Simplified guide to thermal-spray coatings.
Metal surface property improvement by thermal- spray coating noting flame plating
FLAME PLATING↗
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Characterization of a Laminate Flat Plate Diffusion Flame in Microgravity using PIV, Visible and CH Emissions
Motivated by fire safety concerns and the advent of long-term micro-gravity facilities, a cooperative program has been developed to study the mechanisms and material properties that control flow assisted (co-current) flame spread. This program has used as a common fire scenario a reacting steady-state boundary layer. Preliminary studies explored the aerodynamics of a reacting boundary layer by simulating a condensed fuel by means of a gas burner. Stability curves for ethane air flames were obtained and different burning regimes were identified. An important feature of this study was the independent identification of the different mechanisms leading to the instability of the flow. It was observed that fuel injection velocity and thermal expansion independently contributed to the separation of the flow at the leading edge of the burner. The occurrence of separation resulted in complex three-dimensional flow patterns that have a dominant effect on critical fire safety parameters such as the stand-off distance and flame length. This work was extended to a solid fuel (PMMA) leading to a Sounding Rocket experiment (Mini-Texus-6). The solid phase showed similar flow patterns, mostly present at low flow velocities (<100 mm/s) but the results clearly demonstrated that the thermal balance at the pyrolyzing fuel surface is the dominant mechanism that controls both stand-off distance and flame length. This thermal balance could be described in a global manner by means of a total mass transfer or "B" number. This "B" number incorporates surface re-radiation, radiative feedback and in-depth heat conduction as first prescribed by Emmons. The mass transfer number becomes the single parameter that determines the evolution of these fire safety variables (flame length, stand-off distance) and therefore can be used as a ranking criterion to assess the flammability of materials. The particular configuration is representative of the NASA upward flame spread test (Test 1) therefore this approach can be used in the interpretation of the results obtained from this test. Nevertheless, complete validation of this approach has not been fully achieved due, mainly because all the measurements necessary to compare with the theoretical predictions have not been obtained. Following these studies two different directions have been taken. The first attempts to elucidate the details of the gas phase combustion reaction and the associated flow field by means of quantitative and qualitative measurements. The second approach, a more practical one, is to apply this methodology to the assessment of material flammability. The former is currently being conducted with a gas burner because it allows for easier control and longer experimentation time. The results obtained so far will be presented in more detail. The latter is a new program therefore only a brief summary of the objectives will be presented.
Joulain, P.↗
The effect of turbulence on pollutant formation in a tubular burner
The role of turbulence in pollutant formation was investigated both experimentally and analytically with the objective of understanding the important mechanisms of a fairly basic level. Preliminary measurements of the cold-flow turbulence characteristics downstream of three perforated plate flame holders, of varying solidity ratio, were made. In the combustion experiment, measurements of the concentration distributions of CO, NO(x), HC, and CO2, downstream of the same flame holders, were made. The combustor configuration was tubular and constant-area, and the fuel was premixed, prevaporized propane. The experimental results were modeled by a one-dimensional analysis in which transport phenomena were neglected, and more successfully, by a quasi-one-dimensional analysis containing recirculation zones and turbulent transport effects.
Robinson, G. F.↗
Effects of percentage of blockage and flameholder downstream counterbores on lean combustion limits of premixed, prevaporized propane-air mixture
Lean combustion limits were determined for a premixed prevaporized propane air mixture with flat plate flame stabilizers. Experiments were conducted in a constant area flame tube combustor utilizing flameholders of varying percentages of blockage and downstream counterbores. Combustor inlet air velocity at ambient conditions was varied from 4 to 9 meters per second. Flameholders with a center hole and four half holes surrounding it were tested with 63, 73, and 85 percent blockage and counterbore diameters of 112 and 125 percent of the thru hole diameter, in addition to the no counterbore configuration. Improved stability was obtained by using counterbore flameholders and higher percentages of blockage. Increases in mixture velocity caused the equivalence ratio at blowout to increase in all cases.
