SEARCH · Search NASA
Results for “perforate”
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.
Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.
Dimensionless parameters to categorize the failure modes of ductile plate perforation
In this work, two dimensionless parameters were derived organically from impact mechanics equations to remove the need for empirical constants. These two dimensionless parameters effectively collapse the ballistic performance of ductile metal plates along two distinct loci, depending on the projectile geometry and the corresponding failure mode. Projectiles that initiate ductile hole enlargement via cavity expansion fall along a linear curve, while shear-plugging failure modes tend to fall along a cubic curve. Results were demonstrated for various projectiles of different calibers impacting aluminum and Ti-6Al-4V alloys. The main advantage of the approach in this work is to drastically reduce the number of features for input into machine learning algorithms.
Dimensionless parameters to categorize the failure modes of ductile plate perforation
In this work, two dimensionless parameters were derived organically from impact mechanics equations to remove the need for empirical constants. These two dimensionless parameters effectively collapse the ballistic performance of ductile metal plates along two distinct loci, depending on the projectile geometry and the corresponding failure mode. Projectiles that initiate ductile hole enlargement via cavity expansion fall along a linear curve, while shear-plugging failure modes tend to fall along a cubic curve. Results were demonstrated for various projectiles of different calibers impacting aluminum and Ti-6Al-4V alloys, and further explored for more complex target combinations. The main advantage of the approach in this work is to drastically reduce the number of features for input into machine learning algorithms.
Improved Damage Resistant Composite Materials Incorporating Shape Memory Alloys
Metallic shape memory alloys (SMA) such as nitinol have unique shape recovery behavior and mechanical properties associated with a material phase change that have been used in a variety of sensing and actuation applications. Recent studies have shown that integrating nitinol-SMA actuators into composite materials increases the composite material's functionality. Hybrid composites of conventional graphite/epoxy or glass/epoxy and nitinol-SMA elements can perform functions in applications where monolithic composites perform inadequately. One such application is the use of hybrid composites to function both in load bearing and armor capacities. While monolithic composites with high strength-to-weight ratios function efficiently as loadbearing structures, because of their brittle nature, impact loading can cause significant catastrophic damage. Initial composite failure modes such as delamination and matrix cracking dissipate some impact energy, but when stress exceeds the composite's ultimate strength, fiber fracture and material perforation become dominant. One of the few methods that has been developed to reduce material perforation is hybridizing polymer matrix composites with tough kevlar or high modulus polyethynylene plies. The tough fibers increase the impact resistance and the stiffer and stronger graphite fibers carry the majority of the load. Similarly, by adding nitinol-SMA elements that absorb impact energy through the stress-induced martensitic phase transformation, the composites' impact perforation resistance can be greatly enhanced. The results of drop-weight and high velocity gas-gun impact testing of various composite materials will be presented. The results demonstrate that hybridizing composites with nitinol-SMA elements significantly increases perforation resistance compared to other traditional toughening elements. Inspection of the composite specimens at various stages of perforation by optical microscope illustrates the mechanisms by which perforation is initiated. Results suggest that the out-of-plane transverse shear properties of the composite and nitinol elements have a significant effect on the perforation resistance. Applications that can utilize the hybrid composites effectively will also be presented with the experimental studies.
Low-Drag Acoustic Liner Development
Interest in characterization of the aerodynamic drag of acoustic liners has increased in the past several years. This report details experiments in the NASA Langley Grazing Flow Impedance Tube to quantify the relative drag of several perforate-over-honeycomb liner configurations at flow speeds of M=0.3 and 0.5. Various perforate geometries and orientations are investigated to determine their resistance factors using a static pressure drop approach. Comparison of these resistance factors gives a relative measurement of liner drag. For these same flow conditions, acoustic measurements are performed simultaneously with the drag measurements for tonal excitation from 400 to 3000 Hz at source sound pressure levels of 140 and 150 dB. Educed impedance and attenuation spectra are used to determine the impact of variations in perforate geometry on acoustic performance. The goal is to identify a perforate that will reduce the drag penalty associated with conventional round-hole perforates by 60%. One perforate design, based on a slot geometry, is shown to reduce this penalty by 50%. Further reductions may be possible but require a reduction in measurement uncertainty to allow a statistically rigorous evaluation.
