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All sourcesNASA NTRSDOE OSTI
NASA NTRSDate not supplied

In-Situ Detection of Process-Induced Porosity During Cure of Out-of-Autoclave Composites

Composite materials offer unique benefits in aerospace applications, including high strength-to-weight ratio, and are becoming increasingly used by industry manufacturers. Current manufacturing and processing methods can lead to defects in the composites, which are identified after fabrication using inspection methods. This study utilized a high-temperature ultrasonic inspection system to detect process-induced porosity in an out-of-autoclave (OOA) composite panel during cure. In order to perform ultrasonic scans in-situ during cure, the system needed to be able to operate at oven temperatures up to 200 °C. There are no commercially available ultrasonic scanning systems that can operate continuously at these temperatures, so an enclosure was fabricated to insulate the ultrasonic system in the curing oven. The enclosure housed a MISTRAS® motorized X-Y raster scanner and contact transducer (Olympus® X2002). The Olympus® X2002 contact transducer is a continuous high-temperature delay line transducer with a center frequency of 2.25 MHz. In order to prevent the inside of the enclosure from reaching high temperatures, a sparge pipe inside the cooling enclosure was connected to a liquid nitrogen (LN2) tank outside of the oven via insulated hoses. The cooling system was automatically controlled by a temperature controller that was programmed to open a solenoid valve along the hose at 31 ℃ and close at 28 ℃ inside the cooling enclosure. When the solenoid valve was open, LN2 would flow from the LN2 tank and vaporize prior to reaching cooling enclosure. A U-shaped sparge pipe had holes drilled along its length to uniformly introduce cold nitrogen gas into the cooling enclosure. This prevented the motors from ever reaching the maximum desired operating temperature of 38 ℃. In the bottom of the enclosure, the tool plate was placed with the composite facing the outside of the enclosure, exposing it to the temperatures of the oven. The tool plate was 63.5 mm thick borosilicate glass, which was chosen for its low ultrasonic attenuation and moderate thermal conductivity. A thin layer of ultrasonic couplant was placed on the tool plate. The transducer sent and received ultrasonic waves through the tool plate into the composite. A MISTRAS® Remote UT System performed all wave generation, analog to digital conversion, and data acquisition and processing. The transducer was connected directly to the Remote UT System via a high-temperature BNC cable (CD International, RG-316). Polyimide insulated copper wire was used to connect the scanner to a 2-axis motor drive, which was connected to the Remote UT System. The motor drive and Remote UT System were located outside the industrial oven. A diagram of the ultrasonic system is shown in Figure 1. Figure 1: Diagram of ultrasonic in-situ defect detection system. In this study, a porosity gradient was introduced into the carbon fiber reinforced polymer (CFRP) composite through a misfit of the part and caul plate. A 24-ply quasi-isotropic ([0/90, ±45]12S) composite panel was laid up using Newport® AS4C-M/NB321 out-of-autoclave (OOA) plain weave (PW) prepreg (42% resin content, 195 g/m2). The first 16 plies were 203 mm × 203 mm. Ply drops were incorporated into the panel by decreasing the length of plies 17-24. The sizes of each ply are included in Table 1. All plies were centered along their length (x-axis) creating a trapezoidal type cross-section. Table 1: Ply sizes Plies Length (mm) Width (mm) 1-16 203 203 17-18 102 203 19-20 85 203 21-22 68 203 23-24 51 203 A 15-5 stainless steel caul plate (Size: 203 × 203 × 1.2 mm) was placed on the laminate. The composite and caul plate were vacuum bagged to the tool plate. Per the product datasheet, Newport 321 can be cured between 121 °C and 149 °C, depending on service temperature, with a hold for 90-120 minutes. Based on prior thermal testing of the cooling enclosure, the desired composite temperature cycle could be attained when the air temperature of the oven was ramped to 160 °C at a rate of 1.7 °C/min with a 3 hour hold. The extended hold was not necessary to cure the composite, but did allow for additional scans at the cure temperature during preliminary testing. The composite panel was under vacuum pressure for the entire cure cycle. Under vacuum, the caul plate deformed causing high and low pressure regions. The low-pressure regions formed high porosity in the composite part. The ultrasonic data collected showed that the inspection system was able to monitor the evolution of porosity within the composite throughout the cure cycle. Fifty scans of a 203 mm × 51 mm (8 in. × 2 in.) area of the composite were completed throughout the cure cycle. The scan speed was set to 43 mm/s in the x-direction and 36 mm/s in the y-direction, with a 1.0 mm/pixel resolution in both directions. Each scan took approximately five minutes to complete. Figure 2 shows C-scan amplitude data (top view) from one scan during the cure cycle. The color map indicates the maximum amplitude (%) measured with a time gate that contains reflections from the back surface (furthest from the transducer in contact with the caul plate) of the composite. Because porosity in the composite increases the ultrasonic attenuation in the composite part, a higher amplitude (red) indicates low porosity and a lower amplitude (blue) indicates high porosity. The regions where the caul plate was applying increased pressure (center and ends of the panel) resulted in reduced porosity, whereas the ply drop regions had reduced pressure and thus had higher porosity. Figure 2: Amplitude C-scan (top view) of OOA composite from one scan during the 160 °C temperature hold. Higher amplitude (red) indicates low porosity. Lower amplitude (blue) indicates high porosity. A B-scan is a two-dimensional image plotting the ultrasonic signals from a single y-position at every x-location of the composite panel. The travel time (μs) of the ultrasonic wave (representing the through-thickness location) is plotted along the y-axis, and the ultrasonic wave signal is represented as a contour map. Based on the B-scan data, the location of the defects with respect to the composite thickness was able to be determined. The ply drop regions had high porosity near the front (tool plate) surface of the composite (Figure 3). Figure 3: B-scan (cross-section view) of OOA composite from one scan during the 160 °C temperature hold. Using the data obtained from amplitude C-scans and B-scans throughout the cure cycle, the high and low porosity regions within the composite laminate were detected and localized with high spatial resolution. This paper will discuss the evolution of porosity content in the OOA composite during cure. OOA tests aided the transition of this system to an autoclave, which is the primary method of curing aerospace-grade thermoset composites.

