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At least 19 records
All sourcesNASA NTRSDOE OSTI
NASA NTRS2021

Wake Instability Behind Isolated Trip Near the Leading Edge of the BOLT-II Configuration

The BOLT-II (Holden Mission) configuration is an extended version of the BOLT flight article and depicts hypersonic boundary-layer transition in the presence of multiple and potentially interacting instability mechanisms. Several numerical studies of the boundary-layer instabilities over these configurations have been reported in the recent literature, including our previous studies of the modal instability characteristics of boundary-layer streaks adjacent to the minor-axis symmetry plane of the BOLT configuration and the wake instabilities behind a diamond planform (“pizza-box”) trip along the symmetry plane on the secondary side of the BOLT-II configuration. The present work extends the latter study to a scaled version of the same trip that is located in the region of nonzero crossflow in the vicinity of the leading edge at X/L = 0.5. Collectively, the trips along the symmetry plane and near the leading edge are the focus of the NASA roughness experiment on the secondary side of the BOLT-II configuration. The laminar basic state computation at the nominal flight design condition of Re ∞ = 5.44 x 10 6 /m and Re ∞ = 2.5 x 10 6 /m shows that the leading-edge trip with k/δ ≈ 0.70 and planform-side-length-to-height ratio of b/k = 3.0 induces multiple asymmetric, longitudinal streaks within the trip wake. The most prominent streak among these resembles a finite amplitude crossflow vortex, and it supports the amplification of multiple families of unstable modes. The application of multi-dimensional instability analysis to the wake flow reveals that the most amplified unstable mode can achieve a peak N-factor of up to 20 by X/L = 0.80, indicating that the onset of transition is more than likely to occur within eighty percent of the model length. To the best of our knowledge, the present study represents the first analysis including nonparallel and curvature effects on hypersonic tripwake instabilities in the presence of boundary-layer crossflow over a three-dimensional configuration.

Boundary layer transition↗
NASA NTRSDate not supplied

Development of the BOLT II Roughness Experiment for Flight

BOLT II is a sounding rocket research project with the goal of studying hypersonic boundary layer transition and turbulence. The BOLT II research vehicle is based on a three-dimensional geometry (a slightly longer version of BOLT) with concave surfaces and swept leading edges that provides two separate and distinct, also redundant, flow paths for conducting measurements. One side of BOLT II is dedicated to smooth surface transition and turbulence, to better study the natural instability processes, while the other has been assigned to study forced transition and turbulence using discrete roughness trips. The present paper is intended to document the primary drivers and decisions made leading up to finalizing the roughness side experiment for the BOLT II flight.

Hypersonic↗
NASA NTRSDate not supplied

Development of the BOLT II Roughness Experiment for Flight

BOLT II is a sounding rocket research project with the goal of studying hypersonic boundary layer transition and turbulence. The BOLT II research vehicle is based on a three-dimensional geometry (a slightly longer version of BOLT) with concave surfaces and swept leading edges that provides two separate and distinct, also redundant, flow paths for conducting measurements. One side of BOLT II is dedicated to smooth surface transition and turbulence, to better study the natural instability processes, while the other has been assigned to study forced transition and turbulence using discrete roughness trips. The present paper is intended to document the primary drivers and decisions made leading up to finalizing the roughness side experiment for the BOLT II flight.

hypersonic↗
NASA NTRS2021

Transition Analysis for Isolated Trips on BOLT-II Wind-Tunnel and Flight Configuration

The BOLT-II configuration designed for an upcoming flight experiment exemplifies the complexities of hypersonic boundary layer transition in the presence of multiple and potentially interacting instability mechanisms. The present paper is related to the NASA-led roughness experiment on the secondary side of the BOLT-II configuration. First, computations are performed to aid mean-flow based correlations for the transition measurements acquired during an experimental campaign in the Ludwieg Tube facility at the United States Air Force Academy. To that end, both laminar and turbulent flow computations are performed for selected conditions of the experiment with a 1:3 scale model of the slightly shorter BOLT configuration. The variation in well-known correlation parameters for transition due to isolated roughness elements with respect to element position, height, and flow Reynolds number is delineated. Furthermore, the wake instability theory is used to examine the amplification of unstable disturbances behind the centerline trip at the design conditions of the BOLT-II flight experiment and for its dynamically scaled version on the 1:3 scale model of the wind tunnel experiment. To our knowledge, this study represents the first analysis of the wake instabilities in the presence of a prominent entropy layer outside the boundary layer. At the nominal flight design condition of Re ∞ ) = 5.44 and Re ∞ = 2.5 x 10 6 /m, a diamond planform (“pizza-box”) trip with k/δ = 0.70 and planform-halfwidth-to-height ratio of b/k = 3.0 at X/L = 0.254 induces a strong distortion of the boundary-layer flow in the vicinity of the symmetry plane, such that the wake structure includes a centerline streak produced by the flow retardation behind the trip along with multiple additional, prominent vorticity structures representing the necklace vortex system. Stability results reveal that each of these streaks can support a strong amplification of wake instabilities within a frequency band of 95 kHz–255 kHz, with a peak N-factor of greater than 15 beyond X/L ≈ 0.42. The dynamically scaled wind tunnel configuration with Re ∞ = 20.25 x 10 6 /m is also found to support N > 15 at similar axial stations.

