Development and evaluation of controlled viscosity coatings for superalloys
Controlled viscosity glass based protective coatings for superalloys for turbine blade applications
Chapman, J. W.↗
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Applications for Gradient Metal Alloys Fabricated Using Additive Manufacturing
Recently, additive manufacturing (AM) techniques have been developed that may shift the paradigm of traditional metal production by allowing complex net-shaped hardware to be built up layer-by-layer, rather than being machined from a billet. The AM process is ubiquitous with polymers due to their low melting temperatures, fast curing, and controllable viscosity, and 3D printers are widely available as commercial or consumer products. 3D printing with metals is inherently more complicated than with polymers due to their higher melting temperatures and reactivity with air, particularly when heated or molten. The process generally requires a high-power laser or other focused heat source, like an electron beam, for precise melting and deposition. Several promising metal AM techniques have been developed, including laser deposition (also called laser engineered net shaping or LENS® and laser deposition technology (LDT)), direct metal laser sintering (DMLS), and electron beam free-form (EBF). These machines typically use powders or wire feedstock that are melted and deposited using a laser or electron beam. Complex net-shape parts have been widely demonstrated using these (and other) AM techniques and the process appears to be a promising alternative to machining in some cases. Rather than simply competing with traditional machining for cost and time savings, the true advantage of AM involves the fabrication of hardware that cannot be produced using other techniques. This could include parts with "blind" features (like foams or trusses), parts that are difficult to machine conventionally, or parts made from materials that do not exist in bulk forms. In this work, the inventors identify that several AM techniques can be used to develop metal parts that change composition from one location in the part to another, allowing for complete control over the mechanical or physical properties. This changes the paradigm for conventional metal fabrication, which relies on an assortment of "post-processing" methods to locally alter properties (such as coating, heat treating, work hardening, shot peening, etching, anodizing, among others). Building the final part in an additive process allows for the development of an entirely new class of metals, so-called "functionally graded metals" or "gradient alloys." By carefully blending feedstock materials with different properties in an AM process, hardware can be developed with properties that cannot be obtained using other techniques but with the added benefit of the net-shaped fabrication that AM allows.
Hofmann, Douglas C.↗
3-D foam adhesive deposition
Bonding method, which reduces amount and weight of adhesive, is applicable to foam-filled honeycomb constructions. Novel features of process include temperature-viscosity control and removal of excess adhesive by transfer to cellophane film.
Lemons, C. R.↗
Longer shelf life for ceramic slurries
Viscosity of ceramic-coating slurries containing organic acrylate viscosity-control agent is stabilized for over 2 months by addition of ammonium hydroxide without significant changes.
Izu, Y. D.↗
The industrial processing of unidirectional fiber prepregs
Progress made in the industrial processing of preimpregnated composites with unidirectional fibers is discussed, with particular emphasis on applications within the aerospace industry. Selection of industrial materials is considered. Attention is given to the conditions justifying the use of composites and the properties required of industrial prepregs. The hardening cycle is examined for the cases of nonmodified and polymer modified resins, with attention given to the stabilization of flow, the necessary changes of state, viscosity control, and the elimination of porosity. The tooling necessary for the fabrication of a laminated plate is illustrated, and the influence of fabrication and prepreg properties on the mechanical characteristics of a laminate are indicated. Finally, the types of prepregs available and the processing procedures necessary for them are summarized.
Laird, B.↗
A study of convective inertia effects and methods of controlling gas ingestion in large diameter viscoseals
Gas ingestion control, and characteristic length and aspect ratio effects on viscoseals
Luttrull, L. H.↗
Localization of toroidal motion and shear heating in 3-D high Rayleigh number convection with temperature-dependent viscosity
We have applied spectral-transform methods to study three-dimensional thermal convection with temperature-dependent viscosity. The viscosity varies exponentially with the form exp(-BT), where B controls the viscosity contrast and T is temperature. Solutions for high Rayleigh numbers, up to an effective Ra of 6.25 x 10(exp 6), have been obtained for an aspect-ratio of 5x5x1 and a viscosity contrast of 25. Solutions show the localization of toroidal velocity fields with increasing vigor of convection to a coherent network of shear-zones. Viscous dissipation increases with Rayleigh number and is particularly strong in regions of convergent flows and shear deformation. A time-varying depth-dependent mean-flow is generated because of the correlation between laterally varying viscosity and velocity gradients.
