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DOE OSTI2024

Chloride-Induced Stress Corrosion Cracking of Friction Stir-Welded 304L Stainless Steel: Effect of Microstructure and Temperature

Dry storage canisters of used nuclear fuels are fabricated using SUS 304L stainless steel. Chloride-induced stress corrosion cracking (CISCC) is one of the major failure modes of dry storage canisters. The cracked canisters can be repaired by friction stir welding (FSW), a low-heat input ‘solid-phase’ welding process. It is important to evaluate the ClSCC resistance of the friction stir welded material. Stress corrosion cracking (SCC) studies were carried out on mill-annealed base materials and friction stir welded 304L stainless U-bend specimens in 3.5% NaCl + 5 N H2SO4 solution at room temperature and boiling MgCl2 solution at 155 °C. The engineering stress on the outer fiber of the FSW U-bend specimen was ~60% higher than that of the base metal (BM). In spite of the higher stress level of the FSW, both materials (FSW and BM) showed almost similar SCC failure times in the two different test solutions. The SCC occurred in the thermo-mechanically affected zone (TMAZ) of the FSW specimens in the 3.5% NaCl + 5 N H2SO4 solution at room temperature, while the stirred zone (SZ) was relatively crack-free. The failure occurred at the stirred zone when tested in the boiling MgCl2 solution. Hydrogen reduction was the cathodic reaction in the boiling MgCl2 solution, which promoted hydrogen-assisted cracking of the heavily deformed stirred zone. The emergence of the slip step followed by passive film rupture and dissolution of the slip step could be the SCC events in the 3.5% NaCl + 5 N H2SO4 solution at room temperature. However, the slip step height was not sufficient to cause passivity breakdown in the fine-grained SZ. Therefore, the SCC occurred in the partially recrystallized softer TMAZ. Overall, the friction-stirred 304L showed higher tolerance to ClSCC than the 304L base metal.

304L austenitic stainless steel↗

NASA NTRS1973

Aerodynamic simulation tests of RSI panels

The technique of mixing argon with air was used to simulate the temperature-time trajectory experienced by space shuttle vehicle insulation panels. Gap heating appears to be highly dependent upon gap design, it is relatively low for interlocking and tapered panel designs and significantly higher for a wider, unfilled gap design. The heating rate appears to be significantly higher at the windward facing edges of flush tiles and is aggravated at forward facing steps. This heating, however, is highly dependent on step heights relative to some characteristic thickness of the boundary layer.

Centolanzi, F. J.↗

NASA NTRS1973

Base pressure in laminar supersonic flow.

An asymptotic description is proposed for supersonic laminar flow over a wedge or a backward-facing step, for large Reynolds number and for a base or step height which is small compared with the boundary-layer length. The analysis is carried out for adiabatic wall conditions and a viscosity coefficient proportional to temperature. In a particular limit corresponding to a very thick boundary layer, a similarity law is obtained for the base pressure. For a thinner boundary layer an asymptotic form for the base pressure is obtained which shows the dependence on the parameters explicitly and which permits good agreement with experiment. This latter result is based on an inviscid-flow approximation for the corner expansion and for reattachment with viscous forces important primarily in a thin sublayer about the dividing streamline. A prediction of the pressure distribution at reattachment is given and the result is compared with experimental pressure distributions.

Messiter, A. F.↗

NASA NTRS1974

Turbulent boundary-layer separation due to a forward-facing step

Pressure distribution tests were made at Mach numbers of 1.61 and 2.20, over a step-height range from 0 to 2.54 centimeters, and an effective Reynolds number range from about 8 to 150 million. The results were compared with some obtained at higher Mach numbers at approximately comparable boundary-layer conditions. The comparison showed several unexplainable anomalies, and pointed up the lack of boundary-layer information necessary for a proper analysis. An analysis of the data indicates the existence of a transverse vortex in the separated-flow region which weakens with increases in Reynolds and Mach number and significantly affects the pressure distributions.