BOLT↗
NASA NTRS2021

Transition Analysis for Isolated Trips on BOLT-II Wind-Tunnel and Flight Configuration

The BOLT-II configuration designed for an upcoming flight experiment exemplifies the complexities of hypersonic boundary layer transition in the presence of multiple and potentially interacting instability mechanisms. The present paper is related to the NASA-led roughness experiment on the secondary side of the BOLT-II configuration. First, computations are performed to aid mean-flow based correlations for the transition measurements acquired during an experimental campaign in the Ludwieg Tube facility at the United States Air Force Academy. To that end, both laminar and turbulent flow computations are performed for selected conditions of the experiment with a 1:3 scale model of the slightly shorter BOLT configuration. The variation in well-known correlation parameters for transition due to isolated roughness elements with respect to element position, height, and flow Reynolds number is delineated. Furthermore, the wake instability theory is used to examine the amplification of unstable disturbances behind the centerline trip at the design conditions of the BOLT-II flight experiment and for its dynamically scaled version on the 1:3 scale model of the wind tunnel experiment. To our knowledge, this study represents the first analysis of the wake instabilities in the presence of a prominent entropy layer outside the boundary layer. At the nominal flight design condition of Re ∞ ) = 5.44 and Re ∞ = 2.5 x 10 6 /m, a diamond planform (“pizza-box”) trip with k/δ = 0.70 and planform-halfwidth-to-height ratio of b/k = 3.0 at X/L = 0.254 induces a strong distortion of the boundary-layer flow in the vicinity of the symmetry plane, such that the wake structure includes a centerline streak produced by the flow retardation behind the trip along with multiple additional, prominent vorticity structures representing the necklace vortex system. Stability results reveal that each of these streaks can support a strong amplification of wake instabilities within a frequency band of 95 kHz–255 kHz, with a peak N-factor of greater than 15 beyond X/L ≈ 0.42. The dynamically scaled wind tunnel configuration with Re ∞ = 20.25 x 10 6 /m is also found to support N > 15 at similar axial stations.

BOLT↗
NASA NTRSDate not supplied

BOLT II Roughness-Side Flight Results

An initial review of the roughness data from the BOLT II flight is provided. The BOLT II roughness experiment was designed to investigate discrete trips in flight based on the diamond configuration, which has been shown to be an efficient vortex generator and boundary layer trip from extensive ground-based testing. There were three trip locations chosen for the flight test and their size (height and width) were tailored to the local boundary layer thickness, but all three were expected to trip at the same time or flight condition. Details about the flight vehicle design, instrumentation, and best estimated trajectory are discussed. The present paper is limited to only a review and analysis of the thermocouple data. Boundary layer transition onset times are derived from the thermocouple analysis, thus allowing an initial assessment of the performance of these discrete trips. Since the three trips were sized to trip the boundary layer at the same time, based on a previous wind tunnel study, the present analysis indicates that they performed as expected.

Hypersonic↗
NASA NTRS2023

BOLT II Forebody Surface Measurement Analysis

Surface impression molds of the nosetip/forebody interface, discrete tripping elements, and other surface imperfections were formed on the BOLT II flight vehicle prior to its launch in March 2022. The silicon-rubber molds cast on the interface between the nickel nosetip and the stainless steel forebody were measured using a 3D optical measurement system and a stylus profilometer and were evaluated for step direction and height. The step around the nosetip/forebody interface was found to vary in both magnitude and direction, but values were generally modest with most samples below 60 μm across the span and only two samples, both cast in the gutter, with step values larger than 100 μm. Impressions of the secondary-side tripping elements were strictly scanned with the optical device and similar methods were used to calculate trip height as step height. The measured centerline trip height was 2623 ±12 μm, while the leading-edge, quadrant 2 and 3, trip heights were 897 ±5 μm and 891 ±18 μm, respectively. Surface imperfections on the nose and forebody were also evaluated. Surface roughness values and spectra were estimated, and profiles were extracted across the imperfections to quantify the magnitude of those features.

