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DOE OSTI2024

Modeling of Additively Manufactured Ceramic Heat Exchangers with Semi-Elliptical Cross-Section Flow Channels

An approximate and easily applied analytical model was developed for heat transfer calculations of heat exchangers consisting of multiple rows and columns of heat transfer fluid flow channels with semi-elliptical cross sections. Heat exchangers of this type are being developed by using ceramic material and additive manufacturing for high temperature and pressure-concentrating solar electric power plants. Calculations using the model require only the geometrical dimensions and flow conditions of the heat exchanger. Comparisons of modeling predictions, with both simulation results and experimental data, were conducted to verify the viability of the model. The results showed good agreement where almost all the modeling predictions were within 20% of the simulation results or the experimental data. Finally, the proposed modeling approach is more generally applicable to heat transfer analysis of heat exchangers with similar flow channel configurations to those considered in this study.

Ceramic↗

NASA NTRS1990

Secondary instability in rotating disk flow

Primary instability of the three-dimensional boundary layer on a rotating disk introduces periodic modulation of the mean flow in the form of cross-flow vortices. The stability of this modulated base flow to secondary disturbances is studied. In a three-dimensional boundary layer the threshold primary amplitude for secondary instability is larger than that for a two-dimensional boundary layer. The secondary instability results in a pair of traveling counter-rotating vortices, tilted up and oriented at an angle to the primary cross-flow vortices.

Balachandar, S.↗

NASA NTRS1967

Local measurements in turbulent flows through cross correlation of optical signals

Crossed beam correlation method measures turbulent fluctuations in transonic and supersonic flows. Two collimated beams of radiation are crossed at the point of interest in the flow, and the power loss of each beam is measured with two independent photodetectors, which yield information about the turbulent properties.

Fisher, M. J.↗

DOE OSTI2020

Performance evaluation of an air conditioning system based on quasi isothermal dehumidifcation

This work presents a first study of novel air conditioning system based on quasi isothermal dehumidification combined with dew-point evaporative cooling through the Maisotsenko cycle (M-Cycle). The dehumidification process is realized in desiccant coated heat exchanger with heat rejection system. The key idea behind the solution is to maximize the cooling effectiveness by creating favourable conditions for dehumidification and evaporative cooling process. This is achieved by rejecting the heat of sorption in the desiccant system and providing cold and dry air for M-Cycle air cooler, which allows the system to be powered by using low-grade heat energy at 50 °C. The analysis is performed on the basis of experimentally validated numerical models of each component combined in a unified model of the system. The goal of the study is to determine the performance of the solution under different operational conditions. In addition two types of M-Cycle air coolers (i.e. cross-flow and regenerative unit) are compared to establish which unit is more suitable as the source of cooling energy for the system. It was established that proposed system is able to provide comfortable room parameters (supply air temperature equal 17 °C and humidity ratio equal 0.010 kg/kg-da) for outdoor air temperatures ranging from 28 to 36 °C and outdoor air humidity ranging from 0.010 to 0.018 kg/kg-da. This means that the proposed solution is able to provide comfortable conditions in temperate and humid climates. Results also indicate that the system consisting of the regenerative M-Cycle HMX allows better cooling load management, offers higher thermal Coefficient of Performance (COP th ) and uses less water compared to the system with the cross-flow HMX. However, the system with cross-flow heat and mass exchanger (HMX) has a relatively greater electrical Coefficient of Performance (COP el ) in most cases.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

