate and 48 h survival rates through the novel runner were 100% except at the highest speed condition (95.6% survival at 48 h). These results clearly indicate that turbine design has a profound effect on fish survival, and suggest that thoughtful redesign of hydropower equipment could significantly ameliorate the risks of blade strike mortality.

13 HYDRO ENERGY↗

Measurement of Photovoltaic Module Deformation Dynamics During Hail Impact Using Digital Image Correlation

Stereo high-speed video of photovoltaic modules undergoing laboratory hail tests was processed using digital image correlation to determine module surface deformation during and immediately following impact. The purpose of this work was to demonstrate a methodology for characterizing module impact response differences as a function of construction and incident hail parameters. Video capture and digital image analysis were able to capture out-of-plane module deformation to a resolution of ±0.1 mm at 11 kHz on an in-plane grid of 10 × 10 mm over the area of a 1 × 2 m commercial photovoltaic module. With lighting and optical adjustments, the technique was adaptable to arbitrary module designs, including size, backsheet color, and cell interconnection. Furthermore, impacts were observed to produce an initially localized dimple in the glass surface, with peak deflection proportional to the square root of incident energy. Subsequent deformation propagation and dissipation were also captured, along with behavior for instances when the module glass fractured. Natural frequencies of the module were identifiable by analyzing module oscillations postimpact. Limitations of the measurement technique were that the impacting ice ball obscured the data field immediately surrounding the point of contact, and both ice and glass fracture events occurred within 100 μs, which was not resolvable at the chosen frame rate. Increasing the frame rate and visualizing the back surface of the impact could be applied to avoid these issues. Applications for these data include validating computational models for hail impacts, identifying the natural frequencies of a module, and identifying damage initiation mechanisms.

14 SOLAR ENERGY↗

Influence of Process Parameters and Alloy Composition on Crack Mitigation in Selective Laser Melting

Microcracking and residual stresses are key limitations of laser powder bed fusion (LPBF), an additive manufacturing (AM) technique that uses a high power laser to consolidate successive layers of metal powder. For tungsten, these microcracks find their origin in the combination of a ductile-to-brittle transition (DBT) between 200°C and 400°C and high residual stresses. This work utilized in situ high speed video to capture the cracking mechanisms, and combined the experimental results with thermomechanical modeling to unveil correlations between crack network morphology and process parameter-related variables, such as the local temperature and residual stress distributions. Consequently, preheating and alloying with rare earth oxides were adopted as possible crack mitigation strategies, the efficacy of which was tested against the initial fundamental baseline results. Preheating temperatures above 500°C eliminated all cracking, though this threshold is expected to be higher when tungsten powder (higher oxygen content) is introduced. Alloying can serve as an active oxygen getter in the system, but the rare earth oxides in this work were too large to have significant contributions to crack-mitigation.

36 MATERIALS SCIENCE↗

Lifetime extension drop-test of real-world corroded 5 Quart Hagan nuclear material storage container

A 5Qt Hagan container with a 20-year history of nuclear material storage was challenged with three successive drop tests at a height of 3.7 meters. The total mass of the test package was 12.1 kg. The 1st and 2nd drop tests (center of gravity over the container bottom corner but 180 degrees apart on the container bottom face) passed the pre- and post- impact helium leak criterion at less than 1.00E-6 atm-cc/sec (ambient cubic centimeters per second). The 3rd and final test (center of gravity over top corner) failed with a post-impact gross leak of 1.1E-1 atmcc/sec. The RRFMC (Respirable Release Fraction Measurement Chamber) is a drop tower test system that is critical for the sustainability of the SAVY-4000™ series and Hagan-type (NFT Inc. Golden CO) nuclear material storage containers. These are the primary in-use nuclear material storage container types at the Los Alamos National Laboratory TA-55 facility. Results are presented to expand the technical knowledge basis for container lifetime, regarding actual exposure to corrosive gas species on the container inner surfaces. The primary source of general corrosion throughout the container is gaseous hydrogen chloride (HCl). This gas is generated by the degradation of the polyvinylchloride (PVC) bag-out bag. Additionally, in most cases, the nuclear material itself also releases HCl gas (due to residual chemical components associated with the material formation). The RRFMC drop tower gives the end-user the ability record and analyze high-speed video and photography and if needed aerosol mass release measurements. In this report the principal issue is the physical deformation of the 5Qt Hagan container. There were no mass release experiments of test aerosol mass in the present study.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