Partition Thickness Considerations for Additively Manufactured Acoustic Liners
Three types of uniform-depth liners are evaluated to explore the effects of partition thickness on the surface impedance achieved with additively manufactured liners. A transmission line code is used to predict the effects of sound transmission through empty chambers and wire mesh facesheets, and is combined with the Motsinger and Kraft model to account for sound transmission through perforated facesheets. The inclusion of partitions causes a blockage effect, i.e., a portion of the surface is ‘blocked’ (nonactive surface). For liners with no facesheet, these blockage effects are incorporated simply by accounting for the change in cross sectional area between the individual chamber and the unit cell that includes half of a partition thickness around the perimeter of this chamber. Comparison of impedances predicted in this manner with data acquired in the NASA Langley Normal Incidence Tube (NIT) confirms the efficacy of this modeling approach. Two approaches are considered to account for the inclusion of a wiremesh or perforated plate facesheet on these same cores. The first accounts for the effects of partition thickness before including the transfer impedance across the facesheet, while the second reverses these steps. A comparison of data acquired in the NASA NIT with modeled impedances suggests the first approach is best when the facesheet is a wire mesh, but the second approach is preferred when a perforated plate facesheet is used. It is hypothesized that this is due to the fact that a lumped element model is used to compute the transfer impedance across a wire mesh, while the corresponding transfer impedance across a perforated sheet explicitly incorporates the efffects of the liner core. However, comparisons of data acquired in the NASA Langley Grazing Flow Impedance Tube with modeled impedances seem slightly better when the first approach is employed with a perforated plate facesheet. Thus, the effects of partition thickness on liners with perforated sheets subjected to grazing incidence sound require further review
Analysis of Completion Design Impact on Cluster Efficiency and Pressure-Based Well Communication in HFTS-2 Delaware Basin
The Hydraulic Fracturing Test Site 2 (HFTS-2) is a joint industry project in the Delaware basin to advance hydraulic fracturing understanding and improve productivity in shale reservoirs. The project integrates multi-disciplinary approaches to evaluate different completion designs, well spacing, inter-well communication, and stimulated rock volume, among other factors. This paper focused on two major areas related to hydraulic fracture performance. First, an analysis of different completion designs on cluster efficiency based on near well Distributed Acoustic Sensing (DAS). Second, an evaluation of well and completion designs on inter-well fracture driven interactions (FDIs) based on downhole pressure monitoring. Fluid/sand distribution and cluster efficiency analyses were based on near wellbore DAS data collected from two adjacent horizontal wells completed in two different landing zones in the Wolfcamp formation. These wells had different completion designs aiming to evaluate the effect of normal vs. extended stage lengths, perforation hole tapering and limited entry. Standard deviation from ideal fluid/sand distribution and waterfall plots were used to evaluate cluster efficiency for each design and stage. Inter-well FDIs analysis was conducted among the horizontal wells and a vertical monitor well. One horizontal well served as the monitor well while the other horizontal well was being treated. The vertical well was instrumented with downhole pressure and temperature gauges to aid monitoring fracture height growth. The pressure response during and after fracturing was characterized based on maximum pressure increase value and slope. Pressure response vs. FDIs trigger factors such distance, cluster efficiency and stage fluid volume were also analyzed. Based on the different completion and perforation designs tested, DAS analysis suggests that limited entry design worked best. Extreme limited entry showed the potential of high perforation erosion and reduced cluster efficiency. Here, the limited entry and tapered perforation design demonstrated potential to improve the cluster efficiency for extended stage lengths. Pressure monitoring across formation units proved to be critical to understand fracture interactions and fracture vertical growth. Pressure communication across different formation units during hydraulic fracturing operation indicate fractures grew upwards during Wolfcamp wells fracturing. However, this pressure communication dissipated over time. High intensity FDIs were recorded when the frac stages Downloaded from http://onepetro.org/URTECONF/proceedings-pdf/21URTC/1-21URTC/D011S018R001/2477607/urtec-2021-5289-ms.pdf/1 by Carol Worster on 28 February 2022 URTeC 5289 were closer to the pressure gauge location in the monitor wells. Some of these stages that produced high intensity FDIs also had high fluid volume per cluster and low cluster efficiency. The multi-disciplinary and high-quality data collected from HFTS-2 helped to further understand why completion approaches such as limited entry and tapered perforation design are successful in improving cluster efficiency. The DAS data combined with downhole high-resolution pressure measurements also helped to quantify the effect of lower cluster efficiency data on the incidence and intensity of FDIs.
