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To prevent fatigue due to flow-induced vibrations in metal bellows connected to ducts carrying liquid hydrogen, a study was made which shows that the flexure lines are in general a function of the vibration coupling between the fluid and bellows structure, and the nature of the external environment.
Flows over two curved vane configurations were computed using a time-accurate compressible Navier-Stokes flow model. One configuration showed the presence of strong flow-induced vibrations at Strouhal numbers near 0.19 and 0.38 for bending and torsional excitation. In the other configuration, a simple modification reduced both types of response. Laminar flows were analyzed for the effects of flow-induced vibrations, and flow fields were solved for a rigid vane and a vane undergoing forced vibrations at prescribed amplitude and frequency simulating vibration response to a coupled vortex-shedding/elastic motion feedback cycle.
Viscous flow-induced vibrations of elastically restrained flat plates in narrow channel, considering one dimensional viscous flow theory
The liquid-oxygen (LOX) posts are exposed to hot hydrogen flowing over the tubes on its way to the combustion chamber. Fatigue cracking of some LOX posts was observed after test firing of the SSMEs. A current design modification consists of attaching impingement shields to the LOX posts in the outer row. The modification improved the vibration/fatigue problem of the LOX posts, but resulted in an increased pressure drop that ultimately shortened the life expectancy of other components. A fundamental study of vibration of the LOX posts was initiated to understand the flow-induced vibration problem and to develop techniques to avoid detrimental vibrational effects with the overall objective of improving engine life. This effort, including an assessment of the problem, scoping calculation and experiment, and a work plan for an integrated theoretical/experimental study of the problem is summarized.
Flow-induced vibration of bellows with internal cryogenic fluid flows
Components of the Space Shuttle Main Engines (SSMEs) are subjected to a severe environment that includes high-temperature, high-velocity flows. Such flows represent a source of energy that can induce and sustain large-amplitude vibratory stresses and/or result in fluidelastic instabilities. Three components are already known to have experienced failures in evaluation tests as a result of flow-induced structural motion. These components include the liquid-oxygen (LOX) posts, the fuel turbine bellows shield, and the internal inlet tee splitter vane. Researchers considered the dynamic behavior of each of these components with varying degrees of effort: (1) a theoretical and experimental study of LOX post vibration excited by a fluid flow; (2) an assessment of the internal inlet tee splitter vane vibration (referred to as the 4000-Hz vibration problem); and (3) a preliminary consideration of the bellows shield problem. Efforts to resolve flow-induced vibration problems associated with the SSMEs are summarized.
Flow induced vibrations of rigid plate in narrow channels, noting flow rate dependence on channel width
Hydraulic flow approximation for flow induced vibration analysis on flat plate suspended in narrow channel
Flow induced vibrations of rigid plate in narrow channels, noting flow rate dependence on channel width
Longitudinal vibrations induced by internal flow in metal bellows resembling vortex shedding excitations of elastically restrained cylinders, discussing spring mass mechanical model
Results of theoretical and experimental investigations of bellows typical of those found in space shuttle external tanks are presented. Correlation parameters are identified which generalize the alternating stress calculations cited in an earlier study. Alternating stress amplitudes and mean stress levels form the basis of a fatigue analysis incorporating seven ordinate charts for 347 stainless steel, alloy 21 6-9, and Inco 718. A crack propagation model is included with a program for computing bellows fatigue life. Two phase flow and material hardness properties are discussed.
The bellows flow excitation mechanism and results of comprehensive test program are summarized. The analytical model for predicting bellows flow induced stress is refined. The model includes the effects of an upstream elbow, arbitrary geometry, and multiple piles. A refined computer code for predicting flow induced stress is described which allows life prediction if a material S-N diagram is available.
The analysis and results developed in a fresh approach to calculate flow induced vibration response of a flexible flow passage are summarized. The vibration results are further examined in the frequency domain to obtain dominant frequency information. A cumulative damage analysis due to cyclic strains is performed to obtain the number of cycles to failure for a metallic bellows of particular specifications under a variety of operational conditions. Sample plots of time and frequency domain responses are included. The complex listing of a computer program is provided. The program successively executes each of the analyses needed to calculate the vibration response, the frequency response, the cyclic strains and the number of cycles to failure. The program prompts the user for necessary input information. Sample data from the program is provided. The fatigue life results obtained by the computer model lie within an acceptable range of previously measured available data.
