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NASA NTRS2003

Thin-Film Air-Mass-Flow Sensor of Improved Design Developed

Researchers at the NASA Glenn Research Center have developed a new air-mass-flow sensor to solve the problems of existing mass flow sensor designs. NASA's design consists of thin-film resistors in a Wheatstone bridge arrangement. The resistors are fabricated on a thin, constant-thickness airfoil to minimize disturbance to the airflow being measured. The following photograph shows one of NASA s prototype sensors. In comparison to other air-mass-flow sensor designs, NASA s thin-film sensor is much more robust than hot wires, causes less airflow disturbance than pitot tubes, is more accurate than vane anemometers, and is much simpler to operate than thermocouple rakes. NASA s thin-film air-mass-flow sensor works by converting the temperature difference seen at each leg of the thin-film Wheatstone bridge into a mass-flow rate. The following figure shows a schematic of this sensor with air flowing around it. The sensor operates as follows: current is applied to the bridge, which increases its temperature. If there is no flow, all the arms are heated equally, the bridge remains in balance, and there is no signal. If there is flow, the air passing over the upstream legs of the bridge reduces the temperature of the upstream legs and that leads to reduced electrical resistance for those legs. After the air has picked up heat from the upstream legs, it continues and passes over the downstream legs of the bridge. The heated air raises the temperature of these legs, increasing their electrical resistance. The resistance difference between the upstream and downstream legs unbalances the bridge, causing a voltage difference that can be amplified and calibrated to the airflow rate. Separate sensors mounted on the airfoil measure the temperature of the airflow, which is used to complete the calculation for the mass of air passing by the sensor. A current application for air-mass-flow sensors is as part of the intake system for an internal combustion engine. A mass-flow sensor is used to provide accurate information about the amount of air entering the engine so that the amount of fuel can be adjusted to give the most efficient combustion. The ideal mass-flow sensor would be a rugged design that minimizes the disturbance to the flow stream and provides an accurate reading of both smooth and turbulent flows; NASA's design satisfies these requirements better than any existing design. Most of the mass-flow sensors used today are the hot wire variety. Hot wires can be fragile and cannot accurately measure a turbulent or reversing flow, which is often encountered in an intake manifold. Other types of mass-flow sensors include pitot tubes, vane anemometers, and thermocouple rakes-all of which suffer from some type of performance problem. Because it solves these performance problems while maintaining a simple design that lends itself to low-cost manufacturing techniques, NASA s thin-film resistance temperature detector air-mass-flow sensor should lead to more widespread use of mass-flow sensors.

Fralick, Gustave C.↗

NASA NTRSDate not supplied

Summary of Shock Wave Turbulent Boundary Layer Interaction Experiments In a Circular Test Section

A series of experiments were performed at Mach 2.5 in a 17 cm diameter circular test section to characterize an impinging/reflected shock wave turbulent boundary layer interaction generated by a cone-cylinder centerbody. The cone-cylinder centerbody generates a conical shock wave that interacts with the naturally occurring boundary layer developing on the test section wall. Three different cone angles were used in the experiment to study unseparated, incipiently separated, and separated interactions. When the cone-cylinder centerbody is positioned on the centerline, a flowfield which is two-dimensional in the mean is generated. Three dimensional interactions were also created by offsetting the cone-cylinder centerbody from the test section centerline. The results are intended to provide benchmark quality datasets for computational fluid dynamics (CFD) validation without the pitfalls inherent in rectangular configurations where corner effects prohibit a truly two-dimensional flow in the mean. The experimental measurements included surface flow visualization, wall static pressure, flowfield Pitot tube pressure, constant-voltage anemometry (CVA) normal hot-wire, and particle image velocimetry (PIV) measurements. The hot-wire measurements were used to calculate mean mass flux and total temperature profiles, mass flux and total temperature turbulence intensities, and the mass flux-total temperature correlation. The PIV measurements provide three-dimensional mean velocity measurements. Agreement between the pressure, hot-wire, and PIV measurements is established in the undisturbed upstream flowfield.

Supersonic↗

NASA NTRSDate not supplied

Summary of Shock Wave Turbulent Boundary Layer Interaction Experiments in a Circular Test Section

compressible flow↗

NASA NTRS1982

A color video display technique for flow field surveys

Color video display techniques for flow field surveys are presented. The following techniques were examined: traverse device, used for flow field surveys above and behind finite wing models; flow chart of data reduction for color video display technique; location of spanwise survey stations above and behind wing; hot wire data at first three survey stations on fully stalled wing; hot wire data at last three stations behind fully stalled wing; hot wire and pitch probe data; magnitude of velocity, yaw angle, pitch angle, and cross flow direction from 5 tube survey at X/C = 2.70 behind fully stalled wing.

