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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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At least 145 records · Page 8
All sourcesNASA NTRSDOE OSTI
NASA NTRS1973

Droplet breakup in accelerating gas flows. Part 2: Secondary atomization

An experimental investigation to determine the effects of an accelerating gas flow on the atomization characteristics of liquid sprays was conducted. The sprays were produced by impinging two liquid jets. The liquid was molten wax and the gas was nitrogen. The use of molten wax allowed for a quantitative measure of the resulting dropsize distribution. The results of this study, indicate that a significant amount of droplet breakup will occur as a result of the action of the gas on the liquid droplets. Empirical correlations are presented in terms of parameters that were found to affect the mass median dropsize most significantly, the orifice diameter, the liquid injection velocity, and the maximum gas velocity. An empirical correlation for the normalized dropsize distribution is also presented. These correlations are in a form that may be incorporated readily into existing combustion model computer codes for the purpose of calculating rocket engine combustion performance.

Zajac, L. J.↗
DOE OSTI2020

In-situ monitoring for liquid metal jetting using a millimeter-wave impedance diagnostic

Abstract This article presents a millimeter-wave diagnostic for the in-situ monitoring of liquid metal jetting additive manufacturing systems. The diagnostic leverages a T-junction waveguide device to monitor impedance changes due to jetted metal droplets in real time. An analytical formulation for the time-domain T-junction operation is presented and supported with a quasi-static full-wave electromagnetic simulation model. The approach is evaluated experimentally with metallic spheres of known diameters ranging from 0.79 to 3.18 mm. It is then demonstrated in a custom drop-on-demand liquid metal jetting system where effective droplet diameters ranging from 0.8 to 1.6 mm are detected. Experimental results demonstrate that this approach can provide information about droplet size, timing, and motion by monitoring a single parameter, the reflection coefficient amplitude at the input port. These results show the promise of the impedance diagnostic as a reliable in-situ characterization method for metal droplets in an advanced manufacturing system.

42 ENGINEERING↗
DOE OSTI2022

In-process monitoring and prediction of droplet quality in droplet-on-demand liquid metal jetting additive manufacturing using machine learning

Abstract In droplet-on-demand liquid metal jetting (DoD-LMJ) additive manufacturing, complex physical interactions govern the droplet characteristics, such as size, velocity, and shape. These droplet characteristics, in turn, determine the functional quality of the printed parts. Hence, to ensure repeatable and reliable part quality it is necessary to monitor and control the droplet characteristics. Existing approaches for in-situ monitoring of droplet behavior in DoD-LMJ rely on high-speed imaging sensors. The resulting high volume of droplet images acquired is computationally demanding to analyze and hinders real-time control of the process. To overcome this challenge, the objective of this work is to use time series data acquired from an in-process millimeter-wave sensor for predicting the size, velocity, and shape characteristics of droplets in DoD-LMJ process. As opposed to high-speed imaging, this sensor produces data-efficient time series signatures that allows rapid, real-time process monitoring. We devise machine learning models that use the millimeter-wave sensor data to predict the droplet characteristics. Specifically, we developed multilayer perceptron-based non-linear autoregressive models to predict the size and velocity of droplets. Likewise, a supervised machine learning model was trained to classify the droplet shape using the frequency spectrum information contained in the millimeter-wave sensor signatures. High-speed imaging data served as ground truth for model training and validation. These models captured the droplet characteristics with a statistical fidelity exceeding 90%, and vastly outperformed conventional statistical modeling approaches. Thus, this work achieves a practically viable sensing approach for real-time quality monitoring of the DoD-LMJ process, in lieu of the existing data-intensive image-based techniques.

Gaikwad, Aniruddha (ORCID:0000000285642621)↗
NASA NTRS1989

Holographic diagnostics of breakup phenomena of impinging jets for liquid rocket motor applications

The use of pulsed laser holography in analyzing the atomization of impinging jets is evaluated using a holographic camera system capable of recording a 3D image of the atomization process in 3 x 10 exp -8 seconds. The holocamera and the experimental configuration and procedure are described in detail. Two nozzles were fabricated to produce 1-mm diameter liquid water jets that impinged at 60 and 90 deg. Holograms were obtained for each nozzle at liquid velocities of 20 and 40 m/s. Analysis of the holograms revealed the evolution of the jets from the plane of emergence through the region of droplet formation. Features of interest included the growth of disturbances prior to the breakup region and the effect of these disturbances on the formation of ligaments and liquid globules. Preliminary analyses show that waves of atomized liquid formed after impingement are closely correlated to waves measured on the jets, leading to the possibility of controlling the atomization process at the nozzle.