Material development for laminar flow control wing panels
The absence of suitable porous materials or techniques for the economic perforation of surface materials has previously restricted the design of laminar flow control (LFC) wing panels to a consideration of mechanically slotted LFC surfaces. A description is presented of a program which has been conducted to exploit recent advances in materials and manufacturing technology for the fabrication of reliable porous or perforated LFC surface panels compatible with the requirements of subsonic transport aircraft. Attention is given to LFC design criteria, surface materials, surface concepts, the use of microporous composites, perforated composites, and perforated metal. The described program was successful in that fabrication processes were developed for producing predictable perforated panels both of composite and of metal.
Aluminum 2219-T87 and 5456-H116 - A comparative study of spacecraft wall materials in dual-wall structures under hypervelocity impact
All earth-orbiting spacecraft are susceptible to high-speed impacts by pieces of orbital debris. To prevent mission failure and possibly loss of life, protection against perforation by high-speed orbital debris particles must be included in the spacecraft design. Although any number of materials can be used to manufacture perforation-resistant structures, aluminum is often used in such systems because of its relatively high strength-to-weight ratio. This paper presents the results of a study in which the high speed impact response characteristics of dual-wall structures made from two different aluminum alloys were analyzed to determine which alloy would be more suitable for use in a perforation-resistant dual-wall structural system that is to be exposed to the orbital debris environment. Impact response characteristics were obtained numerically and experimentally. At impact speeds below 7 km/s, it was found that the two aluminum alloys considered contributed similar levels of perforation resistance; at speeds in excess of 7 km/s, aluminum 2219-T87 was superior to aluminum 5546-H116 in preventing perforation of dual-wall structural systems.
Innovative Liner Concepts: Experiments and Impedance Modeling of Liners Including the Effect of Bias Flow
The study of normal impedance of perforated plate acoustic liners including the effect of bias flow was studied. Two impedance models were developed by modeling the internal flows of perforate orifices as infinite tubes with the inclusion of end corrections to handle finite length effects. These models assumed incompressible and compressible flows, respectively, between the far field and the perforate orifice. The incompressible model was used to predict impedance results for perforated plates with percent open areas ranging from 5% to 15%. The predicted resistance results showed better agreement with experiments for the higher percent open area samples. The agreement also tended to deteriorate as bias flow was increased. For perforated plates with percent open areas ranging from 1% to 5%, the compressible model was used to predict impedance results. The model predictions were closer to the experimental resistance results for the 2% to 3% open area samples. The predictions tended to deteriorate as bias flow was increased. The reactance results were well predicted by the models for the higher percent open area, but deteriorated as the percent open area was lowered (5%) and bias flow was increased. A fit was done on the incompressible model to the experimental database. The fit was performed using an optimization routine that found the optimal set of multiplication coefficients to the non-dimensional groups that minimized the least squares slope error between predictions and experiments. The result of the fit indicated that terms not associated with bias flow required a greater degree of correction than the terms associated with the bias flow. This model improved agreement with experiments by nearly 15% for the low percent open area (5%) samples when compared to the unfitted model. The fitted model and the unfitted model performed equally well for the higher percent open area (10% and 15%).