Tyler B. Hudson↗
NASA NTRSDate not supplied

A Novel Additive Manufacturing Process Metric for Predicting Spatter-related Porosity in Laser Powder Bed Fusion

Components fabricated using the powder bed fusion laser beam metallic (PBF) additive manufacturing (AM) process comprise a multitude of sequential weld passes. Porosity defects resulting from weld pass inconsistencies are a concern for PBF materials and have a strong adverse effect on the mechanical properties. In an effort to understand and avoid spatter induced porosity, this work aims to provide a novel computational technique that can be used to quantify and predict the sequence-sensitive impact of spatter upon the PBF process stability and consequential porosity in as-printed material. A novel spatter impact AM model-based process metric (AM-PM) is introduced to model and quantify the impact that spatter has on the PBF process. The occurrence of spatter induced porosity is studied using thermal rise, lack of fusion, and spatter impact AM-PMs synchronized with porosity measured by high-resolution X-ray computed tomography. Six cylindrical specimens were designed to compare the AM-PM correlations with porosity across two different laser powers and three hatch scanning strategies. A point field based computational approach is shown to be effective for testing the influence of the different AM-PMs and interrogating the physical process conditions underlying the porosity formation. Further, characterization using optical metallography and scanning electron microscopy indicated that both keyhole and lack of fusion porosity correlated with the spatter impact AM-PM, which can be exploited to predict and control spatter related porosity by the hatch strategy. Efforts to predict porosity composition within PBF material should incorporate the PBF process disturbances that can result from spatter. The spatter impact AM-PM can be readily incorporated into the development of defect prediction models at the part scale.

Additive Manufacturing↗
NASA NTRS2017

An Efficient Modelling Approach for Prediction of Porosity Severity in Composite Structures

Porosity, as a manufacturing process-induced defect, highly affects the mechanical properties of cured composites. Multiple phenomena affect the formation of porosity during the cure process. Porosity sources include entrapped air, volatiles and off-gassing as well as bag and tool leaks. Porosity sinks are the mechanisms that contribute to reducing porosity, including gas transport, void shrinkage and collapse as well as resin flow into void space. Despite the significant progress in porosity research, the fundamentals of porosity in composites are not yet fully understood. The highly coupled multi-physics and multi-scale nature of porosity make it a complicated problem to predict. Experimental evidence shows that resin pressure history throughout the cure cycle plays an important role in the porosity of the cured part. Maintaining high resin pressure results in void shrinkage and collapse keeps volatiles in solution thus preventing off-gassing and bubble formation. This study summarizes the latest development of an efficient FE modeling framework to simulate the gas and resin transport mechanisms that are among the major phenomena contributing to porosity.