Hess, C. F.↗
NASA NTRS1990

Atomization modeling in a multiphase flow environment and comparison with experiments

An atomization model based on Reitz's instability wave analysis has been implemented into the ARICC3D multiphase CFD combustion code. Preliminary test runs with cold non-evaporating liquid jet and coaxial gas-liquid atomization cases appeared to have verified basic performance of the model, generating realistic-looking sprays. Furthermore, the extended liquid jet is explicitly resolved, and predicted jet lengths agree well with classical correlations. Fair agreement with test data is obtained for predicted spray tip penetrations and liquid mass flux radial distributions, with obvious room for improvement. Some numerical problems also appear to have resulted with the current implementation when low gas Mach number and high liquid velocities are involved.

Liang, P. Y.↗
NASA NTRS2005

Analysis of a Free Surface Film from a Controlled Liquid Impinging Jet over a Rotating Disk Including Conjugate Effects, with and without Evaporation

A detailed analysis of the liquid film characteristics and the accompanying heat transfer of a free surface controlled liquid impinging jet onto a rotating disk are presented. The computations were run on a two-dimensional axi-symmetric Eulerian mesh while the free surface was calculated with the volume of fluid method. Flow rates between 3 and 15 1pm with rotational speeds between 50 and 200 rpm are analyzed. The effects of inlet temperature on the film thickness and heat transfer are characterized as well as evaporative effects. The conjugate heating effect is modeled, and was found to effect the heat transfer results the most at both the inner and outer edges of the heated surface. The heat transfer was enhanced with both increasing flow rate and increasing rotational speeds. When evaporative effects were modeled, the evaporation was found to increase the heat transfer at the lower flow rates the most because of a fully developed thermal field that was achieved. The evaporative effects did not significantly enhance the heat transfer at the higher flow rates.

Sankaran, Subramanian↗
NASA NTRS1989

Gas density effect on dropsize of simulated fuel sprays

Two-phase flow in pneumatic two-fluid fuel nozzles was investigated experimentally to determine the effect of atomizing-gas density and gas mass-flux on liquid-jet breakup in sonic-velocity gas-flow. Dropsize data were obtained for the following atomizing-gases: nitrogen; argon; carbon dioxide; and helium. They were selected to cover a gas molecular-weight range of 4 to 44. Atomizing-gas mass-flux ranged from 6 to 50 g/sq cm-sec and four differently sized two-fluid fuel nozzles were used having orifice diameters that varied from 0.32 to 0.56 cm. The ratio of liquid-jet diameter to SMD, D sub o/D sub 32, was correlated with aerodynamic and liquid-surface forces based on the product of the Weber and Reynolds number, We*Re, and gas-to-liquid density ratio, rho sub g/rho sub l. To correlate spray dropsize with breakup forces produced by using different atomizing-gases, a new molecular-scale dimensionless group was derived. The derived dimensionless group was used to obtain an expression for the ratio of liquid-jet diameter to SMD, D sub o/D sub 32. The mathematical expression of this phenomenon incorporates the product of the Weber and Reynolds number, liquid viscosity, surface tension, acoustic gas velocity, the RMS velocity of gas molecules, the acceleration of gas molecules due to gravity, and gas viscosity. The mathematical expression encompassing these parameters agrees well with the atomization theory for liquid-jet breakup in high velocity gas flow. Also, it was found that at the same gas mass-flux, helium was considerably more effective than nitrogen in producing small droplet sprays with SMD's in the order of 5 micrometers.