Trip height↗
NASA NTRSDate not supplied

Recent BOLT Discrete-Roughness Trip Results from the 20-Inch Mach 6 Tunnel

- Air Force Office of Scientific Research (AFOSR) primary sponsor of BOLT (for Boundary Layer Transition) sounding rocket flight project as continuation of previous HIFiRE flights (1 & 5) - Sounding rockets provide cost-effective flight research tool - Study hypersonic BoLT on increasingly complex geometries - BOLT shape includes concave surfaces and swept leading edges - Two missions, two flights: - BOLT mission at Esrange, Sweden - Johns Hopkins University Applied Physics Laboratory as lead - Focus on transition onset measurements - Flew June 2021 (staging anomaly) - BOLT II mission at Wallops Flight Facility, Virginia - Texas A&M and CUBRC provide primary leadership - Focus on turbulence measurements - Flew March 2022 - Flight named in memory of Mike Holden - NASA’s support to both BOLT missions provided through the Hypersonic Technologies Project (HTP)

Hypersonic↗
NASA NTRSDate not supplied

Development of Optical Step Height Measurement Capability for the BOLT Flight Vehicle

This paper presents details on the development of testing procedures to evaluate two different optical step height sensors that were intended for use on the first and second Boundary Layer Transition (BOLT and BOLT II) flight vehicle as well as other flight vehicles. The accurate and precise measurement of step height at the interface of different sections of a flight vehicle is important, as small changes in the step height (in some instances < 10 microns) at such locations can have a significant influence on the development of a boundary layer over the outer surface of the vehicle, which in turn can significantly impact aeroheating (among other things). In this paper, testing procedures have been developed, and test hardware assembled, to determine the capabilities of two optical step height sensor candidates. The first candidate is a miniaturized camera sensor that would be embedded into the body of a flight vehicle and would image the interface between two sections of that vehicle. The second candidate is a small fiber-based optical sensor that would also be embedded into the body of the flight vehicle, but projects light onto the interface between two sections of the flight vehicle, and then monitors any reflected/scattered light from that interface. Preliminary data from these two sensor candidates are presented, and a discussion of improvements that will be made in the testing procedures and to the test hardware is provided.

Brett F Bathel↗
NASA NTRS2016

Free-Piston Stirling Power Conversion Unit for Fission Power System, Phase II Final Report

In Phase II, the manufacture and testing of two 6-kW(sub e)Stirling engines was completed. The engines were delivered in an opposed 12-kW(sub e) arrangement with a common expansion space heater head. As described in the Phase I report, the engines were designed to be sealed both hermetically and with a bolted O-ring seal. The completed Phase II convertor is in the bolted configuration to allow future disassembly. By the end of Phase II, the convertor had passed all of the final testing requirements in preparation for delivery to the NASA Glenn Research Center. The electronic controller also was fabricated and tested during Phase II. The controller sets both piston amplitudes and maintains the phasing between them. It also sets the operating frequency of the machine. Details of the controller are described in the Phase I final report. Fabrication of the direct-current to direct-current (DC-DC) output stage, which would have stepped down the main controller output voltage from ~700 to 120 V(sub DC), was omitted from this phase of the project for budgetary reasons. However, the main controller was successfully built, tested with the engines, and delivered. We experienced very few development issues with this high-power controller. The project extended significantly longer than originally planned because of yearly funding delays. The team also experienced several hardware difficulties along the development path. Most of these were related to the different thermal expansions of adjacent parts constructed of different materials. This issue was made worse by the large size of the machine. Thermal expansion problems also caused difficulties in the brazing of the opposed stainless steel sodium-potassium (NaK) heater head. Despite repeated attempts Sunpower was not able to successfully braze the opposed head under this project. Near the end of the project, Glenn fabricated an opposed Inconel NaK head, which was installed prior to delivery for testing at Glenn. Engine development prior to this was performed using both single- and dual-opposed (common expansion space) Inconel heads with clamp-on electric heaters.