Czarnecki, K. R.↗

NASA NTRS1975

Theoretical face pressure and drag characteristics of forward-facing steps in supersonic turbulent boundary layers

A theoretical investigation of the pressure distributions and drag characteristics was made for forward facing steps in turbulent flow at supersonic speeds. An approximate solution technique proposed by Uebelhack has been modified and extended to obtain a more consistent numerical procedure. A comparison of theoretical calculations with experimental data generally indicated good agreement over the experimentally available range of ratios of step height to boundary layer thickness from 7 to 0.05.

Patel, D. K.↗

NASA NTRS1980

Aerodynamic heating for gaps in laminar and transitional boundary layers

The presence of gaps, slots, and/or steps in a surface may significantly perturb a supersonic boundary layer. The paper discusses heat-transfer distributions for a variety of gap configurations which were obtained by placing instrumented inserts in a flat-plate structural carrier. The data were obtained in a 3.50 foot hypersonic wind tunnel at a freestream Mach number of 5.10 over a range of Reynolds number from 2,570,000 to 8,110,000. The variables of the test program included the freestream Reynolds number and the gap configuration, e.g., width, depth, step height, number, and orientation.

Bertin, J. J.↗

NASA NTRS1981

The design of a mechanical referencing system for the rear drum of the Longwall Shearer Coal Miner

The design of two systems which reference the position of a longwall shearer coal miner to the mine roof of the present cut and of the last cut are presented. This system is part of an automation system that will guide the rear cutting drum in such a manner that the total depth of cut remains constant even though the front drum may be following an undulating roof profile. The rear drum referencing mechanism continually monitors the distance from the mine roof to the floor for the present cut. This system provides a signal to control a constant depth of cut. The last cut follower mechanism continually monitors the distance from the mine roof of the prior cut to the cutting drum. This latter system provides a signal to minimize the step height in the roof between cuts. The dynamic response of this hydraulic-pneumatic and mechanical system is analyzed to determine accumulator size and precharge pressure.

Jones, E. W.↗

NASA NTRS1982

Phenomenological study of subsonic turbulent flow over a swept rearward-facing step

The phenomenology of turbulent, subsonic flow over a swept, rearward-facing step was studied. Effects of variations in step height, sweep angle, base geometry, and end conditions on the 3-D separated flow were examined. The separated flow was visualized using smoke wire, oil drop, and surface tuft techniques. Measurements include surface pressure, reattachment distance and swirl angle. Results indicate: (1) model/test section coupling affects the structure of the separated flow, but spanwise end conditions do not; (2) the independence principle is evidently valid for sweep angles up to 38 deg; (3) a sweep angle/swirl angle correlation exists; and (4) base modifications can significantly reduce the reattachment distance.

Selby, G. V.↗

NASA NTRS1982

Provisions for nonintrusive flow-evaluation tools in the National Transonic Facility

The national transonic facility fan driven, closed circuit, continuous flow, pressurized wind tunnel is examined. The test section is 2.500 m x 2.500 m and 7.620 m long with a slotted wall configuration. There are six slots each in the top and bottom walls and two slots per sidewall. To maintain good flow quality and aerodynamic efficiency over the wide range of test capabilities the test section geometry is variable. The position of the test section and bottom walls, the reentry flaps at the rear of the test section slots, and the step height for reentering slot flow are remotely controlled. The test gas may be dry air or nitrogen, which for the elevated temperature (340 K) mode of operation the test medium is normally air, and heat removal is by a water cooled heat exchanger (cooling coil) located at the upstream end of the settling chamber. For the cryogenic mode of operation, heat removal is by evaporation of liquid nitrogen, which is sprayed into the circuit upstream of the fan. By utilizing liquid nitrogen as a coolant, the tunnel test temperature range is variable from 340 to 78 K. When nitrogen is injected into the circuit, venting must occur to maintain a constant pressure. Thermal insulation is installed internal to the pressure shell to minimize energy consumption.