Bio-inspired alula-based winglet design for enhanced heat transfer in high temperature fin-and-tube heat exchangers
Fin-and-tube heat exchangers (FTHEs) are widely used for high-temperature flue-gas heat recovery, but their performance is often limited by wake regions and non-uniform fin-surface temperatures. This study proposes and numerically evaluates four bio-inspired longitudinal vortex generator (VG) configurations in a high-temperature FTHE with flue-gas inlet temperature ∼1230 K: double-delta, curved double-delta, alula, and a new curved-alula geometry. The reference fin is not hydraulically plain; it already incorporates leading-edge separation columns and convex protrusions, so the alula-type winglets are assessed as downstream add-ons acting on a strongly disturbed flow. In a second step, perforations (one, two and three circular holes) are introduced into the curved-alula VGs to further tailor the flow field. Three-dimensional simulations with the Shear Stress Transpor (SST) $k - ω$ model, temperature-dependent flue-gas properties and conjugate conduction are carried out for gas-side Reynolds numbers $Re_g ≈ 8.0$ x $10^2 - 3.6$ x $10^3$ (mass flow rates 0.5 – 2.5 g/s), and the designs are compared in terms of surface heat flux, Nusselt number, friction factor and hydrothermal performance factor (HTPF). For this already-promoted fin, the additional downstream winglets provide moderate, incremental hydrothermal gains. At the highest Reynolds number, the best non-perforated design (curved-alula) increases surface heat flux from 1630.9 to 1794.7 kW/m² (∼ 10 % gain) and the Nusselt number from 227.6 to 242.6 (∼ 7 % gain), while the friction factor rises from 0.26 to about 0.30, yielding HTPF values close to unity (∼ 0.9 – 1.0). Introducing circular perforations into the curved-alula winglets acts mainly as a wake-bleeding refinement: the three-hole configuration provides a heat flux of 1824.7 kW/m² and a pressure drop of 127.9 Pa, with HTPF in the range ∼ 1.03 – 1.14 and a small (∼ 1 – 3 %) improvement over the solid curved-alula design. Flow-field analysis shows that the perforated curved-alula VGs shrink tube-wake regions, thin the thermal boundary layer and homogenize the fin-surface temperature (outlet-gas temperature ∼ 510 – 520 K and fin-surface temperature ∼ 420 – 421 K for the three-hole case). An optimal flue-gas mass flow rate of ∼ 1 g/s ($Re_g ≈ 1.5$ x $10^3$) is identified, beyond which additional heat-transfer gains are offset by rapidly increasing pressure losses. Overall, the results highlight that initial fin geometry and VG placement are as important as VG shape: alula-based winglets are expected to yield larger relative gains on simpler flat-fin layouts or when positioned closer to the fin leading edge and tube
Catalyst cartridge for carbon dioxide reduction unit
A catalyst cartridge, for use in a carbon dioxide reducing apparatus in a life support system for space vehicles, is described. The catalyst cartridge includes an inner perforated metal wall, an outer perforated wall space outwardly from the inner wall, a base plate closing one end of the cartridge, and a cover plate closing the other end of the cartridge. The cover plate has a central aperture through which a supply line with a heater feeds a gaseous reaction mixture comprising hydrogen and carbon dioxide at a temperature from about 1000 to about 1400 F. The outer surfaces of the internal wall and the inner surfaces of the outer wall are lined with a ceramic fiber batting material of sufficient thickness to prevent carbon formed in the reaction from passing through it. The portion of the surfaces of the base and cover plates defined within the inner and outer walls are also lined with ceramic batting. The heated reaction mixture passes outwardly through the inner perforated wall and ceramic batting and over the catalyst. The solid carbon product formes is retained within the enclosure containing the catalyst. The solid carbon product formed is retained within the enclosure containing the catalyst. The water vapor and unreacted carbon dioxide and any intermediate products pass through the perforations of the outer wall.