Bedayat, Houman↗
NASA NTRS2013

Constraints on Porosity and Mass Loss in O-star Winds from the Modeling of X-ray Emission Line Profile Shapes

We fit X-ray emission line profiles in high resolution XMM-Newton and Chandra grating spectra of the early O supergiant Zeta Pup with models that include the effects of porosity in the stellar wind. We explore the effects of porosity due to both spherical and flattened clumps. We find that porosity models with flattened clumps oriented parallel to the photosphere provide poor fits to observed line shapes. However, porosity models with isotropic clumps can provide acceptable fits to observed line shapes, but only if the porosity effect is moderate. We quantify the degeneracy between porosity effects from isotropic clumps and the mass-loss rate inferred from the X-ray line shapes, and we show that only modest increases in the mass-loss rate (40%) are allowed if moderate porosity effects (h(sub infinity) less than approximately R(sub ∗)) are assumed to be important. Large porosity lengths, and thus strong porosity effects, are ruled out regardless of assumptions about clump shape. Thus, X-ray mass-loss rate estimates are relatively insensitive to both optically thin and optically thick clumping. This supports the use of X-ray spectroscopy as a mass-loss rate calibration for bright, nearby O stars

porosity↗
NASA NTRS2021

Porosity Detection and Localization During Composite Cure Inside an Autoclave Using Ultrasonic Inspection

Composite materials offer unique benefits in aerospace applications such as increased strength-to-weight ratio and improved fatigue properties. They are increasingly being used in major commercial aircraft programs. However, current processing methods can lead to defects in composite parts, which must be detected using post-manufacturing inspection methods. Porosity (i.e., pores, voids) is a critical defect from the cure process that is detrimental to performance of the composite part. It is therefore necessary to understand and eliminate the formation of porosity defects. At NASA Langley Research Center, an in-situ cure monitoring system was developed to detect porosity defects as they form in real-time inside an autoclave. A capability to directly detect and localize porosity within a composite during cure did not exist before. This study is focused on an elevated-temperature ultrasonic inspection system to detect porosity defects in composites during autoclave cure. The ultrasonic inspection system operated inside an autoclave within an enclosure cooled by intermittent liquid nitrogen (LN_2) injections. A high-temperature, 2.25 MHz, transducer transmitted ultrasonic waves through the tool plate and into the composite part and measured the amplitude and time of flight of the reflected waves with a 1 mm × 1 mm step size/areal resolution. Porosity was observed via the ultrasonic reflections, which experienced increased attenuation in regions of high porosity. Distinct regions of increased porosity were present due to uneven pressure across the panel, which was driven by an intentional misfit between the flat caul plate and the tapered composite panel with ply drops. The results were validated by post-cure ultrasonic inspection and micrographs. The in-situ inspection system was able to successfully provide porosity detection and localization in the tapered ply-drop panel. The successful results indicate the promise of this system for future implementation in the manufacturing of composite structures for aerospace applications.