Free-piston Stirling Power Conversion Unit↗
NASA NTRSDate not supplied

Transition prediction in hypersonic regime on complex geometries with RANS-based models

In the near future, RANS computations will continue to play a significant role in the design of hypersonic vehicles with complex geometries. Therefore, it is imperative to continue testing, benchmarking, and refining the RANS models. In the present study, we evaluate RANS-like, transport equations-based models for predicting laminar-turbulent transition over a full-scale scale model of the BOLT flight configuration that was tested in the CUBRC LENS-II wind tunnel test facility. Based on the availability of the experimental results, comparisons are made between computations from several pre-existing transition models and Computational Fluid Dynamics (CFD) codes, with an emphasis on using the same computational meshes and flow conditions for all computations. The analysis covers the sensitivity of the transition predictions to the input parameters for five different transition models (four mainstream models designed for low-speed flows and a uniquely high-speed model), grid resolution, and the details of model implementation across three different flow solvers. The results show that the phenomenological models can describe significant aspects of the measured transition front. However, a number of additional improvements are required before these models can offer more reliable estimates of transition in high-speed flows.

CFD↗
NASA NTRSDate not supplied

Transition Prediction in Hypersonic Regime on Complex Geometries With Rans-Based Models

In the near future, RANS computations will continue to play a significant role in the design of hypersonic vehicles with complex geometries. Therefore, it is imperative to continue testing, benchmarking, and refining the RANS models. In the present study, we evaluate RANS-like, transport equations-based models for predicting laminar-turbulent transition over a full-scale scale model of the BOLT flight configuration that was tested in the CUBRC LENS-II wind tunnel test facility. Based on the availability of the experimental results, comparisons are made between computations from several pre-existing transition models and Computational Fluid Dynamics (CFD) codes, with an emphasis on using the same computational meshes and flow conditions for all computations. The analysis covers the sensitivity of the transition predictions to the input parameters for five different transition models (four mainstream models designed for low-speed flows and a uniquely high-speed model), grid resolution, and the details of model implementation across three different flow solvers. The results show that the phenomenological models can describe significant aspects of the measured transition front. However, a number of additional improvements are required before these models can offer more reliable estimates of transition in high-speed flows.

CFD↗
NASA NTRS2012

Process Sensitivity, Performance, and Direct Verification Testing of Adhesive Locking Features

Phase I: The use of adhesive locking features or liquid locking compounds (LLCs) (e.g., Loctite) as a means of providing a secondary locking feature has been used on NASA programs since the Apollo program. In many cases Loctite was used as a last resort when (a) self-locking fasteners were no longer functioning per their respective drawing specification, (b) access was limited for removal & replacement, or (c) replacement could not be accomplished without severe impact to schedule. Long-term use of Loctite became inevitable in cases where removal and replacement of worn hardware was not cost effective and Loctite was assumed to be fully cured and working. The NASA Engineering & Safety Center (NESC) and United Space Alliance (USA) recognized the need for more extensive testing of Loctite grades to better understand their capabilities and limitations as a secondary locking feature. These tests, identified as Phase I, were designed to identify processing sensitivities, to determine proper cure time, the correct primer to use on aerospace nutplate, insert and bolt materials such as A286 and MP35N, and the minimum amount of Loctite that is required to achieve optimum breakaway torque values. The .1900-32 was the fastener size tested, due to wide usage in the aerospace industry. Three different grades of Loctite were tested. Results indicate that, with proper controls, adhesive locking features can be successfully used in the repair of locking features and should be considered for design. Phase II: Threaded fastening systems used in aerospace programs typically have a requirement for a redundant locking feature. The primary locking method is the fastener preload and the traditional redundant locking feature is a self-locking mechanical device that may include deformed threads, non-metallic inserts, split beam features, or other methods that impede movement between threaded members. The self-locking resistance of traditional locking features can be directly verified during assembly by measuring the dynamic prevailing torque. Adhesive locking features or LLCs are another method of providing redundant locking, but a direct verification method has not been used in aerospace applications to verify proper installation when using LLCs because of concern for damage to the adhesive bond. The reliability of LLCs has also been questioned due to failures observed during testing with coupons for process verification, although the coupon failures have often been attributed to a lack of proper procedures. It is highly desirable to have a direct method of verifying the LLC cure or bond integrity. The purpose of the Phase II test program was to determine if the torque applied during direct verification of an adhesive locking feature degrades that locking feature. This report documents the test program used to investigate the viability of such a direct verification method. Results of the Phase II testing were positive, and additional investigation of direct verification of adhesive locking features is merited.