Fernandez, M. A. B.↗
Effect of Flame Stabilizer Design on Performance and Exhaust Pollutants of a Two-Row Swirl-Can Combustor Operated to Near-Stoichiometric Conditions
Emissions and performance characteristics were determined for two full annulus modular combustors operated to near stoichiometric fuel air ratios. The tests were conducted to obtain stoichiometric data at inlet air temperatures from 756 to 894 K and to determine the effects of a flat plate circular flame stabilizer with upstream fuel injection and a contraswirl flame stabilizer with downstream fuel injection. Levels of unburned hydrocarbons were below 0.50 gram per kilogram of fuel for both combustors and thus there was no detectable difference in the two methods of fuel injection. The contraswirl flame stabilizer did not produce the level of mixing obtained with a flat plate circular flame stabilizer. It did produce higher levels of oxides of nitrogen, which peaked at a fuel air ratio of 0.037. For the flat plate circular flame stabilizer, oxides of nitrogen emission levels were still increasing with fuel air ratio to the maximum tested value of 0.045.
Biaglow, James A.↗
Porous plate analog burner study of composite solid propellant flame structure
A porous plate burner system for studying the structure and interaction of diffusion flames from adjacent unlike sources of oxidizer to simulate the behavior of solid propellant flames is presented. The passage of oxidizer gases through ports of determined diameters represents decomposing oxidizer crystals, and are adjustable for various oxidizer/fuel ratio experiments. Tests with air, ethane, oxygen, and oxygen-air mixtures are described, with parameters of flow rate, oxygen/fuel ratio, and pressure. Coarse ports are found to be oxidizer rich, while fine ports are stoichiometric. More heat feedback is found with fine ports, indicating that fine particle propellant systems burn faster unless fuel allocation is such that the reduced temperature overcomes the reduced diffusion length. Further observations on the interactions of flames are reported.
Strand, L. D.↗
Application of Shear Plate Interferometry to Jet Diffusion Flame Temperature Measurements
The recent ban on the production of bromotrifluoromethane (CF3Br) because of its high stratospheric ozone depletion potential has led to interest in finding alternative agents for fire extinguishing applications. Some of the promising alternatives are fluorinated hydrocarbons. A clear understanding of the effects of CF3Br and alternative chemical suppressants on diffusion flames is therefore necessary in the selection of alternative suppressants for use in normal and microgravity. The flame inhibition effects of halogen compounds have been studied extensively in premixed systems. The effect of addition of halocarbons (carbon-halogen compounds) to diffusion flames has been studied experimentally in coflow configurations and in counterflow gaseous and liquid-pool flames. Halogenated compounds are believed to inhibit combustion by scavenging hydrogen radicals to form the relatively unreactive compound HF, or through a catalytic recombination cycle involving HBr to form H2. Comparisons between halogens show that bromine inhibition is significantly more effective than chlorine or fluorine. Although fluorinated compounds are only slightly more effective inhibitors on a mass basis than nitrogen, they are more effective on a volume basis and are easily stored in liquid form. The objectives of this study are (a) to determine the stability limits of laminar jet diffusion flames with respect to inhibitor concentration in both normal and microgravity, and (b) to investigate the structure of halocarbon-inhibited flames. In the initial phase of this project, visual diagnostics were used to observe the structure and behavior of normal and microgravity flames. The initial observations showed significant changes in the structure of the flames with the addition of halocarbons to the surrounding environment, as discussed below. Furthermore, the study established that the flames are more stable relative to the addition of halocarbons in microgravity than in normal gravity. Visual diagnostics of flames are, however, necessarily limited to detection of radiative emission in the visible range, and offer only qualitative information about the nature of the processes in the flame. In particular, the study sought to understand the structure of the inhibitor-perturbed flames with regard to temperature and species concentration in the outer region of the flame. Whereas thermocouple measurements can be used in ground based studies, their implementation in drop-tower rigs is limited. A possible approach to determine the temperature field around the flame is to use interferometric techniques. The implementation and testing of a shear-plate interferometry technique is described below.