Composites↗
NASA NTRS1993

Porosity and the ecology of icy satellites

The case for a significant role for porosity in the structure and evolution of icy bodies in the Solar System has been difficult to establish. We present a relevant new data set and a series of structure models including a mechanical compression, not thermal creep, model for porosity that accounts satisfactorily for observed densities, moments of inertia, geologic activity, and sizes of tectonic features on icy satellites. Several types of observational data sets have been used to infer significant porosity, but until recently, alternative explanations have been preferred. Our first area of concern is the occurrence of cryovolcanism as a function of satellite radius; simple radiogenic heating models of icy satellites suggest minimum radii for melting and surface cryovolcanism to be 400 to 500 km, yet inferred melt deposits are seen on satellites half that size. One possible explanation is a deep, low conductivity regolith which lowers conductivity and raises internal temperatures, but other possibilities include tidal heating or crustal compositions of low conductivity. Our second area of concern is the occurrence and magnitude of tectonic strain; tectonic structures have been seen on icy satellites as small as Mimas and Proteus. The structures are almost exclusively extensional, with only a few possible compression Al features, and inferred global strains are on the order of 1 percent expansion. Expansions of this order in small bodies like Mimas and prevention of late compressional tectonics due to formation of ice mantles in larger bodies like Rhea are attained only in structure models including low-conductivity, and thus possibly high porosity, crusts. Thirdly, inferred moments of inertia less than 0.4 in Mimas and Tethys can be explained by high-porosity crusts, but also by differentiation of a high density core. Finally, the relatively low densities of smaller satellites like Mimas and Miranda relative to larger neighbors can be explained by deep porosity, but also by bulk compositional differences. Recent work has strengthened the case for significant porosity. Halley's nucleus was found to have a density near 0.6 g/cu cm, Janus and Epimethus were proposed to have densities near 0.7 g/cu cm, densities almost certainly due to high porosity. The irregular-spherical shape transition of icy satellites was quantitatively explained by low conductivity regoliths. A creative structure/thermal history model for Mimas simultaneously accounts quantitatively for Mimas' low density and moment of inertia by invoking initial high-porosity and subsequent compaction in the deep interior by thermal creep. The main problem with this promising model is that approximately 7 percent predicts a reduction in Mimas' radius, implying significant compressional failure and prevention of extensional tectonics, in contradiction to the observed extensional features and inferred 1 percent expansion in radius.

Croft, Steven K.↗
NASA NTRS1996

Porosity and Permeability of Chondritic Materials

We have investigated the porosity of a large number of chondritic interplanetary dust particles and meteorites by three techniques: standard liquid/gas flow techniques, a new, non-invasive ultrasonic technique, and image processing of backscattered images . The latter technique is obviously best suited to sub-kg sized samples. We have also measured the gas and liquid permeabilities of some chondrites by two techniques: standard liquid/gas flow techniques, and a new, non-destructive pressure release technique. We find that chondritic IDP's have a somewhat bimodal porosity distribution. Peaks are present at 0 and 4% porosity; a tail then extends to 53%. These values suggest IDP bulk densities of 1.1 to 3.3 g/cc. Type 1-3 chondrite matrix porosities range up to 30%, with a peak at 2%. The bulk porosities for type 1-3 chondrites have the same approximate range as exhibited by matrix, indicating that other components of the bulk meteorites (including chondrules and aggregates) have the same average porosity as matrix. These results reveal that the porosity of primitive materials at scales ranging from nanogram to kilogram are similar, implying similar accretion dynamics operated through 12 orders of size magnitude. Permeabilities of the investigated chondrites vary by several orders of magnitude, and there appears to be no simple dependence of permeability with degree of aqueous alteration, or chondrite type.

Zolensky, Michael E.↗
NASA NTRS1999

Interaction of Porosity with an Advancing Solid/Liquid Interface: a Real-Time Investigation

Problems associated with formation of porosity during solidification continue to have a daily impact on the metal forming industry. Several past investigations have dealt with the nucleation and growth aspects of porosity. However, investigations related to the interaction of porosity with that of a solidification front has been limited mostly to organic analogues. In this paper we report on real time experimental observations of such interactions in metal alloys. Using a state of the art X-Ray Transmission Microscope (XTM) we have been able to observe and record the dynamics of the interaction. This includes distortion of the solid/liquid interface near a poro.sity, solute segr,egation patterns surrounding a porosity and the change in shape of the porosity during interaction with an advancing solid/liquid interface. Results will be presented for different Al alloys and growth conditions. The experimental data will be compared to theory using a recently developed 2D numerical model. The model employs a finite difference approach where the solid/liquid interface is defined through the points at which the interface intersects the grid lines. The transport variables are calculated at these points and the motion of the solidification front is determined by the magnitude of the transport variables. The model accounts for the interplay of the thermal and solutal field and the influence of capilarity to predict the shape of the solid/liquid interface with time in the vicinity of porosity. One can further calculate the perturbation of the solutal field by the presence of porosity in the melt.