Impact Testing of Heat Source Exemplars

This report details the heat source impact testing performed at the Shock Thermodynamics Applied Research Facility (STAR). The purpose of these tests were to measure the impact behavior of a heated Ta-10W tantalum/tungsten alloy heat source exemplar. Each exemplar resembled a cylinder with a rectangular through-hole orthogonal to the cylinder axis-of-symmetry. In each test, the exemplar was impacted by a hardened steel impactor accelerated using the STAR air gun. The exemplars were impacted perpendicular to the through-hole and at an an angle to the cylindrical axis-of-symmetry. The exemplar bar stock source, impact angle, and impact velocity were varied throughout the testing series. High-speed video was used to measure dynamic impact behavior while photon doppler velocimetry (PDV) and shorting pins were used to measure the impact velocity. Foam support structures were used to thermally isolate the exemplar and provide a support structure which was non-perturbative to the impact event. Soft-catch techniques were used to minimize secondary impacts and enable recovery for detailed post-shot analysis. Results indicate positive correlation between exemplar fracture and the variables of impact velocity and impact angle. Exemplar fracture occurred consistently along a single corner of the through-hole.

36 MATERIALS SCIENCE↗

Data-driven particle dynamics: Structure-preserving coarse-graining for emergent behavior in non-equilibrium systems

Multiscale systems are ubiquitous in science and technology, but are notoriously challenging to simulate as short spatiotemporal scales must be appropriately linked to emergent bulk physics. When expensive high-dimensional dynamical systems are coarse-grained into low-dimensional models, the entropic loss of information leads to emergent physics which are dissipative, history-dependent, and stochastic. To machine learn coarse-grained dynamics from time-series observations of particle trajectories, we propose a framework using the metriplectic bracket formalism that preserves these properties by construction; most notably, the framework guarantees discrete notions of the first and second laws of thermodynamics, conservation of momentum, and a discrete fluctuation-dissipation balance crucial for capturing non-equilibrium statistics. We introduce the mathematical framework abstractly before specializing to a particle discretization. As labels are generally unavailable for entropic state variables, we introduce a novel self-supervised learning strategy to identify emergent structural variables. We validate the method on benchmark systems and demonstrate its utility on two challenging examples: (1) coarse-graining star polymers at challenging levels of coarse-graining while preserving non-equilibrium statistics, and (2) learning models from high-speed video of colloidal suspensions that capture coupling between local rearrangement events and emergent stochastic dynamics. We provide open-source implementations in both PyTorch and LAMMPS, enabling large-scale inference and extensibility to diverse particle-based systems.

Computational Engineering, Finance, and Science (c↗

The visualization of low speed separated and wake flows

The use of smoke-like tracers to study the laminar separation bubble and several wake flows is discussed. The unobtrusive nature of this technique is an advantage for the study of laminar steady or laminar periodic flows. The recent development of scanning laser-light sheet, combined with high-speed video and image processing techniques, allow for the study of three-dimensional turbulent separated and wake flows.

Mueller, Thomas J.↗

Observations of breakup processes of liquid jets using real-time X-ray radiography

To unravel the liquid-jet breakup process in the nondilute region, a newly developed system of real-time X-ray radiography, an advanced digital image processor, and a high-speed video camera were used. Based upon recorded X-ray images, the inner structure of a liquid jet during breakup was observed. The jet divergence angle, jet breakup length, and fraction distributions along the axial and transverse directions of the liquid jets were determined in the near-injector region. Both wall- and free-jet tests were conducted to study the effect of wall friction on the jet breakup process.

Char, J. M.↗