NASA NTRS2015

Visualization and Quantification of Rotor Tip Vortices in Helicopter Flows

Helicopter aeromechanics encompasses a highly vortical flow field. The vortices generated at each blade tip contain unsteady, complex, three-dimensional structures, which interact with each other, other blades, the fuselage and various components of the helicopter. It is crucial to understand vortex kinematics and their subsequent dynamic evolution. Much research has been devoted to the understanding of helicopter vortex dynamics, including a number of experimental studies.1-6 In May 2010 Particle Image Velocimetry (PIV) measurements of a full-scale UH-60A rotor were acquired in the National Full-Scale Aerodynamics Complex (NFAC) 40- by 80-Foot Wind Tunnel.1 These measurements were taken at a plane just downstream of the advancing blade in the vicinity of the blade tip—the so-called PIV plane. The resulting PIV data were then processed using an ensemble-average approach to create graphical representations of the vortical wake velocity and vorticity fields, which, in turn, have enhanced the understanding of rotorcraft vortical wake flow field physics and have provided a more detailed validation of vortical wake computer simulations.7 A common approach used to analyze flow field features is to compute and plot color contour maps of various scalar quantities such as pressure, velocity magnitude and vorticity magnitude. For example, the color map of the vorticity magnitude is typically used to determine vortical flow structure. With this approach the vortex core may appear larger or smaller, depending on the contour levels that are selected. Thus, the resulting visualization is sensitive to user-specified contour levels. For vortex core radius measurements, it is more accurate to calculate the vortex core radius using the cross-flow velocity profile across the vortex core. The task of extracting the cross-flow velocity profile can be time consuming with existing tools since the user needs to manually select the core center then specify sampling points along the profile axis. The task becomes even more challenging when the associated grid system uses AMR (Adaptive Mesh Refinement) where the profile axis could span multiple grid blocks. There are a number of existing techniques for profiling of vortex core attributes;8-9 however, these techniques are not fully automatic in that the user still needs to select the vortex core center to compute the cross-flow velocity profile. The present study introduces a new color map scheme that is based on the vortex core radius, which is fully automatic and does not require user intervention. Analysis and visualization of blade tip vortices on the PIV plane using the proposed new color map scheme are described in Section II. The new approach is evaluated using two case studies, which are described in Section III. The paper ends with a summary in Section IV.

Quantification↗

NASA NTRS1973

Analysis of the Flow About Delta Wings with Leading Edge Separation at Supersonic Speeds

A research program was conducted to develop an improved theoretical flow model for the flow about sharp edge delta wings with leading-edge separation at supersonic speeds. The flow model incorporates a representation of the secondary separation region which occurs just inboard of the leading edge on such wings and is based on a slender-wing theory whereby the full three-dimensional problem is reduced to a quasi two-dimensional problem in the cross-flow plane. The secondary separation region was modeled by a surface distribution of singularities or a linearized type of cavity representation. The primary vortex and separation were modeled by a concentrated vortex and cut in the cross-flow potential which represents its feeding sheet. The cross-flow solutions for the cavity model were obtained, but these solutions have physical significance only in a very restricted range of angle of attack. The reasons for the failure of the flow model are discussed. The analysis is presented so that other interested researchers may critically review the work.

Nenni, J. P.↗

NASA NTRS1987

Experimental flowfield visualization of a high alpha wing at Mach 1.62

Experimental oil-flow and tuft patterns and vapor-screen flow-visualization data were obtained on a cambered wing model at Mach 1.62 for an angle-of-attack range of 0 to 14 deg. These data were used as flow diagnostic tools along with surface-pressure and force data and full-potential theory calculations. A large separation bubble was found on the lower wing surface at low angle of attack. The high-angle-of-attack flowfield was characterized by a large attached-flow leading-edge expansion followed by a cross-flow shock. At 14 deg, the cross-flow shock apparently induced discrete regions of streamwise separated flow which were clearly indicated in the vapor-screen and oil-flow photographs.

Pittman, James L.↗

NASA NTRS1986

A comparison of experimental and numerical results for delta wings with vortex flaps

Computational and experimental results are presented for delta wings with vortex flaps. The wings have an undeflected leading-edge sweep of 75 deg. Flap angles of 5 deg and 10 deg, measured in the streamwise direction, are considered. The nominal angle of attack alpha is varied from 4 deg to 12 deg. Results for freestream Mach numbers of 1.7 and 2.4 are shown. Surface pressure, tuft patterns and vapor screens are given for the experimental data. Surface pressure, tuft patterns, cross-flow velocities, total pressure loss and cross-flow Mach number are given for the numerical data. C(l)-vs-alpha curves are shown for experimental and computational results. The flows are shown to be very sensitive to angle of attack, and the agreement between experimental and theoretical results is improved if the calculations are made at angles of attack slightly larger than the experimental angles of attack. The computational model correctly predicts the topology of the flow in each of the cases considered. The lift is predicted well at the higher angles of attack, but slightly overpredicted at the lower angles of attack.