Sen, S.↗
NASA NTRS2001

Friction Factor Characterization for High-Porosity Random Fiber Regenerators

NASA Glenn Research Center, the Department of Energy (DOE), and Stirling Technology Company (STC) of Kennewick, Washington are developing a Stirling convertor for a high-efficiency Stirling Radioisotope Power System to provide electric power for NASA Space Science Missions. STC is developing the 55-We Technology Demonstration Convertor (TDC) under contract to DOE. Steady-flow tests were completed to determine the friction factor for the high-porosity regenerators that are used in the TDC. STC fabricated a flow test fixture and three random fiber regenerator test samples, one each at approximately 80, 88, and 96 percent porosities. The flow tests were then completed by the NASA Glenn Flow Calibration Laboratory, and the data reduced to Reynolds number and friction factor. The results showed that the 80 and 88 percent porosity samples had similar characteristics while the 96 percent porosity sample had significantly higher friction factors for given Reynolds numbers compared to the samples with lower porosities. Comparisons were also made between the test data and existing correlations. STC used this data to derive a modified regenerator friction factor correlation for use in the Stirling design code GLIMPS for porosities greater than 88 percent. Using this new correlation, the final optimized regenerator design porosity was reduced from 96 to 90 percent.

Thieme, Lanny G.↗
NASA NTRSDate not supplied

Porosity Prediction and Detection During Composite Cure Using Simulation and Ultrasonic In-Situ Inspection Inside and Autoclave

Composite materials offer unique benefits in aerospace applications such as increased strength-to-weight ratio and improved fatigue properties. They are increasingly being used in major commercial aircraft programs. However, current processing methods can lead to defects in composite parts, which are currently identified using post-manufacturing inspection methods. A cure defects process model has been developed to predict the formation of manufacturing defects (e.g., porosity and fiber waviness) in composites based on the cure parameters and part geometry. However, a capability to directly validate porosity during cure did not exist. Validation methods included comparing resin pressure measured during cure with predictions by the process model and inspection/microscopy after cure. This study developed a high-temperature ultrasonic inspection system to detect porosity defects in composites during autoclave cure and experimentally verify the predictions of the model. The system operated inside an autoclave within an enclosure cooled by intermittent liquid nitrogen(LN2) injections. A high-temperature 2.25 MHz ultrasonic transducer was utilized to transmit ultrasonic waves through the tool plate and into the composite material and to measure the amplitude and time of flight of the reflected waves with a 1 mm × 1 mm resolution. Porosity was observed via the ultrasonic reflections, which experienced increased attenuation in regions of high porosity. Distinct regions of increased porosity were present due to uneven pressure across the panel, which was driven by an intentional misfit between the flat caul plate and the tapered composite panel with ply drops. These observations matched the predictions of the model using the inputs from the experiment (e.g., part material and geometry, cure cycle) and were validated by post-cure ultrasonic inspection and micrographs. The in-situ inspection system was able to successfully provide defect detection and localization and can be applied to future manufacturing of composite structure for aerospace applications.

Porosity↗
NASA NTRS2024

Correlations of Additive Manufacturing Model-Based Process Metrics With Spatter-Induced Porosity in the Powder Bed Fusion-Laser Beam/Metallic Process

Components fabricated using the powder bed fusion laser beam metallic (PBF-LB/M) additive manufacturing (AM) process comprise a multitude of sequential weld passes. Qualifying materials for components in critical applications requires a thorough understanding of pertinent processing-microstructure-property relationships. Porosity defects have a strong adverse effect on the mechanical properties of a material. The morphology of porosity defects created by lack of fusion in PBF-LB/M often exhibit high aspect ratios that can act as stress concentrators and become crack initiation sites. The occurrence of spatter induced porosity is studied using synchronized AM model-based process metrics and porosity measured by high-resolution X-ray computed tomography. A novel AM process metric is introduced to quantify the relative exposure to spatter ejecta impacts and incorporation throughout the sequence of the PBF-LB/M process. Further characterization using optical metallography and scanning electron microscopy indicated that both keyhole and lack of fusion porosity correlated statistically with the spatter ejecta impact field of the PBF-LB/M process. Both keyhole and lack of fusion porosity can be predicted by the spatter exposure process metric, which can be exploited to control the fusion sequence.