Ingebo, Robert D.↗
NASA NTRS1989

Gas density effect on dropsize of simulated fuel sprays

Two-phase flow in pneumatic two-fluid fuel nozzles was investigated experimentally to determine the effect of atomizing-gas density and gas mass-flux on liquid-jet breakup in sonic-velocity gas-flow. Dropsize data were obtained for the following atomizing-gases: nitrogen; argon; carbon dioxide; and helium. They were selected to cover a gas molecular-weight range of 4 to 44. Atomizing-gas mass-flux ranged from 6 to 50 g/sq cm-sec and four differently sized two-fluid fuel nozzles were used having orifice diameters that varied from 0.32 to 0.56 cm. The ratio of liquid-jet diameter to SMD, D sub o/D sub 32, was correlated with aerodynamic and liquid-surface forces based on the product of the Weber and Reynolds number, and gas-to-liquid density ratio, rho sub g/rho sub 1. To correlate spray dropsize with breakup forces produced by using different atomizing-gases, a new molecular-scale dimensionless group was derived. The derived dimensionless group was used to obtain an expression for the ratio of liquid-jet diameter to SMD, D sub o/D sub 32. The mathematical expression of this phenomenon incorporates the product of the Weber and Reynolds number, liquid viscosity, surface tension, acoustic gas velocity, the RMS velocity of gas molecules, the acceleration of gas molecules due to gravity, and gas viscosity. The mathematical expression encompassing these parameters agrees well with the atomization theory for liquid-jet breakup in high velocity gas flow. Also, it was found that at the same gas mass-flux, helium was considerably more effective than nitrogen in producing small droplet sprays with SMD's in the order of 5 micrometers.

Ingebo, Robert D.↗
DOE OSTI2021

The effect of transient needle lift on the internal flow and near-nozzle spray characteristics for modern GDI systems investigated by high-speed X-ray imaging

The development of the injector nozzle is a dynamic area in regard of several technical aspects. At first, the internal flow influences the near-field spray characteristics via various phenomena such as cavitation and turbulence. However, these phenomena are not fully understood due to their extremely fast, complex and multiscale nature. Furthermore, it governs the spray targeting inside the combustion chamber. High-speed X-ray imaging of GDI injector nozzles is performed in this study. The experimental results presented are related to the internal flow and primary breakup of discharged liquid jets. The injectors used are equipped with nozzles made of aluminum which have been specially developed for these investigations to enhance optical accessibility. The visualization of the needle motion, in-nozzle flow and the primary breakup region provides several exciting observations. First, the needle lift tracking exhibits short overshooting right before the steady-state of the injection phase. Additionally, this event leads to a short-term, however, significant change in the associated performance of the breakup. This phenomenon is found to be a consequence of the transient behavior of the in-nozzle flow. It is shown that under some circumstances hydraulic flip may occur during this overshooting period. The primary jet breakup region is visualized and evaluated by means of image processing. Thus, the transient behavior of liquid jet expansion is quantified in the vicinity of the nozzle. It is observed that the liquid jet direction deviates from the hole axis already at the nozzle outlet, which is caused by internal flow characteristics.

42 ENGINEERING↗
NASA NTRS1988

Small-droplet spray measurements with a scattered-light scanner

Interacting two-phase flow through pneumatic two-fluid nozzles was investigated to determine the effect of nitrogen gas mass-velocity on the Sauter mean diameter of water sprays produced by the breakup of small diameter liquid-jets in high velocity gas streams. Tests were conducted primarily in the aerodynamic-stripping regime of liquid-jet atomization. It was found that the loss of droplets due to vaporization and dispersion had a marked effect on drop size measurements. A scattered-light scanner, developed at NASA Lewis Research Center was used to measure Sauter mean diameters, D sub 32, as small as 5 microns, which were correlated with nitrogen gas mass-velocity to give the following expression: D(sup -1)(sub 32) = 11.7(rho (sub n) V(sub n))(sup 1.33) where D sub 32 and p(sub n)V(sub n) are given in centimeters and g/sq cm-sec, respectively. The exponent 1.33 is the same as that predicted by atomizing theory for liquid-jet breakup in high velocity gas streams.

Ingebo, Robert D.↗
DOE OSTI2022

Experimental Demonstration of the Thin-Film Liquid-Metal Jet as a Charge Stripper

For high-power heavy ion accelerators, the development of a suitable charge stripper, which can handle intense beams, is essential. This Letter describes the first experimental demonstration of a heavy ion liquid lithium charge stripper. A 10–20 μm thick liquid lithium jet flowing at >50 m/s was formed and confirmed stable when bombarded by various heavy ion beams, while increasing the charge state of the incoming beams to the desired charge state range. Finally, this demonstration proved the existing power limitation with the conventional strippers can be overcome by the liquid-metal stripper, opening completely new possibilities in high-power accelerator development.