Development of the technology for the fabrication of reliable laminar from control panels
Materials were assessed and fabrication techniques were developed for use in the manufacture of wing surface materials compatible with the application of both aluminum alloys and nonmetallic composites. The concepts investigated included perforations and slots in the metallic test panels and microporosity and perforations in the composite test panels. Perforations were produced in the metallic test panels by the electron beam process and slots were developed by controlled gaps between the metal sheets. Microporosity was produced in the composite test panels by the resin bleed process, and perforations were produced by the fugitive fiber technique. Each of these concepts was fabricated into test panels, and air flow tests were conducted on the panels.
Radiometric tests on wet and dry antenna reflector surface panels
The results of X-band noise temperature tests on two types of antenna surface panels are presented. The first type tested was a solid antenna panel, while the second type was a perforated panel with 3/16-in.-diameter holes. Measurements were made at 8.45 GHz using an X-band radiometric system. Included in this article are measured noise temperature contributions from: (1) thermal diffusive white paint on solid and perforated panels, and (2) water sprayed on both painted and unpainted perforated panels. Experiments on perforated panels were restricted to the 3/16-in.-diameter hole panels formerly used on Deep Space Network 64-m antennas. Rigorous calibration equations, applicable to a variety of antenna panel and dichroic plate test configurations, are presented. It was demonstrated that an accurate, stable radiometric measurement system of the type used for the results of this research makes it possible to obtain information that would be much more difficult to obtain using other techniques.
Anomalous Buckling Characteristics of Laminated Metal-Matrix Composite Plates with Central Square Holes
Compressive buckling analysis was performed on metal-matrix composite (MMC) plates with central square holes. The MMC plates have varying aspect ratios and hole sizes and are supported under different boundary conditions. The finite-element structural analysis method was used to study the effects of plate boundary conditions, plate aspect ratio, hole size, and the composite stacking sequence on the compressive buckling strengths of the perforated MMC plates. Studies show that by increasing the hole sizes, compressive buckling strengths of the perforated MMC plates could be considerably increased under certain boundary conditions and aspect ratios ("anomalous" buckling behavior); and that the plate buckling mode could be symmetrical or antisymmetrical, depending on the plate boundary conditions, aspect ratio, and the hole size. For same-sized plates with same-sized holes, the compressive buckling strengths of the perforated MMC plates with [90/0/0/90]2 lamination could be as much as 10 percent higher or lower than those of the [45/- 45/- 45/45]2 laminations, depending on the plate boundary conditions, plate aspect ratios, and the hole size. Clamping the plate edges induces far stronger "anomalous" buckling behavior (enhancing compressive buckling strengths at increasing hole sizes) of the perforated MMC plates than simply supporting the plate edges.
Two-Piece Screens for Decontaminating Granular Material
Two-piece screens have been designed specifically for use in filtering a granular material to remove contaminant particles that are significantly wider or longer than are the desired granules. In the original application for which the twopiece screens were conceived, the granular material is ammonium perchlorate and the contaminant particles tend to be wires and other relatively long, rigid strands. The basic design of the twopiece screens can be adapted to other granular materials and contaminants by modifying critical dimensions to accommodate different grain and contaminant- particle sizes. A two-piece screen of this type consists mainly of (1) a top flat plate perforated with circular holes arranged in a hexagonal pattern and (2) a bottom plate that is also perforated with circular holes (but not in a pure hexagonal pattern) and is folded into an accordion structure. Fabrication of the bottom plate begins with drilling circular holes into a flat plate in a hexagonal pattern that is interrupted, at regular intervals, by parallel gaps. The plate is then folded into the accordion structure along the gaps. Because the folds are along the gaps, there are no holes at the peaks and valleys of the accordion screen. The top flat plate and the bottom accordion plate are secured within a metal frame. The resulting two-piece screen is placed at the bottom opening of a feed hopper containing the granular material to be filtered. Tests have shown that such long, rigid contaminant strands as wires readily can pass through a filter consisting of the flat screen alone and that the addition of the accordion screen below the flat screen greatly increases the effectiveness of removal of wires and other contaminant strands. Part of the reason for increased effectiveness is in the presentation of the contaminant to the filter surface. Testing has shown that wire type contamination will readily align itself parallel to the material direction flow. Since this direction of flow is nearly always perpendicular to the filter surface holes, the contamination is automatically aligned to pass through. The two-filter configuration reduces the likelihood that a given contaminant strand will be aligned with the flow of material by eliminating the perpendicular presentation angle. Thus, for wires of a certain diameter, a two-piece screen is 20 percent more effective than is the corresponding flat perforated plate alone, even if the holes in the flat plate are narrower. An accordion screen alone is similarly effective in catching contaminants, but lumps of agglomerated granules of the desired material often collect in the valleys and clog the screen. The addition of a flat screen above the accordion screen prevents clogging of the accordion screen. Flat wire screens have often been used to remove contaminants from granular materials, and are about as effective as are the corresponding perforated flat plates used alone.