Additive Manufacturing↗
NASA NTRS1974

Effects of porosity on weld-joint tensile strength of aluminum alloys

Tensile properties in defect-free weldments of aluminum alloys 2014-T6 and 2219-T87 (sheet and plate) are shown to be related to the level or concentration of induced simulated porosity. The scatter diagram shows that the ultimate tensile strength of the weldments displays the most pronounced linear relationship with the level of porosity. The relationships between yield strength or elongation and porosity are either trivial or inconsequential in the lower and intermediate levels of porosity content. In highly concentrated levels of porosity, both yield strength and elongation values decrease markedly. Correlation coefficients were obtained by simple straight line regression analysis between the variables of ultimate tensile strength and pore level. The coefficients were greater, indicating a better correlation, using a pore area accumulation concept or pore volume accumulation than the accumulation of the pore diameters. These relationships provide a useful tool for assessing the existing aerospace radiographic acceptance standards with respect to permissible porosity. In addition, these relationships, in combination with known design load requirements, will serve as an engineering guideline in determining when a weld repair is necessary based on accumulative pore level as detected by radiographic techniques.

Lovoy, C. V.↗
NASA NTRSDate not supplied

Observations of Keyhole Porosity and Comparisons to Analytical Models for Ti-6Al-4V Powder Bed Fusion

Keyhole porosity defects are a common concern in powder bed fusion (PBF) processing. Keyhole porosity prediction models have generally fallen into two categories – high fidelity computational fluid dynamics simulations and low fidelity analytical or empirical models based on keyhole vibration dynamics. The low computational cost of low fidelity models allows them to better approach part-scale predictions. However, studies on low fidelity modeling techniques are limited by the lack of experimental data to assess the validity of the calibration over a wide range of processing conditions. This work extracts and quantifies keyhole porosity across 14 laser velocities, two laser powers, and six+ repetitions for a total of 176 independent trials. The measured porosity data are compared to low fidelity keyhole models to assess their success in predictive porosity occurrence. This work impacts the field by providing independent validation of keyhole porosity models for PBF for use in part-scale defect prediction.

powder bed fusion↗
NASA NTRS2002

A Generalised Porosity Formalism for Isotropic and Anisotropic Effective Opacity and Its Effects on X-ray Line Attenuation in Clumped O Star Winds

We present a generalised formalism for treating the porosity-associated reduction in continuum opacity that occurs when individual clumps in a stochastic medium become optically thick. As in previous work, we concentrate on developing bridging laws between the limits of optically thin and thick clumps. We consider geometries resulting in either isotropic or anisotropic effective opacity, and, in addition to an idealised model in which all clumps have the same local overdensity and scale, we also treat an ensemble of clumps with optical depths set by Markovian statistics. This formalism is then applied to the specific case of bound-free absorption of X- rays in hot star winds, a process not directly affected by clumping in the optically thin limit. We find that the Markov model gives surprisingly similar results to those found previously for the single clump model, suggesting that porous opacity is not very sensitive to details of the assumed clump distribution function. Further, an anisotropic effective opacity favours escape of X-rays emitted in the tangential direction (the venetian blind effect), resulting in a bump of higher flux close to line centre as compared to profiles computed from isotropic porosity models. We demonstrate how this characteristic line shape may be used to diagnose the clump geometry, and we confirm previous results that for optically thick clumping to significantly influence X-ray line profiles, very large porosity lengths, defined as the mean free path between clumps, are required. Moreover, we present the first X-ray line profiles computed directly from line-driven instability simulations using a 3-D patch method, and find that porosity effects from such models also are very small. This further supports the view that porosity has, at most, a marginal effect on X-ray line diagnostics in O stars, and therefore that these diagnostics do indeed provide a good clumping insensitive method for deriving O star mass-loss rates.

generalised↗
NASA NTRS2001

Advanced Aerodynamic Design of Passive Porosity Control Effectors

This paper describes aerodynamic design work aimed at developing a passive porosity control effector system for a generic tailless fighter aircraft. As part of this work, a computational design tool was developed and used to layout passive porosity effector systems for longitudinal and lateral-directional control at a low-speed, high angle of attack condition. Aerodynamic analysis was conducted using the NASA Langley computational fluid dynamics code USM3D, in conjunction with a newly formulated surface boundary condition for passive porosity. Results indicate that passive porosity effectors can provide maneuver control increments that equal and exceed those of conventional aerodynamic effectors for low-speed, high-alpha flight, with control levels that are a linear function of porous area. This work demonstrates the tremendous potential of passive porosity to yield simple control effector systems that have no external moving parts and will preserve an aircraft's fixed outer mold line.