Winkelmann, A. E.↗

NASA NTRS1986

A fast-response aspirating probe for measurements of total temperature and pressure in transonic cryogenic wind tunnel

A newly developed, 3-mm-diam, dual hot-wire aspirating probe was used to measure the time-resolved stagnation temperature and pressure in a transonic cryogenic wind tunnel. The probe consists of two coplanar constant temperature hot wires at different overheat ratios operating in a 1.5-mm-diam channel with a choked exit. Thus, the constant Mach number flow by the wires is influenced only by free-stream stagnation temperature and pressure. Diffusion of the free-stream Mach number to a lower value in the channel reduces the dynamic drag on the hot-wire. Frequency response of the present design is dc to 20 kHz. The probe was used to measure the unsteady wake shed from an oscillating airfoil tested in the 0.3-m Transonic Cryogenic Tunnel at NASA-Langley Research Center. The hot-wire lasted for more than ten hours before breaking, proving the ruggedness of the probe and the usefulness of the technique in a high dynamic pressure, transonic cryogenic wind tunnel. Typical data obtained from the experiment are presented after reduction to stagnation pressure and temperature.

Ng, W.-F.↗

NASA NTRS1999

Investigation of Point Doppler Velocimetry (PDV) for Transition Detection in Boundary Layers

A two-component Point Doppler Velocimeter (PDV) system has been improved through the use of vapor-limited iodine cells that have responses that are insensitive to temperature variations. Two-component PDV velocity measurements have been obtained for a 1 inch diameter uniform circular jet flow at a nominal exit velocity of 60 m/sec, corresponding to a Reynolds number of 100,000. Similar data have also been obtained for an annular jet and a swirling jet, These PDV data runs have been duplicated to judge the repeatability of these measurements, and also have been compared with hot wire anemometer data for the same flow conditions. PDV mean velocity results are repeatable to within approximately 1-2 meters per second; the PDV RMS velocity results are also quite repeatable. Exit profiles of PDV mean axial velocity data generally agree with hot wire anemometer results to within about 2 meters per second as well. However, the PDV RMS velocity results are consistently lower than the hot wire results everywhere but at the exit of the standard jet, where they are too high relative to the hot wire data. This is believed to at least be partially due to the method used to compute the RMS (Root Mean Square).

Kuhlman, John↗

NASA NTRS2006

Validation of Multi-Dimensional Stirling Engine Design Codes: Measurements in the 90-Degree Turn Test Section

The work to be presented herein was motivated largely by a desire to improve the understanding of oscillatory fluid mechanics inside a Stirling engine. To this end, a CFD project was undertaken at Cleveland State University with the goal of accurately predicting the fluid dynamics within an engine or engine component. Along with the CFD efforts, a code validation project was undertaken at the University of Minnesota. The material covered herein consists of four main parts. In section 1, an experimental investigation of a small aspect ratio impinging jet is discussed. Included in this discussion is a description of the test facilities and instrumentation. A presentation of the collected data is given and comments are made. Next, in section 2, a parallel experimental investigation is presented in which the same geometry as that of section 1 is used, but the flow conditions are changed from steady unidirectional flow to sinusoidally oscillating flow. In section Two, collected data are presented and comments are made. In section 3, a comparison is made between the results of sections 1 and 2, namely, sinusoidally oscillating flow results are compared to steady, unidirectional flow results from the same geometry. Finally, in section 4, a comparison is made between experimentally collected data (the main subject of this work) and CFD generated results. Furthermore, in appendix A, an introductory description of the primary measurement tool used in the experimental process the hot wire anemometer is given for the unfamiliar. The anemometer calibration procedure is described in appendix B. A portfolio of data reduction and data processing codes is provided in appendix C and lastly, a DVD and a roadmap of its contents is provided in an appendix D. 1.0 Unidirectional Flow Investigations 1.1 Introduction This unidirectional experimental program was undertaken to complement an oscillatory flow investigation conducted at the University of Minnesota. The oscillatory investigation is discussed thoroughly in section 2. We defer the description of the motivation behind these experiments until the introduction of section 2. The work that is discussed in this thesis began (chronologically) with oscillatory flow visualization experiments. It was decided that it would be valuable and important to investigate the flow under unidirectional conditions in the same geometry as that of the oscillatory experiments. The thought was that the unidirectional case would be less complicated to model with a CFD program (a moving boundary would be replaced with a steady state boundary condition). Thus, a series of unidirectional experiments were carried out to capture the important features of the flow within the test section. The purpose of these experiments was to provide a data set for comparison to CFD generated velocity fields. Hot-wire anemometry data were taken and flow visualization was conducted as a standard for code validation. The flow geometry was simple, such that it could be easily gridded in a CFD program. However, the geometry provided separation and transition zones, shear layers and recirculation zones. These characteristics made the flow complex and challenging for CFD computation. We comment that the order of experiments that produced this report is as follows: experimental flow visualization under oscillatory flow conditions was carried out; this was followed by unidirectional flow visualization and hot wire anemometry; finally, oscillatory hot wire anemometry was conducted. We present the results out of chronological order for the following reason: the unidirectional results are easier