Balachandar, S.↗
On Efficient Multigrid Methods for Materials Processing Flows with Small Particles
Multiscale modeling of materials requires simulations of multiple levels of structural hierarchy. The computational efficiency of numerical methods becomes a critical factor for simulating large physical systems with highly desperate length scales. Multigrid methods are known for their superior efficiency in representing/resolving different levels of physical details. The efficiency is achieved by employing interactively different discretizations on different scales (grids). To assist optimization of manufacturing conditions for materials processing with numerous particles (e.g., dispersion of particles, controlling flow viscosity and clusters), a new multigrid algorithm has been developed for a case of multiscale modeling of flows with small particles that have various length scales. The optimal efficiency of the algorithm is crucial for accurate predictions of the effect of processing conditions (e.g., pressure and velocity gradients) on the local flow fields that control the formation of various microstructures or clusters.
Thomas, James↗
On-line in-situ control of the resin transfer molding process
Resin transfer molding of three-dimensionally stitched fabrics promises to be a cost effective process for obtaining composite parts of exceptional strength. The technique eliminates many problems involving prepreg preparation, storage and layup. It replaces, on the other hand, the single step cure process with a two-stage impregnation and cure process. Of particular importance therefore is selecting and controlling the viscosity during impregnation and cure. The use of in-situ frequency-dependent electromagnetic sensors and the Loos-Springer model for selecting and controllng the processing properties of the resin transfer molding resin during impregnation and cure are discussed.
Kranbuehl, D.↗
Comparison of the AUSM(+) and H-CUSP Schemes for Turbomachinery Applications
Many turbomachinery CFD codes use second-order central-difference (C-D) schemes with artificial viscosity to control point decoupling and to capture shocks. While C-D schemes generally give accurate results, they can also exhibit minor numerical problems including overshoots at shocks and at the edges of viscous layers, and smearing of shocks and other flow features. In an effort to improve predictive capability for turbomachinery problems, two C-D codes developed by Chima, RVCQ3D and Swift, were modified by the addition of two upwind schemes: the AUSM+ scheme developed by Liou, et al., and the H-CUSP scheme developed by Tatsumi, et al. Details of the C-D scheme and the two upwind schemes are described, and results of three test cases are shown. Results for a 2-D transonic turbine vane showed that the upwind schemes eliminated viscous layer overshoots. Results for a 3-D turbine vane showed that the upwind schemes gave improved predictions of exit flow angles and losses, although the HCUSP scheme predicted slightly higher losses than the other schemes. Results for a 3-D supersonic compressor (NASA rotor 37) showed that the AUSM+ scheme predicted exit distributions of total pressure and temperature that are not generally captured by C-D codes. All schemes showed similar convergence rates, but the upwind schemes required considerably more CPU time per iteration.
Chima, Rodrick V.↗
Procedure for the formation of a coating on an object by polymerization by luminescent discharge
The object to be coated was placed in a reaction area located in a luminescent discharge chamber. By introducing the polymerizable material in this reaction area and applying an electrical field to this reaction, a polymerized film was obtained on the coating object under controlled conditions. By the use of thermomechanical treatment on the object, the undesirable effects of discoloration, brittleness, and viscosity can be controlled.
Source record↗
Effect of artificial viscosity on three-dimensional flow solutions
Artificial viscosity is added either implicity or explicitly in practically every numerical scheme for suppressing spurious oscillations in the solution of fluid-dynamics equations. In the present central-difference scheme, artificial viscosity is added explicitly for suppressing high-frequency oscillations and achieving good convergence properties. The amount of artificial viscosity added is controlled through the use of preselected coefficients. In the standard scheme, scalar coefficients based on the spectral radii of the Jacobian of the convective fluxes are used. However, this can add too much viscosity to the slower waves. Hence, the use of matrix-valued coefficients, which give appropriate viscosity for each wave component, is suggested. With the matrix-valued coefficients, the central-difference scheme produces more accurate solutions on a given grid, particularly in the vicinity of shocks and boundary layers, while still maintaining good convergence properties.
Turkel, Eli↗
Effect of artificial viscosity on three-dimensional flow solutions
Artificial viscosity is added either implicitly or explicitly in practically every numerical scheme for suppressing spurious oscillations in the solution of fluid dynamics equations. In the present central-difference scheme, artificial viscosity is added explicitly for suppressing high frequency oscillations and achieving good convergence properties. The amount of artificial viscosity added is controlled through the use of pre-selected coefficients. In the standard scheme, scalar coefficients based on the spectral radii of the Jacobian of convective fluxes are used. However, this can add too much viscosity to the slower waves. Hence, use the matrix-valued coefficients, which give appropriate viscosity for each wave component is suggested. With the matrix-valued coefficients, the central-difference scheme produces more accurate solutions on a given grid, particularly in the vicinity of shocks, while still maintaining good convergence properties.