VanDerWege, Brad A.↗
Transient Evolution of a Planar Diffusion Flame Aft of a Translating Flat Plate
The high degree of spatial symmetry of a planar diffusion flame affords great simplifications for experimental and modeling studies of gaseous fuel combustion. Particularly, in a microgravity environment, where buoyancy effects are negligible, an effectively strain-rate-free, vigorous flame may be obtained. Such a flame can also provide long residence times and large length scales for practical probing of flame structures and soot processes. This 2-D numerical study explores the feasibility of establishing such a planar diffusion flame in an enclosed container utilizing a realistic test protocol for a microgravity experiment. Fuel and oxygen mixtures, initially segregated into two half-volumes of a squat rectangular container by a thin separator, are ignited as soon as a flammable mixture is formed in the wake of the separator withdrawn in the centerplane. A triple-flame ensues that propagates behind the trailing edge of the separator. The results of calculations show that the mechanically- and thermally-induced convection decays in about two seconds. The establishment of a planar diffusion flame after this period seems feasible in the central region of the container with sufficient quantities of reactants left over for subsequent studies. An analysis of the flame initiation and formation process suggests how the feasibility of creating such a flame can be further improved.
Gokoglu, Suleyman A.↗
A Role of the Reaction Kernel in Propagation and Stabilization of Edge Diffusion Flames of C1-C3 Hydrocarbons
Diffusion flame stabilization is of essential importance in both Earth-bound combustion systems and spacecraft fire safety. Local extinction, re-ignition, and propagation processes may occur as a result of interactions between the flame zone and vortices or fire-extinguishing agents. By using a computational fluid dynamics code with a detailed chemistry model for methane combustion, the authors have revealed the chemical kinetic structure of the stabilizing region of both jet and flat-plate diffusion flames, predicted the flame stability limit, and proposed diffusion flame attachment and detachment mechanisms in normal and microgravity. Because of the unique geometry of the edge of diffusion flames, radical back-diffusion against the oxygen-rich entrainment dramatically enhanced chain reactions, thus forming a peak reactivity spot, i.e., reaction kernel, responsible for flame holding. The new results have been obtained for the edge diffusion flame propagation and attached flame structure using various C1-C3 hydrocarbons.
Takahashi, Fumiaki↗
Reaction Kernel Structure of a Slot Jet Diffusion Flame in Microgravity
Diffusion flame stabilization in normal earth gravity (1 g) has long been a fundamental research subject in combustion. Local flame-flow phenomena, including heat and species transport and chemical reactions, around the flame base in the vicinity of condensed surfaces control flame stabilization and fire spreading processes. Therefore, gravity plays an important role in the subject topic because buoyancy induces flow in the flame zone, thus increasing the convective (and diffusive) oxygen transport into the flame zone and, in turn, reaction rates. Recent computations show that a peak reactivity (heat-release or oxygen-consumption rate) spot, or reaction kernel, is formed in the flame base by back-diffusion and reactions of radical species in the incoming oxygen-abundant flow at relatively low temperatures (about 1550 K). Quasi-linear correlations were found between the peak heat-release or oxygen-consumption rate and the velocity at the reaction kernel for cases including both jet and flat-plate diffusion flames in airflow. The reaction kernel provides a stationary ignition source to incoming reactants, sustains combustion, and thus stabilizes the trailing diffusion flame. In a quiescent microgravity environment, no buoyancy-induced flow exits and thus purely diffusive transport controls the reaction rates. Flame stabilization mechanisms in such purely diffusion-controlled regime remain largely unstudied. Therefore, it will be a rigorous test for the reaction kernel correlation if it can be extended toward zero velocity conditions in the purely diffusion-controlled regime. The objectives of this study are to reveal the structure of the flame-stabilizing region of a two-dimensional (2D) laminar jet diffusion flame in microgravity and develop a unified diffusion flame stabilization mechanism. This paper reports the recent progress in the computation and experiment performed in microgravity.