Simon, Terrence W.↗

NASA NTRS1975

Amplification of Reynolds number dependent processes by wave distortion

A system using a hot-wire transducer as an analog of a liquid droplet of propellant was employed to investigate the ingredients of the acoustic instability of liquid-propellant rocket engines. It was assumed that the combustion process was vaporization-limited and that the combustion chamber was acoustically similar to a closed-closed right-circular cylinder. Before studying the hot-wire closed-loop system (the analog system), a microphone closed-loop system, which used the response of a microphone as the source of a linear feedback exciting signal, was investigated to establish the characteristics of self-sustenance of acoustic fields. Self-sustained acoustic fields were found to occur only at resonant frequencies of the chamber. In the hot-wire closed-loop system, the response of hot-wire anemometer was used as the source of the feedback exciting signal. The self-sustained acoustic fields which developed in the system were always found to be harmonically distorted and to have as their fundamental frquency a resonant frequency for which there also existed a second resonant frequency which was approximately twice the fundamental frequency.

Ventrice, M. B.↗

DOE OSTI2023

Hybrid Al Casting + AM Components for Automotive Applications

Although casting Aluminum (Al) alloys is widely used for automotive application, the conventional casting process is showing limitations for modern vehicle production. A hybrid manufacturing method that is capable of fabricating automotive structures with tailored functionality and tuned attributes at a high production rate is proposed in this project, utilizing the merits of conventional casting methods and additive manufacturing (AM) methods. Ford is interested in supplementing conventional casting processes (e.g., shape casting, high pressure die casting) with local modifications to geometry and microstructure using additive manufacturing techniques. Two additive manufacturing methods, wire-arc and laser hot-wire directed energy deposition AM process, were evaluated by deposition of 4043 filler wire onto high-pressure die cast and permanent mold cast Al-Si alloys. The feasibility of this hybrid manufacturing method was determined through trial deposition and evaluation of defects, microstructure, and mechanical properties. Laser hot-wire deposition was found to be beneficial for this application with low porosity, a refined microstructure, and mechanical properties similar to those reported in the literature for 4043. The mechanical properties of the interface between the A356 casting and deposited 4043 were found to be controlled by the weaker deposit material.

36 MATERIALS SCIENCE↗

NASA NTRS2015

An Investigation of Transonic Resonance in a Mach 2.2 Round Convergent-Divergent Nozzle

Hot-wire and acoustic measurements were taken for a round convergent nozzle and a round convergent-divergent (C-D) nozzle at a jet Mach number of 0.61. The C-D nozzle had a design Mach number of 2.2. Compared to the convergent nozzle jet flow, the Mach 2.2 nozzle jet flow produced excess broadband noise (EBBN). It also produced a transonic resonance tone at 1200 Herz. Computational simulations were performed for both nozzle flows. A steady Reynolds-Averaged Navier-Stokes simulation was performed for the convergent nozzle jet flow. For the Mach 2.2 nozzle flow, a steady RANS simulation, an unsteady RANS (URANS) simulation, and an unsteady Detached Eddy Simulation (DES) were performed. The RANS simulation of the convergent nozzle showed good agreement with the hot-wire velocity and turbulence measurements, though the decay of the potential core was over-predicted. The RANS simulation of the Mach 2.2 nozzle showed poor agreement with the experimental data, and more closely resembled an ideally-expanded jet. The URANS simulation also showed qualitative agreement with the hot-wire data, but predicted a transonic resonance at 1145 Herz. The DES showed good agreement with the hot-wire velocity and turbulence data. The DES also produced a transonic tone at 1135 Herz. The DES solution showed that the destabilization of the shock-induced separation region inside the nozzle produced increased levels of turbulence intensity. This is likely the source of the EBBN.