Powell, K. G.↗

NASA NTRS1994

Nonlinear Instability of a Uni-directional Transversely Sheared Mean Flow

It is well known that the presence of a weak cross flow in an otherwise two-dimensional shear flow results in a spanwise variation in the mean streamwise velocity profile that can lead to an amplification of certain three-dimensional disturbances through a kind of resonant-interaction mechanism (Goldstein and Wundrow 1994). The spatial evolution of an initially linear, finite-growth-rate, instability wave in such a spanwise-varying shear flow is considered, The base flow, which is governed by the three-dimensional parabolized Navier-Stokes equations, is initiated by imposing a spanwise- periodic cross-flow velocity on an otherwise two-dimensional shear flow at some fixed streamwise location. The resulting mean-flow distortion initially grows with increasing streamwise distance, reaches a maximum and eventually decays through the action of viscosity. This decay, which coincides with the viscous spread of of the shear layer, means that the local growth rate of the instability wave will eventually decrease as the wave propagates downstream. Nonlinear effects can then become important within a thin spanwise-modulated critical layer once the local instability-wave amplitude and growth rate become sufficiently large and small, respectively. The amplitude equation that describes this stage of evolution is shown to be a generalization of the one obtained by Goldstein and Choi (1989) who considered the related problem of the interaction of two oblique modes in a two-dimensional shear layer.

Wundrow, David W.↗

NASA NTRS1980

On the stabilization of three-dimensional boundary layers by suction and cooling

A significant reduction in the drag of transonic aircraft can be achieved by using an active method of boundary-layer control to maintain laminar flow on the aerodynamic surfaces. The stabilizing influence of suction for both favorable and adverse pressure gradients is demonstrated by means of the self-similar incompressible three-dimensional boundary layers on yawed wedges. Profile instability is measured by the maximum amplification rate of fixed-frequency disturbances computed according to linearized, locally parallel, spatial stability theory. Suction is found to be more effective in controlling Tollmien-Schlichting instability than stationary cross-flow disturbances. The effectiveness of surface cooling as a method of stabilization is compared with suction for the boundary layers on a transonic 35 deg swept wing of infinite span. It is found from compressible stability theory that when the surface is cooled to a uniform temperature such that the maximum cross-flow velocity is reduced by the same amount as with a uniform suction distribution, the stabilizing effect of cooling on cross-flow disturbances is less than with suction.

Mack, L. M.↗

NASA NTRS1986

The flame structure and vorticity generated by a chemically reacting transverse jet

An analytical model describing the behavior of a turbulent fuel jet injected normally into a cross flow is developed. The model places particular emphasis on the contrarotating vortex pair associated with the jet, and predicts the flame length and shape based on entrainment of the oxidizer by the fuel jet. Effects of buoyancy and density variations in the flame are neglected in order to isolate the effects of large-scale mixing. The results are compared with a simulation of the transverse reacting jet in a liquid (acid-base) system. For a wide range of ratios of the cross flow to jet velocity, the model predicts flame length quite well. In particular, the observed transitional behavior in the flame length between cross-flow velocity to jet velocity of orifice ratios of 0.0 to 0.1, yielding an approximate minimum at the ratio 0.05, is reproduced very clearly by the present model. The transformation in flow structure that accounts for this minimum arises from the differing components of vorticity dominant in the near-field and far-field regions of the jet.

Karagozian, A. R.↗

NASA NTRS1988

A review of various flow-solid interaction analysis methods with emphasis on recent advances in turbulence models and flow analysis methods

A review on various experimental, analytical, and numerical methods for the flow-solid interaction of a nest of cylinders subjected to cross flow is presented in this paper. In order to assess the possibility of initiating a development of major numerical analysis method for flow-solid interaction of a nest of cylinders in cross flows, a review on various turbulence models, numerical methods such as the finite element method and the finite difference method, and the available numerical methods for flow-solid interactions have been included in this paper. A multiple-time-scale turbulence model for complex turbulent flows and a finite element method for high Reynolds number flows have been introduced herein for the same reason.