Takahashi, F.↗
CFD Simulations of Supersonic Highly Swirling Flow Exiting a Turbine Vane Row Compared with Experimental Observations
Marshall Space Flight Center (MSFC) has been heavily involved in developing the J2-X engine. The Center has been testing a Work Horse Gas Generator (WHGG) to supply gas products to J2-X turbine components at realistic flight-like operating conditions. Three-dimensional time accurate CFD simulations and analytical fluid analysis have been performed to support WHGG tests at MSFC. The general purpose CFD program LOCI/Chem was utilized to simulate flow of products from the WHGG through a turbine manifold, a stationary row of turbine vanes, into a Can and orifice assembly used to control the back pressure at the turbine vane row and finally through an aspirator plate and flame bucket. Simulations showed that supersonic swirling flow downstream of the turbine imparted a much higher pressure on the Can wall than expected for a non-swirling flow. This result was verified by developing an analytical model that predicts wall pressure due to swirling flow. The CFD simulations predicted that the higher downstream pressure would cause the pressure drop across the nozzle row to be approximately half the value of the test objective. With CFD support, a redesign of the Can orifice and aspirator plate was performed. WHGG experimental results and observations compared well with pre-test and post-test CFD simulations. CFD simulations for both quasi-static and transient test conditions correctly predicted the pressure environment downstream of the turbine row and the behavior of the gas generator product plume as it exited the WHGG test article, impacted the flame bucket and interacted with the external environment.
West, Jeff S.↗
Composite propellant combustion modeling with a porous plate burner
A burner is designed to model on a large scale (millimeters) the complex vapor phase processes that take place on awkwardly small scales (about a hundred microns) in the combustion of practical AP/ composite propellants at conventional pressures. Binder vapor evolution is modeled with gaseous fuel (ethane in the experiments reported) flow through a porous plate and oxidizer vapor with the flow of a gaseous oxidizer (air and enriched air in the experiments reported) through discrete holes in the porous plate. Measured flame standoff distance and surface temperature variations are consistent with theoretical predictions at atmospheric pressure. Data obtained at several atmospheres are discussed in the light of the current theories of propellant burning that place varying emphasis on the roles of chemical kinetics and fluid dynamic diffusion/mixing in the vapor phase of a burning composite propellant. The potential and proposed future applications of the burner are indicated.
Kumar, R. N.↗
Design Evaluation Using Finite Element Analysis of Cooled Silicon Nitride Plates for a Turbine Blade Application
Two- and three-dimensional finite element analyses were performed on uncoated and thermal barrier coated (TBC) silicon nitride plates with and without internal cooling by air. Steady-state heat-transfer analyses were done to optimize the size and the geometry of the cooling channels to reduce thermal stresses, and to evaluate the thermal environment experienced by the plate during burner rig testing. The limited experimental data available were used to model the thermal profile exerted by the flame on the plate. Thermal stress analyses were performed to assess the stress response due to thermal loading. Contours for the temperature and the representative stresses for the plates were generated and presented for different cooling hole sizes and shapes. Analysis indicates that the TBC experienced higher stresses, and the temperature gradient was much reduced when the plate was internally cooled by air. The advantages and disadvantages of several cooling channel layouts were evaluated.
Abdul-Aziz, Ali↗
Extended soot limits for rich n-heptane/air flames
A rich n-heptane/air mixture was burned in a flat flame burner in an inert environment, and the soot limits of stable one-stage flames were measured. With a small thin metal plate placed on the flame to suppress soot-containing cusps on the flamelets, the richest soot-free flame burned was with a mixture for which the equivalence ratio was 2.25. Hydrogen yield was, however, low. Extremely rich soot-free two-stage flames could be obtained, but they were unstable.
Ryason, P. R.↗
Unsteady reacting boundary layer on a vaporizing flat plate.