Turkel, Eli↗
Analysis and Development of Finite Element Methods for the Study of Nonlinear Thermomechanical Behavior of Structural Components
Underintegrated methods are investigated with respect to their stability and convergence properties. The focus was on identifying regions where they work and regions where techniques such as hourglass viscosity and hourglass control can be used. Results obtained show that underintegrated methods typically lead to finite element stiffness with spurious modes in the solution. However, problems exist (scalar elliptic boundary value problems) where underintegrated with hourglass control yield convergent solutions. Also, stress averaging in underintegrated stiffness calculations does not necessarily lead to stable or convergent stress states.
Oden, J. Tinsley↗
CHAP Enhances Versatility in Colloidal Probe Fabrication
A colloidal probe, comprising a colloidal particle attached to an atomic force microscope cantilever, is employed to measure directly interaction forces between the particle and a surface. It is possible to change or even destroy a particle while attaching it to a cantilever, thus limiting the types of systems to which the colloidal probe technique may be applied. Here we present the Controlled Heating and Alignment Platform (CHAP) for fabricating colloidal probes without altering the original characteristics of the attached particle. The CHAP applies heat directly to the atomic force microscope chip to rapidly and precisely control cantilever temperature. This minimizes particle heating and enables control over the viscosity of thermoplastic adhesive, to prevent it from contaminating the particle surface. 3D-printed components made the CHAP compatible with standard optical microscopes and streamlined the fabrication process while increasing the platform’s versatility. Using the CHAP with a thermoplastic wax adhesive, colloidal probes were fabricated using polystyrene and silica particles between 0.7 and 40 μm in diameter. We characterized the properties and interactions of the adhesive and particles, as well as the properties of the completed probes, to demonstrate the retention of particle features throughout fabrication. Pull-off tests with CHAP’s probes measured adhesive force values in the expected ranges and demonstrated that particles were firmly attached to the cantilevers.
Schmitz, Russell C.↗
Viscous theory of surface noise interaction phenomena
A viscous linear surface noise interaction problem is formulated that includes noise production by an oscillating surface, turbulent or vortical interaction with a surface, and scattering of sound by a surface. The importance of viscosity in establishing uniqueness of solution and partitioning of energy into acoustic and vortical modes is discussed. The results of inviscid two dimensional airfoil theory are used to examine the interactive noise problem in the limit of high reduced frequency and small Helmholtz number. It is shown that in the case of vortex interaction with a surface, the noise produced with the full Kutta condition is 3 dB less than the no Kutta condition result. The results of a study of an airfoil oscillating in a medium at rest are discussed. It is concluded that viscosity can be a controlling factor in analyses and experiments of surface noise interaction phenomena and that the effect of edge bluntness as well as viscosity must be included in the problem formulation to correctly calculate the interactive noise.
Yates, J. E.↗
Fluid Interfaces of Triangular Containers in Reduced Gravity Environments
Capillary dominated fluid dynamics will be examined in a reduced-gravity environment onboard the KC-135; in particular, the behavior of the lower portion of the meniscus in triangular tank geometries. Seven clear acrylic tanks were constructed to view seven angles of the four geometries. Silicon oil with two different viscosities, 2cs and 5cs silicon oil, were used on different days of the flight. Six tanks and one control tank are filled with a certain viscosity fluid for each flight day. During each parabola, three tanks are tested at time. The experimental tanks are exchanged between parabola sets on the KC-135. The 60deg -60deg -60deg control tank is viewed throughout the flight. To gather data, two digital video cameras and one digital still camera are placed perpendicular the viewing surface. To provide a greater contrast in the meniscus, an EL backlighting sheet was used to backlight the tanks. These images and video are then digitized, passed through NASA's mini-tracker software, and compared to a theory published my M. M. Weislogel, "Fluid Interface Phenomena in a Low-Gravity Environment: Recent Results from Drop Tower Experimentation." By focusing on a lower portion of the meniscus and using longer periods of reduced gravity, this experiment may confirm that a stationary point exists on the fluid surface. This information will enable better designing of propellant management devices, especially satellite propellant refilling and gas venting. Also, biological and material processing systems in reduced gravity environments will benefit from this data.
Guttromson, Jayleen↗
Precise wet-chemical etching
Controlled amount of etchant applied to surface of rotating sample removes only few angstroms of material. Technique is suited to study of chemical and crystal structures. Rate can be varied through control of spin frequency, liquid viscosity, droplet size, total etchant volume, etchant concentration.
Grunthaner, F. J.↗