Kim, S.-W.↗

NASA NTRS1977

Effects of jet decay rate on jet induced loads on a flat plate

Experimental modelling of the interaction between a jet and an aircraft wing or fuselage in VTOL aircraft was undertaken using a cold jet exiting perpendicular to a flat plate in a uniform cross-flow. Effects of jet decay rate and jet-to-cross-flow velocity ratio, R, on the induced load distribution were investigated. Jet decay rate was increased by using cylindrical centerbodies submerged in the jet nozzle, which caused nonuniform initial jet velocity profiles. Quicker jet decay rate, corresponding to the presence of a centerbody, resulted in as much as 50% reduction in the induced pressure loads on the plate. This has implications in interpretation of results from earlier VTOL model studies of jet induced loads, where the jets have often had relatively slow decay rates due to uniform initial velocity profiles

Kuhlman, J. M.↗

NASA NTRS2008

Hybrid LES/RANS Simulation of Transverse Sonic Injection into a Mach 2 Flow

A computational study of transverse sonic injection of air and helium into a Mach 1.98 cross-flow is presented. A hybrid large-eddy simulation / Reynolds-averaged Navier-Stokes (LES/RANS) turbulence model is used, with the two-equation Menter baseline (Menter-BSL) closure for the RANS part of the flow and a Smagorinsky-type model for the LES part of the flow. A time-dependent blending function, dependent on modeled turbulence variables, is used to shift the closure from RANS to LES. Turbulent structures are initiated and sustained through the use of a recycling / rescaling technique. Two higher-order discretizations, the Piecewise Parabolic Method (PPM) of Colella and Woodward, and the SONIC-A ENO scheme of Suresh and Huyhn are used in the study. The results using the hybrid model show reasonably good agreement with time-averaged Mie scattering data and with experimental surface pressure distributions, even though the penetration of the jet into the cross-flow is slightly over-predicted. The LES/RANS results are used to examine the validity of commonly-used assumptions of constant Schmidt and Prandtl numbers in the intense mixing zone downstream of the injection location.

Boles, John A.↗

NASA NTRS1994

Three-Dimensional Navier-Stokes Simulations with Two-Equation Turbulence Models of Intersecting Shock-Waves/Turbulent Boundary Layer at Mach 8.3

An investigation of the numerical simulation with two-equation turbulence models of a three-dimensional hypersonic intersecting (SWTBL) shock-wave/turbulent boundary layer interaction flow is presented. The flows are solved with an efficient implicit upwind flux-difference split Reynolds-averaged Navier-Stokes code. Numerical results are compared with experimental data for a flow at Mach 8.28 and Reynolds number 5.3x10(exp 6) with crossing shock-waves and expansion fans generated by two lateral 15 fins located on top of a cold-wall plate. This experiment belongs to the hypersonic database for modeling validation. Simulations show the development of two primary counter-rotating cross-flow vortices and secondary turbulent structures under the main vortices and in each corner singularity inside the turbulent boundary layer. A significant loss of total pressure is produced by the complex interaction between the main vortices and the uplifted jet stream of the boundary layer. The overall agreement between computational and experimental data is generally good. The turbulence modeling corrections show improvements in the predictions of surface heat transfer distribution and an increase in the strength of the cross-flow vortices. Accurate predictions of the outflow flowfield is found to require accurate modeling of the laminar/turbulent boundary layers on the fin walls.