Chemical reacting unsteady boundary layer analysis on vaporizing flat plate including compressibility, flame boundary and stagnation point behavior
STAGNATION POINT↗
An Experimental Study of Upward Burning Over Long Solid Fuels: Facility Development and Comparison
As NASA's mission evolves, new spacecraft and habitat environments necessitate expanded study of materials flammability. Most of the upward burning tests to date, including the NASA standard material screening method NASA-STD-6001, have been conducted in small chambers where the flame often terminates before a steady state flame is established. In real environments, the same limitations may not be present. The use of long fuel samples would allow the flames to proceed in an unhindered manner. In order to explore sample size and chamber size effects, two large chambers were developed at NASA GRC under the Flame Prevention, Detection and Suppression (FPDS) project. The first was an existing vacuum facility, VF-13, located at NASA John Glenn Research Center. This 6350 liter chamber could accommodate fuels sample lengths up to 2 m. However, operational costs and restricted accessibility limited the test program, so a second laboratory scale facility was developed in parallel. By stacking additional two chambers on top of an existing combustion chamber facility, this 81 liter Stacked-chamber facility could accommodate a 1.5 m sample length. The larger volume, more ideal environment of VF-13 was used to obtain baseline data for comparison with the stacked chamber facility. In this way, the stacked chamber facility was intended for long term testing, with VF-13 as the proving ground. Four different solid fuels (adding machine paper, poster paper, PMMA plates, and Nomex fabric) were tested with fuel sample lengths up to 2 m. For thin samples (papers) with widths up to 5 cm, the flame reached a steady state length, which demonstrates that flame length may be stabilized even when the edge effects are reduced. For the thick PMMA plates, flames reached lengths up to 70 cm but were highly energetic and restricted by oxygen depletion. Tests with the Nomex fabric confirmed that the cyclic flame phenomena, observed in small facility tests, continued over longer sample. New features were also observed at the higher oxygen/pressure conditions available in the large chamber. Comparison of flame behavior between the two facilities under identical conditions revealed disparities, both qualitative and quantitative. This suggests that, in certain ranges of controlling parameters, chamber size and shape could be one of the parameters that affect the material flammability. If this proves to be true, it may limit the applicability of existing flammability data.
Kleinhenz, Julie↗
Flame Deflector Ablation Analysis based on Artemis 1 Launch Environment
This paper presents the updated ablative analysis methods used to determine Artemis 1 launch load environment on the flame deflector for the design based on Artemis I Assessments. The flame trench under Pad 39B at Kennedy Space Center contains a flame deflector to safely divert the exhaust plume from the SLS rocket during launch. During launch of Artemis I the refurbished flame trench and the new flame deflector experienced peak temperatures of over 2,000 degrees Fahrenheit (over 1,000 degrees Celsius) for several seconds. These extreme conditions caused ablation (material removal) from the steel plates. This paper contains flame deflector heat flux values for design based on Artemis I assessment. Post flight images of the flame deflector are shown along with “Pre vs Post” Flame Deflector scan image to measure the post flight deviations. Using COMSOL, a method to calculate a heat flux value due to measured deviations in the deflector plates caused by ablation is shown.
Artemis I↗
A Simple Transient Thermal Test Assembly for Insulation Materials
A simple transient thermal test was developed for evaluating the thermal performance of high-temperature flexible insulation materials in atmospheric pressure air. The test setup was inspired by the test assembly used for evaluating the performance of fire shelters and fire protective clothing. The heating source used was a burner supplied with propane gas that can generate relatively uniform heating over a wide area. The ratio of the in-plane width to thickness of the insulation test sample in the test assembly was selected to be greater than ten so that the heat transfer in the center of the test assembly was nearly one-dimensional. A rigid, thin Inconel plate was used as the septum plate directly exposed to the flame to provide a relatively uniform, known-temperature boundary condition for the test assembly, and to prevent convective heat transfer through the test insulation from the burner. The test sample, flexible alumina paper insulation, was placed between the Inconel plate and a thin titanium witness plate. The overall assembly was further insulated using a combination of rigid and flexible ceramic insulations to minimize heat losses from the periphery of the test assembly. Thermocouples installed on the septum and witness plates and inside the insulation test sample provided temperature measurements at various locations. For the evaluation tests, the Inconel septum plate reached temperatures between 780°C and 850°C for tests with flame exposure durations of 120 sec to 300 sec. The measured temperatures for various tests with similar flame exposure times were repeatable. A one-dimensional numerical heat transfer model of the test assembly was developed. The close agreement between measured and predicted temperatures on the titanium witness plate and inside the insulation test sample indicated that this test may provide a one-dimensional thermal testing capability for evaluation of thermal performance of similar insulations.
Daryabeigi, Kamran↗