Effects of Layer Spacing for a Multilayered Facesheet Acoustic Liner
A single degree-of-freedom acoustic liner, a perforate facesheet over honeycomb core, is modified to have a facesheet comprised of three layers. The top and bottom perforate layers have the same dimensions with aligned perforations while the middle layer perforate can be longitudinally shifted up to 0.075 inches to change the effective porosity of the facesheet. These configurations range in porosity from 100% open down to 10% open in addition to two closed configurations (0% porosity). Gaps are introduced between the facesheet layers ranging from no gap to 0.016 inches. These configurations are tested in the NASA Langley Grazing Flow Impedance Tube to determine their acoustic impedance spectra. Introduction of a gap affects the acoustic impedance of the liner where the resonant frequency of the liners decreases with increased gap thickness for liners with an open area ratio above 25% but increases with gap thickness for liners with an open area ratio below 25%. Additionally, it is observed that increasing the gap height results in a reduction of the effect of porosity on acoustic impedance. The results show that the presence of such gaps can have a significant effect on liner impedance especially as porosity decreases.
Comparison of interlaminar damage modeling strategies for hybrid composite/aluminum laminates subjected to low-velocity impact
Low-velocity impact of hybrid metal-composite structures was investigated experimentally and computationally. Composite laminates consisting of 2D woven glass fiber reinforced polymer (GFRP) and carbon fiber reinforced polymer (CFRP) were joined with a 6061-T6 aluminum plate using an epoxy adhesive. Two variations of the structure were studied; one consisting of all plies oriented at 0° and one consisting of all plies oriented at 45°. A drop tower was used to impact structures at a range of energies, including energies above and below the threshold at which the aluminum layer was perforated. Numerical simulations were implemented using Sierra/SM, an in-house transient dynamics finite element code developed at Sandia National Laboratories. A Hosford plasticity model was used to describe the response of the aluminum layer. A newly implemented orthotropic continuum damage mechanics (CDM) constitutive model was used to represent the composite laminate. This 3D-CDM model was compared to a cohesive zone model (2D-CDM/CZM) to investigate efficacy of aluminum perforation energy prediction, delamination prediction, and computational cost. Accuracy of each model was evaluated using the experimental results. Each showed good agreement with the tests for both the force and velocity histories, as well as the observed damage mechanisms. The 2D-CDM/CZM model was marginally more accurate in capturing both the composite and aluminum behavior — this model averaged error percentages of -11.2% and 10.8% for residual velocity and peak force, respectively. Meanwhile, the 3D-CDM model predictions yielded average error percentages of -35.5% (velocity) and 22.6% (force). However, the 3D-CDM model generally resulted in a decreased computational cost; the average run time was 14% shorter than the 2D-CDM/CZM model and 3x as many timesteps per hour were computed using the same computational resources. In conclusion, new experimental data on the impact and perforation resistance of metal-composite laminates is presented in addition to numerical predictions of the impact behavior.