Golden, Johnny L.↗
DOE OSTI2020

Structural, Criticality, and Radiation Dose Calculations to support SNF Loading into a DOE Standard Canister

The DOE Standard Canister Demonstration Project includes the development of an internal support structure (ISS) for the 4.6-m long and 45.7-cm diameter canister. This study presents structural evaluations, criticality safety assessments, and dose rate calculations conducted within the scope of the ISS design process to support smooth canister loading operations and to ensure safe storage, transportation, and disposal of Peach Bottom 1 Core II (PB2) and Fort St. Vrain (FSV) SNF, currently stored at the CPP-603 facility of the INL. The ISS includes a 316L stainless steel basket that holds twelve PB2 SNF rods. Further, six individual, 78.7-cm long, 316L stainless steel columns are equally spaced and welded to the inner canister wall at the lower end of the shell. These columns represent the FSV basket and can hold one FSV SNF element. An A92014 T6 aluminum spacer disc is bolted to the bottom plate of the PB2 basket to vertically restrain the FSV SNF element after the PB2 basket is placed inside the canister on top of the FSV basket. The structural evaluations of the ISS followed applicable ASME BPVC.III.3 guidelines and included finite element (FE) analyses of the PB2 basket structure; analyses of welds and bolds; buckling analyses of selected components, and acceptability assessments of the expected basket deformations under loading operations. The criticality safety assessments used the Monte Carlo N-Particle (MCNP) software architecture version 6.2 including ENDF/B-V continuous energy cross-section libraries, considering intact SNF in a single storage overpack or two multi-storage overpack configurations, and intact or failed SNF configured for disposal. The dose rate computations are based on source terms taken from the DOE Spent Fuel Database. The isotopic composition was decay corrected for the year 2022 using the ORIGEN module in the SCALE suite. A 19-group photon spectrum and 27-group neutron-source spectra were generated and used in MCNP to calculate estimated dose-equivalent rates, both on DOE Standard Canister contact and at a radial distance of from the canister surface. The results of this study indicate a structurally sound system that can uphold its criticality safety functions throughout its intended operational phases. Further, they increase confidence that sufficient radiological protection is technically achievable.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2022

Structural, Criticality, and Radiation Dose Calculations to Support SNF Loading into a DOE Standard Canister

The DOE Standard Canister Demonstration Project includes the development of an internal support structure (ISS) for the 4.6-m-long and 45.7-cm-diameter canister. This study presents structural evaluations, criticality safety assessments, and dose rate calculations conducted within the scope of the ISS design process to support smooth canister loading operations and to ensure safe storage, transportation, and disposal of Peach Bottom 1 Core II (PB2) and Fort St. Vrain (FSV) SNF, currently stored at INL’s CPP-603 facility. The ISS includes a 316L stainless-steel basket that holds 12 PB2 SNF rods. The PB2 basket rests on top of six individual, 78.7-cm-long, 316L stainless-steel columns that are equally spaced and welded to the inner canister wall at the lower end of the shell. These columns represent the FSV basket and can hold one FSV SNF element. An A92014 T6 aluminum spacer disc is bolted to the bottom plate of the PB2 basket to vertically restrain the FSV SNF element after the PB2 basket is placed inside the canister above the FSV basket. The structural evaluations of the ISS followed applicable ASME BPVC.III.3 guidelines and included finite element (FE) analyses of the PB2 basket structure; analyses of welds and bolds; buckling analyses of selected components, and acceptability assessments of the expected basket deformations under loading operations. The criticality safety assessments used the Monte Carlo N-Particle (MCNP) software architecture Version 6.2, including ENDF/B-V continuous-energy cross-section libraries, considering intact SNF in a single storage overpack or two multistorage overpack configurations and intact or failed SNF configured for disposal. The dose rate computations are based on source terms taken from the DOE Spent Fuel Database. The isotopic composition was decay corrected for the year 2022 using the ORIGEN module in the SCALE suite. A 19-group photon spectrum and a 27-group neutron-source spectrum were generated and used in MCNP to calculate estimated dose-equivalent rates, both on DOE Standard Canister contact and at a radial distance of 1 m from the canister surface. The results of this study indicate a structurally sound system that can uphold its criticality safety functions throughout its intended operational phases. Furthermore, this study provides confidence that sufficient radiological protection is technically achievable.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