Hunter, Craig A.↗
NASA NTRS2003

Control of Interacting Vortex Flows at Subsonic and Transonic Speeds Using Passive Porosity

A wind tunnel experiment was conducted in the NASA Langley Research Center (LaRC) 8-foot Transonic Pressure Tunnel (TPT) to determine the effects of passive surface porosity on vortex flow interactions about a general research fighter configuration at subsonic and transonic speeds. Flow- through porosity was applied to a wind leading-edge extension (LEX) mounted to a 65 deg cropped delta wind model to promote large nose-down pitching moment increments at high angles of attack. Porosity decreased the vorticity shed from the LEX, which weakened the LEX vortex and altered the global interactions of the LEX and wing vortices at high angles of attack. Six-component forces and moments and wing upper surface static pressure distributions were obtained at free- stream Mach numbers of 0.50, 0.85, and 1.20, Reynolds number of 2.5(10(exp-6) per foot, angles of attack up to 30 deg and angles of sideslip to plus or minus 8 deg. The off-surface flow field was visualized in selected cross-planes using a laser vapor screen flow visualization technique. Test data were obtained with a centerline vertical tail and with alternate twin, wing-mounted vertical fins having 0 deg and 30 deg cant angles. In addition, the porosity of the LEX was compartmentalized to determine the sensitivity of the vortex- dominated aerodynamics to the location and level of porosity applied to the LEX.

NATO FURNISHED↗
NASA NTRS2003

Control of Interacting Vortex Flows at Subsonic and Transonic Speeds Using Passive Porosity

A wind tunnel experiment was conducted in the NASA Langley Research Center (LaRC) 8-Foot Transonic Pressure Tunnel (TPT) to determine the effects of passive surface porosity on vortex flow interactions about a general research fighter configuration at subsonic and transonic speeds. Flow-through porosity was applied to a wing leading-edge extension (LEX) mounted to a 65 deg cropped delta wing model to promote large nose-down pitching moment increments at high angles of attack. Porosity decreased the vorticity shed from the LEX, which weakened the LEX vortex and altered the global interactions of the LEX and wing vortices at high angles of attack. Six-component forces and moments and wing upper surface static pressure distributions were obtained at free-stream Mach numbers of 0.50, 0.85, and 1.20, Reynolds number of 2.5(10(exp 6)) per foot, angles of attack up to 30 deg, and angles of sideslip to +/- 8 deg. The off-surface flow field was visualized in selected cross-planes using a laser vapor screen flow visualization technique. Test data were obtained with a centerline vertical tail and with alternate twin, wing-mounted vertical fins having 0 deg and 30 deg cant angles. In addition, the porosity of the LEX was compartmentalized to determine the sensitivity of the vortex-dominated aerodynamics to the location and level of porosity applied to the LEX.

Erickson, Gary E.↗
NASA NTRS2005

A Novel Porosity Model for Use in Hydrocode Simulations

Introduction: Numerical modeling of impact cratering has reached a high degree of sophistication; however, the treatment of porous materials still poses a large problem in hydrocode calculations. Porosity plays only a minor role in the formation of large craters on most planetary objects, but impacts on comets are believed to be highly affected by the presence of porosity, which may be as much as 80%. The upcoming Deep Impact Mission (launched January 2005) will provide more detailed data about the composition of a comet (Tempel 1) by shooting a approx.370 kg projectile onto the surface of its nucleus. The numerical simulations of such impact events requires an appropriate model for how pore space in the comet is crushed out during the violent initial stage of the impact event. Most hydro-codes compute the pressure explicitly using an "equation of state" (EOS) for each material, which relates changes in density and internal energy to changes in pressure. The added complication introduced by porosity is that changes in a material s density are due to both the closing of pore space (compaction) and compression of the matrix. The amount of resistance to volume change and the amount of irreversible work done during these two processes is very different; it is far easier to compact a porous material sample than to compress a non-porous sample of the same material. As an alternative to existing porosity models, like the Pdot(alpha) model [1], we present a novel approach for dealing with the compaction of porosity in hydrocode calculations.

Wuennemann, K.↗