43 PARTICLE ACCELERATORS↗
NASA NTRS2006

A Computational and Experimental Investigation of Shear Coaxial Jet Atomization

The instability and subsequent atomization of a viscous liquid jet emanated into a high-pressure gaseous surrounding is studied both computationally and experimentally. Liquid water issued into nitrogen gas at elevated pressures is used to simulate the flow conditions in a coaxial shear injector element relevant to liquid propellant rocket engines. The theoretical analysis is based on a simplified mathematical formulation of the continuity and momentum equations in their conservative form. Numerical solutions of the governing equations subject to appropriate initial and boundary conditions are obtained via a robust finite difference scheme. The computations yield real-time evolution and subsequent breakup characteristics of the liquid jet. The experimental investigation utilizes a digital imaging technique to measure resultant drop sizes. Data were collected for liquid Reynolds number between 2,500 and 25,000, aerodynamic Weber number range of 50-500 and ambient gas pressures from 150 to 1200 psia. Comparison of the model predictions and experimental data for drop sizes at gas pressures of 150 and 300 psia reveal satisfactory agreement particularly for lower values of investigated Weber number. The present model is intended as a component of a practical tool to facilitate design and optimization of coaxial shear atomizers.

Ibrahim, Essam A.↗
DOE OSTI2020

Shock Damage Analysis in Serial Femtosecond Crystallography Data Collected at MHz X-ray Free-Electron Lasers

Serial femtosecond crystallography (SFX) data were recorded at the European X-ray free-electron laser facility (EuXFEL) with protein microcrystals delivered via a microscopic liquid jet. An XFEL beam striking such a jet may launch supersonic shock waves up the jet, compromising the oncoming sample. To investigate this efficiently, we employed a novel XFEL pulse pattern to nominally expose the sample to between zero and four shock waves before being probed. Analyzing hit rate, indexing rate, and resolution for diffraction data recorded at MHz pulse rates, we found no evidence of damage. Notably, however, this conclusion could only be drawn after careful identification and assimilation of numerous interrelated experimental factors, which we describe in detail. Failure to do so would have led to an erroneous conclusion. Femtosecond photography of the sample-carrying jet revealed critically different jet behavior from that of all homogeneous liquid jets studied to date in this manner.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Full-Strength Additive Manufacturing of Pure Aluminum Alloy 7075 Using Liquid Metal Jet Printing

Additive manufacturing (AM) of high-strength aluminum alloys can produce high-performance aerospace and biomedical parts with unique geometries and functions. However, many high-performance alloy systems such as AA 7075 pose challenges during AM due to thermal cycles that cause hot cracking, limiting AM to casting-friendly alloys. Stock AA 7075 alloy poses additional challenges due to the excessive growth of insoluble precipitates during casting and needs to be thermomechanically processed to obtain acceptable mechanical properties. Here, this work uses liquid metal jet printing to produce high-resolution pure AA 7075 parts at high strength (593 MPa) and ductility (10 pct), surpassing the specific strength of any type of steel. The parts are printed by depositing fine droplets on a high-temperature substrate that reduces cooling rates, preventing hot cracking. The results show that fully dense, crack-free parts can only be printed at substrate temperatures of 500 °C with a cooling rate threshold of < 2000 K/s to prevent cracking and < 500 K/s to eliminate porosity. The tensile strength, microhardness, and ductility of the parts matched or were beyond the wrought alloy specifications after heat treatment, possibly due to high solidification rates that produce finer insoluble precipitates. Our results indicate that many challenging high-performance alloy systems can now be 3D printed based on the critical thresholds for cooling rates using any AM method that can satisfy these conditions.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Characterization and automated optimization of laser-driven proton beams from converging liquid sheet jet targets