This paper describes the results of a program initiated to identify the cause and the mechanism of 4-kHz vibrations of the Space Shuttle main engine's (SSME's) LOX inlet tee, which were revealed in 17 percent of the SSMEs during ground tests. The results of the engines' inspection, structural analyses, computational fluid dynamics studies, literature reviews, expert consultations, and laboratory testings identified the probable cause of the 4-kHz vibrations being related to the fact that the walls of some tees were thinner than in the mojority of tees, resulting in less stiff structures. The mechanism of the vibrations was identified as vortex shedding in combination with a structural coupling with the thrust cone, which increased the vane mobility, which, in turn, aggravated the fluid coupling with the thrust cone. As a result, the vane mobility was increased, aggravating the fluid coupling with the vanes. An internal modification was developed and was successfully demonstrated on an engine that had previously exhibited a 4-kHz problem.
This report presents a preliminary plan to guide the qualification testing of advanced heat exchanger (HX) components for nuclear-to-industrial heat transfer applications. The objective is to establish a defensible, physics-based methodology that integrates computational modeling, targeted experimentation, and in-service inspection considerations to demonstrate component performance and reliability under representative reactor conditions. The analysis identifies Sodium-cooled Fast Reactor (SFR) and High-Temperature Gas-cooled Reactor (HTGR) systems as reference configurations in terms of temperature, pressure, and chemical environment. Within these operating envelopes, dominant degradation mechanisms— including creep–fatigue interaction, flow-induced vibration, corrosion, and diffusion-bond deterioration—were evaluated to define test requirements. A comprehensive computationalexperimental framework is proposed to support life prediction and qualification activities. The framework couples high-fidelity structural-mechanics, thermal-hydraulic, and fluid-structure interaction models with accelerated degradation testing to produce a traceable linkage between microstructural evolution, mechanical performance, and remaining useful life (RUL). The approach adheres to established Verification, Validation, and Uncertainty Quantification (VVUQ) standards (ASME V&V 10/20; NUREG-2152) and incorporates a digital-twin architecture for continuous model refinement through data assimilation. The plan further outlines testing methodologies, including pre-test analyses, test-loop design parameters, and sensor placement strategies that maximize information yield while maintaining mechanistic fidelity. Complementary sections describe in-service inspection (ISI), on-line monitoring (OLM), and structural-health-monitoring (SHM) techniques applicable to compact HX geometries typical of advanced reactors. Collectively, these activities establish the technical foundation for demonstrating 40-60-year equivalent service life of advanced heat exchangers in support of the U.S. Department of Energy’s Advanced Reactor and Integrated Energy Systems programs. The forthcoming phase will execute the defined pre-test analyses, initiate hardware fabrication, and implement the integrated testing campaign to validate the proposed qualification methodology.
Experimental research describes fluid flow and the fluid-elastic mechanism causing bellows flow excitation, and aids in design of conventional bellows liner which suppresses flow-induced vibrations. Analytical models facilitate prediction of flow excitation occurrence and estimation of severity of bellows vibrations.
The fluid flow-induced vibration of the Space Shuttle main engine (SSME) components are being studied with a view to correlating the frequency characteristics of the pressure fluctuations in a rocket engine to its operating conditions and geometry. An overview of the data base development for SSME test firing results and the interactive computer software used to access, retrieve, and plot or print the results selectively for given thrust levels, engine numbers, etc., is presented. The various statistical methods available in the computer code for data analysis are discussed. Plots of test data, nondimensionalized using parameters such as fluid flow velocities, densities, and pressures, are presented. Results are compared with those available in the literature. Correlations between the resonant peaks observed at higher frequencies in power spectral density plots with pump geometry and operating conditions are discussed. An overview of the status of the investigation is presented and future directions are discussed.
Fatigue failure of bellows when subjected to passage of fluids at high speeds is discussed. It is assumed that flow through bellows generates sound in fluid and vibration caused by sound waves is principal contributor to failure. Effects of sound waves on bellows structure are analyzed.