Fuller, D. E.↗

NASA NTRS1982

3-D supersonic combustion experiments with hydrogen in V-trough

Both supersonic blowdown and free jet wind tunnels were used in oil flow visualization and hydrogen gas burning tests of 60- and 90-deg V-shaped trough combustion characteristics. Oil dots showed that mass outflow from the reattachment region at the bottom of the V-trough dominated flow behavior, and occupied the trough's entire length and 10% of its cross-section. Intermingled vortex pairs were also found to superimpose themselves upon the outflow, and hydrogen burning within troughs reduced missile base drag by 25%. The troughs were aligned so that their long dimensions were parallel to the airflow, and the two top edges of the V section were mounted flush with respect to the upstream flat surfaces. Step heights tested ranged from 3.4 mm to 6.25 cm.

Friedberg, R. A.↗

NASA NTRS1983

Filler bar heating due to stepped tiles in the shuttle orbiter thermal protection system

An analytical study was performed to investigate the excessive heating in the tile to tile gaps of the Shuttle Orbiter Thermal Protection System due to stepped tiles. The excessive heating was evidence by visible discoloration and charring of the filler bar and strain isolation pad that is used in the attachment of tiles to the aluminum substrate. Two tile locations on the Shuttle orbiter were considered, one on the lower surface of the fuselage and one on the lower surface of the wing. The gap heating analysis involved the calculation of external and internal gas pressures and temperatures, internal mass flow rates, and the transient thermal response of the thermal protection system. The results of the analysis are presented for the fuselage and wing location for several step heights. The results of a study to determine the effectiveness of a half height ceramic fiber gap filler in preventing hot gas flow in the tile gaps are also presented.

Petley, D. H.↗

NASA NTRS1983

Life considerations of the shuttle orbiter densified-tile thermal protection system

The Shuttle orbiter themal protection system (TPS) incorporates ceramic reusable surface insulation tiles bonded to the orbiter substructure through a strain isolation pad. Densification of the bonding surface of the tiles increases the static strength of the tiles. The densification proces does not, however, necessarily lead to an equivalent increase in fatigue strength. Investigation of the expected lifetime of densified tile TPS under both sinusoidal loading and random loading simulating flight conditions indicates that the strain isolation pads are the weakest components of the TPS under fatigue loading. The felt pads loosen under repetitive loading and, in highly loaded regions, could possibly cause excessive step heights between tiles causing burning of the protective insulation between tiles. A method of improving the operational lifetime of the TPS by using a strain isolation pad with increased stiffness is presented as is the consequence of the effect of increased stiffness on the tile inplane strains and transverse stresses.

Cooper, P. A.↗

NASA NTRS1983

Combustion in a turbulent mixing layer formed at a rearward-facing step

A premixed propane/air flame was stabilized in a turbulent mixing layer formed at a rearward-facing step. The mean and rms averages of the turbulent velocity flowfield were determined by laser velocimetry for both reacting (phi = 0.57) and nonreacting flows (Re = 15,000-37,000 based on step height). The reacting-flow was visualized by high-speed schlieren photography. Large-scale structures dominate the reacting mixing layer. The growth of the large-scale structures was tied to the propagation of the flame. The linear growth rate of the reacting mixing layer defined by the mean velocity profiles was unchanged by combustion but the virtual origin moves downstream. The reacting mixing layer boundaries based on the mean velocity profiles were shifted toward the recirculation zone and reattachment lengths were shortened by 30 percent. The edge of the flame controlled by the large-scale structure development propagated faster into the incoming reactants than the boundary of the mixing layer given by the mean velocity flowfield. Thus, the region of high velocity gradient did not coincide with the region of high reaction and heat transfer.