Compact, stable, and versatile laser-driven ion sources hold great promise for applications ranging from medicine to materials science and fundamental physics. While single-shot sources have demonstrated favorable beam properties, including the peak fluxes necessary for several applications, high-repetition-rate operation will be necessary to generate and sustain the high average flux needed for many of the most exciting applications of laser-driven ion sources. Further, to navigate through the high-dimensional space of laser and target parameters toward experimental optima, it is essential to develop ion acceleration platforms compatible with machine learning techniques and capable of autonomous real-time optimization. Here, we present a multi-Hz ion acceleration platform employing a liquid sheet jet target. We characterize the laser-plasma interaction and the laser-driven proton beam across a variety of key parameters governing the interaction using an extensive suite of online diagnostics. We also demonstrate real-time, closed-loop optimization of the ion beam maximum energy by tuning the laser wave front using a Bayesian optimization scheme. This approach increased the maximum proton energy by 11% compared to a manually optimized wave front by enhancing the energy concentration within the laser focal spot, demonstrating the potential for closed-loop optimization schemes to tune future ion accelerators for robust high-repetition-rate operation.

Glenn, G. D. [SLAC National Accelerator Laboratory↗
NASA NTRS1989

High speed commercial transport fuels considerations and research needs

NASA is currently evaluating the potential of incorporating High Speed Civil Transport (HSCT) aircraft in the commercial fleet in the beginning of the 21st century. NASA sponsored HSCT enabling studies currently underway with airframers and engine manufacturers, are addressing a broad range of technical, environmental, economic, and related issues. Supersonic cruise speeds for these aircraft were originally focused in the Mach 2 to 5 range. At these flight speeds, both jet fuels and liquid methane were considered potential fuel candidates. For the year 2000 to 2010, cruise Mach numbers of 2 to 3+ are projected for aircraft fuel with thermally stable liquid jet fuels. For 2015 and beyond, liquid methane fueled aircraft cruising at Mach numbers of 4+ may be viable candidates. Operation at supersonic speeds will be much more severe than those encountered at subsonic flight. One of the most critical problems is the potential deterioration of the fuel due to the high temperature environment. HSCT fuels will not only be required to provide the energy necessary for flight, but will also be subject to aerodynamic heating and, will be required to serve as the primary heat sink for cooling the engine and airframe. To define fuel problems for high speed flight, a fuels workshop was conducted at NASA Lewis Research Center. The purpose of the workshop was to gather experts on aviation fuels, airframe fuel systems, airport infrastructure, and combustion systems to discuss high speed fuel alternatives, fuel supply scenarios, increased thermal stability approaches and measurements, safety considerations, and to provide directional guidance for future R and D efforts. Subsequent follow-up studies defined airport infrastructure impacts of high speed fuel candidates. The results of these activities are summarized. In addition, an initial case study using modified in-house refinery simulation model Gordian code (1) is briefly discussed. This code can be used to simulate different types of refineries, emphasizing jet fuel production and relative cost factors.

Lee, C. M.↗
NASA NTRS1972

Vehicle-scale investigation of a fluorine jet-pump liquid hydrogen tank pressurization system

A comprehensive analytical and experimental program was performed to evaluate the performance of a fluorine-hydrogen jet-pump injector for main tank injection (MTI) pressurization of a liquid hydrogen (LH2) tank. The injector performance during pressurization and LH2 expulsion was determined by a series of seven tests of a full-scale injector and MTI pressure control system in a 28.3 cu m (1000 cu ft) flight-weight LH2 tank. Although the injector did not effectively jet-pump LH2 continuously, it showed improved pressurization performance compared to straight-pipe injectors tested under the same conditions in a previous program. The MTI computer code was modified to allow performance prediction for the jet-pump injector.

Cady, E. C.↗
DOE OSTI2025

Ultrathin liquid sheets: water gets in shape for VUV absorption

We present absorption spectra of thin, free-flowing liquid sheets in the vacuum ultraviolet energy range using a gas-squeezed liquid jet. Compared to liquid flow cells, operation without transmission windows eliminates restrictions on the energy range. The temperature of the water sheet is estimated at 0 ± 3 °C, at the verge of the supercooled regime. By adjusting flow conditions in situ, we recorded absorption spectra at water sheet thicknesses ranging from 20 to 50 nm. We show that the absorption spectra of thin jets contain significant contributions from interference effects that need to be deconvoluted from spectral contributions due to the electronic structure. We employ a Fresnel propagation model to model the spectral changes and understand the impact of thickness variations and thin film interference. This opens the door for the investigation of solvation, interface, and similar effects by recording valence band spectra.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