Bardina, J. E.↗

DOE OSTI2022

Innovative, Versatile and Cost-Effective Solid Oxide Fuel Cell Stack Concept

This report summarizes the work performed for the U. S. Department of Energy/National Energy Technology Laboratory (DOE/NETL) under Cooperative Agreement DE-FE0026211 entitled “Innovative, Versatile and Cost-Effective Solid Oxide Fuel Cell Stack Concept”. The overall objective of this project was to develop and evaluate a solid oxide fuel cell (SOFC) stack configuration based on a novel prime-surface interconnect design for a broad range of power generation applications. The prime-surface is a one-piece metallic interconnect that incorporates both fuel and oxidant flow fields with peaks on one side of the interconnect serving as flow channels (valleys) on the other side. (One example is the egg-carton shaped interconnect design.) This stack technology has several attractive features including reduced stack weight and volume, decreased performance losses in stacking, improved sealing, versatility in incorporation of different types of cell construction (thin-film cells or sintered cells) and flexibility in gas flow configuration (cross-flow, co-flow or counter-flow). These features lead to lower cost, better performance, and enhanced reliability for the stack. The R&D work of this project focused on demonstrating fabrication, operability and cost effectiveness of the stack design and was conducted by University of California, San Diego (UCSD) in conjunction with OxEon Energy (OxEon). The key technical activities of this project involved prime-surface interconnect design and fabrication development; supported thin-film cell structure development; stack development; stack operation demonstration; and stack cost assessment. The results of these activities are summarized in this report.

30 DIRECT ENERGY CONVERSION↗

DOE OSTI2023

Cummins R-SOFC System Development

The overall purpose of this project was to reduce the Reversible-Solid Oxide Fuel Cell (R-SOFC) system cost by developing two technologies, an improved cell design and the incorporation of an ejector in the fuel recycle loop instead of a blower. A Simulink model of the baseline SOFC system was developed and calibrated with experimental test data. The R-SOFC system model was built by integrating GT Suite developed models of the steam generation components into the baseline Simulink SOFC system model. The ability to run the stack in SOEC operating mode was also added to the model. The system model was used to explore the ability of the R-SOFC system to meet operational constraints on Steam/Carbon ratio and H2 concentration on the fuel side electrode. A CFD ejector model was developed and used to explore a range of ejector design parameters, leading to the final ejector design that was prototyped for testing. A prototype steam ejector was first tested in a laboratory environment using room temperature air. The steam ejector was subsequently tested using the full hot recycle loop with all relevant heat exchangers and steam generation components. The test conditions utilized temperatures, pressures, and flow rates expected in an R-SOFC application. Throughout the experimental testing work, ejector performance test data was used to improve and then validate the CFD ejector model. A CFD cell model was developed and used to optimize thermal gradients, voltage, and cost of a new cell substrate design. A CFD comparison of co-flow and cross-flow cell designs informed the decision to use a co-flow design for the new cell substrate. Multiple rounds of CFD simulation were used to improve the cell design to minimize the variation in air and fuel distribution across cell channels and to minimize the variation in air and fuel distribution across different cells in the stack. A few prototypes of the new cell substrate design were produced and validated in a laboratory environment by thermally spraying and verifying that they met established manufacturing specifications. The cell manufacturing process was adjusted in order to bring these metrics within acceptable tolerances. Cummins’ internal calculations show that the new cell design reduces cost ~50% compared to the baseline cell, while the ejector + superheater/boiler concept reduces cost of the recycle loop by ~40%. The impact of these cost reductions on the cost of producing H2 will depend on the specific system where they are applied. Therefore, a Techno-Economic Analysis was completed using system cost as a variable, and showing how the NREL Current and Future system costs translate into H2 production cost.

Henrichsen, Lars↗

NASA NTRS1981

Computation of hypersonic viscous flow around three-dimensional bodies at high angles of attack

A parabolized Navier-Stokes code capable of predicting steady viscous supersonic flows with cross-flow separation is applied to three-dimensional arbitrary geometries at high angles of attack. The numerical procedure, which is implicit, noniterative, and of second-order accuracy in the marching direction, has been used to compute complicated flow fields containing a relatively thick sonic layer and regions of strong viscous-inviscid interaction. A consistent and accurate procedure has also been developed to provide the necessary starting data through timewise integration of the equations of motion near the nose-tip region of the body. Numerical results obtained from the present method compare well with experiment for both the surface pressures and heat transfer.

Rizk, Y. M.↗