DES↗

NASA NTRS1992

An assessment of particle velocimetry potential in hypersonic flow

Future progress in the computation of hypersonic flow fields is restricted by the need for a reliable turbulence modeling data base which could be used for the development of empirical models for use in numerical codes. Currently, there are few compressible flow measurements which could be used for this purpose. Procedures for hot wire measurements in hypersonic flows are presently outlined, and assessments are made of the potential for hot wire and laser velocimeter measurements of turbulent fluctuations in hypersonic flow fields. The results of recent experiments conducted in two hypersonic wind tunnels will be presented and comparisons made with previous hot wire turbulence measurements.

Owen, F. K.↗

NASA NTRS1991

A real time dynamic data acquisition and processing system for velocity, density, and total temperature fluctuation measurements

The real time Dynamic Data Acquisition and Processing System (DDAPS) is described which provides the capability for the simultaneous measurement of velocity, density, and total temperature fluctuations. The system of hardware and software is described in context of the wind tunnel environment. The DDAPS replaces both a recording mechanism and a separate data processing system. DDAPS receives input from hot wire anemometers. Amplifiers and filters condition the signals with computer controlled modules. The analog signals are simultaneously digitized and digitally recorded on disk. Automatic acquisition collects necessary calibration and environment data. Hot wire sensitivities are generated and applied to the hot wire data to compute fluctuations. The presentation of the raw and processed data is accomplished on demand. The interface to DDAPS is described along with the internal mechanisms of DDAPS. A summary of operations relevant to the use of the DDAPS is also provided.

Clukey, Steven J.↗

NASA NTRS1998

Turbulence Measurements on a Flap-Edge Model

Turbulence measurements have been made on a flap-edge and leading-edge slat model using hot-wire anemometry, and, later, particle image velocimetry. The properties of hot-wire anemometry were studied using facilities at NASA Ames Research Center. Hot-film probes were used because of their durability, but cross-films were limited by non-linear end effects. As a warm-up exercise, hot-film probes were used to measure velocities in the farfield wake of a cylinder with an airfoil in the near-field wake. The airfoil reduced the drag coefficient of the system by 10%. A single-wire hot-film probe was used to measure velocity profiles over the top of a NACA 63(sub 2)-215 Mod. B wing with a Fowler flap and leading,-edge slat. Results showed the size of slat wake was dependent upon the slat deflection angle. Velocity increased through the slat gap with increased deflection. The acoustically modified slat decreased the chance of separation. Measurements were taken at the flap edge with a single hot-film. Trends in the data indicate velocity and turbulence levels increase at the flap edge. The acoustically modified flap modifies the mean flow near the flap edge. Correlations were made between the hot-film signal and the unsteady pressure transducers on the wing which were published in a NASA CDTM. The principles of Particle Image Velocimetry (PIV) were studied at Florida State University. Spectral PIV was used to measure the spectra of a subsonic jet. Measured frequencies were close to the predicted frequency of jet shedding. Spectral PIV will be used to measure the spectra of the slat flow in the second 7 x lO-ft. wind tunnel test. PIV has an advantage that it can measure velocity and spectra of the entire flowfield instantaneously. However, problems arise when trying, to store this massive amount of PIV data. Support for this research has continued through a NASA Graduate Student Program Fellowship which will end in June 1999. The thesis should be completed by this time.

Moriarty, Patrick↗

NASA NTRS1976

Effect of velocity gradients on measurements of turbulent shear stress

Experiments were carried out to evaluate the effects of normal velocity gradients on hot wire measurements in a subsonic boundary layer of the same size as the flow investigated by Johnson and Rose (1975). Both hot wire and film anemometers were used to measure the turbulent properties of the boundary layer. A special X-wire probe with one wire vertical and the other at an angle of about 40 deg to the flow was used to demonstrate the gradient effects. The results indicate that major errors are encountered when mean and turbulent velocity gradients exist along the length of hot wire sensors, the problem being more pronounced at high speeds. Although the split film sensor results show a significant improvement over the X-wire sensor, further reduction in the space resolution of sensors by roughly an order of magnitude would appear to be necessary to reduce the error to acceptable values near the wall.