Pitz, R. W.↗

NASA NTRS1985

A three-dimensional turbulent boundary layer undergoing transverse strain and streamwise pressure gradient

Results from an experimental investigation designed to provide data on both mean and turbulence quantities in the axisymmetric, swirling boundary layer (with and without pressure gradient) flowing over a stationary cylinder downstreams of a spinning cylindrical section are presented. The pressure gradient was introduced into the flow field by a 25.4 mm-high, forward-facing, circular step mounted on the stationary cylinder, the step height being nearly equal to the thickness of the approaching boundary layer. All the measurements were made at a nominal upstream reference Reynolds number of 2.4 x 10 to the 6th power/m (corresponding to an upstream reference velocity of 36 to 37 m/sec) with the rotation of the spinner set to make its peripheral speed equal the reference velocity. The data reported included measurements of surface pressure and the mean surface shear-stress vector taken with a miniature, directional, surface-fence gage. These measurements were supplemented by oil-flow visualization studies of the stationary cylinder. The data indicates that the streamwise pressure gradient controls the development of the streamwise component of wall shear, but leaves the peripheral component of wall shear practically unaffected.

Hebbar, S. K.↗

NASA NTRS1985

An experimental investigation of a swirling, axisymmetric, turbulent boundary layer with pressure gradient

The results of an experimental investigation designed to document data on both mean and turbulence quantities in the axisymmetric, swirling boundary layer (with and without a pressure gradient) flowing over a stationary cylinder downstream of a spinning cylindrical section are discussed. The pressure gradient was introduced into the flow field by a 25.4-mm-high, forward-facing circular step mounted on the stationary cylinder, the step height being nearly equal to the approaching boundary-layer thickness. All the measurements were made at upstream reference velocity of 36-37 m/sec, with the rotation of the spinner set to make its peripheral speed equal to the reference velocity. The data reported include measurements of surface pressure and the mean surface-shear-stress vector (using a miniature directional surface-fence gage) and oil-flow visualization studies of the stationary cylinder. The data indicate that the streamwise pressure gradient controls the development of the streamwise component of wall shear but leaves the peripheral component of wall shear practically unaffected.

Hebbar, S. K.↗

NASA NTRS1988

Design optimization and testing of a pump wear ring labyrinth seal

It has been demonstrated that design optimization of labyrinth seals using the present numerical model is quite beneficial. The results shown include important, but previously unknown effects on the leakage rate, especially that of step height. Further, complete details are given of a very effective seal designed using this technique for the SSME high pressure hydrogen turbopump. Measurements using turbine flow meters revealed that the optimized configuration gives 67 percent leakage reduction over the original design. These measurements also reveal important leakage effects of the axial straining of the stator, which begins during pump start-up.

Rhode, D. L.↗

NASA NTRS1991

An experimental investigation of the separating/reattaching flow over a backstep

Reynolds number effects on the evolution of the turbulence structure in the recovery region of a turbulent separated flow generated by a backward-facing step were studied experimentally. Five different flow conditions and four Reynolds numbers were investigated. All single point measurements were conducted on the plane of symmetry of the wind tunnel starting at approximately x/h = 10 for each flow condition. The upper limit of the measuring domain depends upon the physical size of the tunnel and ranged from 50 to 114 step heights. It is apparent that most of the boundary layer recovery was captured by the experiment. Normal stresses, shear stress, mixing length scales and eddy viscosity are shown, while the higher order velocity products related to the diffusion of the turbulence energy are planned for latter stages of the data analysis.

Jovic, Srboljub↗

NASA NTRS1992

An experimental investigation of the separating/reattaching flow over a backstep

Transport characteristics of the turbulent kinetic energy, k, and the shear stream, bar(-uv), were studied in an incompressible boundary layer downstream of the reattachment of the separated flow behind a backward facing step. Hot-wire measurement techniques were used to measure three Reynolds stresses and higher order mean products of velocity fluctuations. These quantities were used to evaluate advection, turbulent diffusion, and production terms of the k and bar(-uv) transport equations. The dissipation rate and pressure-strain terms were obtained as the difference of all the other terms. The Reynolds number based on the step height was 37,000 and the upstream oncoming flow was fully developed turbulent boundary layer with the R(sub theta) = 3600.

Jovic, Srboljub↗