Sandborn, V. A.↗

NASA NTRS1994

Separated and Recovering Turbulent Boundary Layer Flow Behind a Backward Facing Step For Different Reynolds Numbers

Experimental results for a two-dimensional separated turbulent boundary layer behind a backward facing step for five different Reynolds numbers are reported. Results are presented in the form of tables, graphs and a floppy disk for an easy access of the data. Reynolds number based on the step height was varied by changing the reference velocity upstream of the step, U(sub o), and the step height, h. Hot-wire measurement techniques were used to measure three Reynolds stresses and four triple-velocity correlations. In addition, surface pressure and skin friction coefficients were measured. All hot-wire measurements were acquired in a measuring domain which excluded recirculating flow region due to the directional insensitivity of hot-wires. The downstream extent of the domain from the step was 51 h for the largest and I 14h for the smallest step height. This significant downstream length permitted extensive study of the flow recovery. Prediction of perturbed flows and their recovery is particularly attractive for popular turbulence models since variations of turbulence length and time scales and flow interactions in different regions are generally inadequately predicted. The data indicate that the flow in the free shear layer region behaves like the plane mixing layer up to about 2/3 of the mean reattachment length when the flow interaction with the wall commences the flow recovery to that of an ordinary turbulent boundary layer structure. These changes of the flow do not occur abruptly with the change of boundary conditions. A reattachment region represents a transitional region where the flow undergoes the most dramatic adjustments to the new boundary conditions. Large eddies, created in the upstream free-shear layer region, are being torn, recirculated, reentrained back into the main stream interacting with the incoming flow structure. It is foreseeable that it is quite difficult to describe the physics of this region in a rational and quantitative manner other than statistical. Downstream of the reattachment point the flow recovers at different rates near the wall, in the newly developing internal boundary layer, and in the outer part of the flow. It appears that Reynolds stresses do not fully recover up to the longest recovery length of 114 h.

Jovic, Srba↗

NASA NTRS1990

Turbulence and shear stress measurements in hypersonic flow

An assessment has been made of the potential for hot wire and laser anemometer measurements of turbulent fluctuations in hypersonic flow fields. The results of laser velocimeter experiments conducted in two hypersonic wind tunnels are reported and comparisons made with previous hot wire turbulence measurements. A new concept for the measurement of the compressible shear stress terms which combines the attributes of both hot wire and laser anemometry is presented.

Owen, F. K.↗

NASA NTRS1999

Investigation of Point Doppler Velocimetry (PDV) for Transition Detection in Boundary Layers

A two component Point Doppler Velocimetry (PDV) system has been developed and tested. Improvements were made to an earlier PDV system, in terms of experimental techniques, as well as the data acquisition and reduction software. Measurements of the streamwise and spanwise mean and fluctuating velocities for flows from a rectangular channel and over an NACA 0012 airfoil were made, and the data were compared against hot wire data. The closest to the airfoil surface that PDV measurements could be made was on the order of 0.005 m(0.2", z/c = 0.0169). When the PDV and hot wire data were compared, the time traces for each appeared similar. The mean velocities agreed to within plus or minus 2 m/sec, while the RMS velocities agreed to plus or minus 0.4 m/sec. While the PDV time autocorrelations agreed with those of the hot wire data, the PDV power spectral densities were noisier above 750 Hz. A major source of error in these experiments was determined to be the drifting of the iodine cell stem temperatures. While the stem temperatures were controlled to within plus or minus 0.1 C, this could lead to a frequency shift of as much as 6 MHz, which translates into an error of 1.6 m/sec for the back scatter channel, and up to 6.9 m/sec for the forward scatter channel. These error estimates are consistent with the observed error magnitudes.

Kuhlman, John M.↗

NASA NTRS1988

A high speed data acquisition and analysis system for transonic velocity, density, and total temperature fluctuations

The high speed Dynamic Data Acquisition System (DDAS) is described which provides the capability for the simultaneous measurement of velocity, density, and total temperature fluctuations. The system of hardware and software is described in context of the wind tunnel environment. The DDAS replaces both a recording mechanism and a separate data processing system. The data acquisition and data reduction process has been combined within DDAS. DDAS receives input from hot wires and anemometers, amplifies and filters the signals with computer controlled modules, and converts the analog signals to digital with real-time simultaneous digitization followed by digital recording on disk or tape. Automatic acquisition (either from a computer link to an existing wind tunnel acquisition system, or from data acquisition facilities within DDAS) collects necessary calibration and environment data. The generation of hot wire sensitivities is done in DDAS, as is the application of sensitivities to the hot wire data to generate turbulence quantities. The presentation of the raw and processed data, in terms of root mean square values of velocity, density and temperature, and the processing of the spectral data is accomplished on demand in near-real-time- with DDAS. A comprehensive description of the interface to the DDAS and of the internal mechanisms will be prosented. A summary of operations relevant to the use of the DDAS will be provided.

Clukey, Steven J.↗