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Experiments are being conducted in the NASA Ames Hypervelocity Free Flight Aerodynamic Facility to quantify the effects on turbulent convective heat transfer of surface roughness representative of a new class of 3D woven thermal protection system mRough-wall turbulent heat transfer measurements were obtained on ballistic-range models in hypersonic flight in the NASA Ames Hypervelocity Free Flight Aerodynamic Facility. Each model had three different surface textures on segments of the conic frustum: smooth wall, sand roughness, and a pattern roughness, thus providing smooth-wall and sand-roughness reference data for each test. The pattern roughness was representative of a woven thermal protection system material developed by NASA's Heatshield for Extreme Entry Environment Technology project. The tests were conducted at launch speeds of 3.2 km/s in air at 0.15 atm. Roughness Reynolds numbers, k+, ranged for 12 to 70 for the sand roughness, and as high as 200 for the pattern roughness. Boundary-layer parameters required for calculating k+ were evaluated using computational fluid dynamics simulations. The effects of pattern roughness are generally characterized by an equivalent sand roughness determined with a correlation developed from experimental data obtained on specifically-designed roughness patterns that do not necessarily resemble real TPS materials. Two sand roughness correlations were examined: Dirling and van Rij, et al. Both gave good agreement with the measured heat-flux augmentation for the two larger pattern roughness heights tested, but not for the smallest height tested. It has yet to be determined whether this difference is due to limitations in the experimental approach, or due to limits in the correlations used. Future experiments are planned that will include roughness patterns more like those used in developing the equivalent sand roughness correlations.aterials being developed by NASA's Heatshield for Extreme Entry Environment Technology (HEEET) project. Data were simultaneously obtained on sand-grain roughened surfaces and smooth surfaces, which can be compared with previously obtained data. Results are presented in this extended abstract for one roughness pattern. The full paper will include results from three roughness patterns representing virgin HEEET, nominal turbulent ablated HEEET, and twice the roughness of nominal turbulent ablated HEEET. Results will be used to compare with commonly used equivalent sand grain roughness correlations.
Roughness is unavoidable on practical high-speed vehicles, so it is critical to determine its impact on boundary layer transition. The flow field downstream of a streamwise array of cylindrical roughness elements is probed with hot-wire anemometry in this experiment. Mean flow distortion is examined in several measurement planes in the wake of the cylindrical roughness using the streak strength profiles and contour plots of the mass flux and total temperature. The roughness element heights and spacings were varied and their instability modes were examined. Cylindrical roughness elements approximately 140 micron tall produce an odd instability mode that grows weakly with downstream distance in the measurement range of this experiment. Cylindrical roughness elements approximately 280 micron tall produce an even instability mode that grows, becomes nonlinear, and then breaks down. Transition onset remains constant relative to the most downstream roughness in the streamwise array when the 280 micron roughness elements are spaced 2 diameters apart. Transition onset occurs at an earlier upstream location relative to the most downstream roughness in the streamwise array when the roughness elements are spaced 4 diameters appear to recover before the next downstream roughness element, so the location of transition shifts with the location of the most downstream roughness element in the array. When the rough- apart. The wake behind roughness elements spaced 2 diameters apart do not ness elements are spaced 4 diameters apart, the flow behind the first roughness element has enough space to recover before feeding into the second roughness element, and thus, moves transition forward.
Drag partition measurements were made in the atmospheric inertial sublayer for six roughness configurations made up of solid elements in staggered arrays of different roughness densities. The roughness was in the form of a patch within a large open area and in the shape of an equilateral triangle with 60 m long sides. Measurements were obtained of the total shear stress (tau) acting on the surfaces, the surface shear stress on the ground between the elements (tau(sub S)) and the drag force on the elements for each roughness array. The measurements indicated that tau(sub S) quickly reduced near the leading edge of the roughness compared with tau, and a tau(sub S) minimum occurs at a normalized distance (x/h, where h is element height) of approx. -42 (downwind of the roughness leading edge is negative), then recovers to a relatively stable value. The location of the minimum appears to scale with element height and not roughness density. The force on the elements decreases exponentially with normalized downwind distance and this rate of change scales with the roughness density, with the rate of change increasing as roughness density increases. Average tau(sub S): tau values for the six roughness surfaces scale predictably as a function of roughness density and in accordance with a shear stress partitioning model. The shear stress partitioning model performed very well in predicting the amount of surface shear stress, given knowledge of the stated input parameters for these patches of roughness. As the shear stress partitioning relationship within the roughness appears to come into equilibrium faster for smaller roughness element sizes it would also appear the shear stress partitioning model can be applied with confidence for smaller patches of smaller roughness elements than those used in this experiment.
The present contribution reviews recent experimental results of roughness effects on boundary layer transition on capsule geometries with spherical windward geometries. Experiments in three wind tunnel facilities are considered. The ACE Tunnel of Texas AM University, USA, provided Mach 6 experiments with distributed roughness at relatively low Reynolds numbers, 2.5 · 10(exp 5) < Re(sub d) < 5 · 10(exp 5), with d denoting the capsule diameter. The observed boundary layer transition compared well with correlations based on transient growth theory, even though the roughness heights were in the order of boundary layer thickness. Larger Reynolds numbers, 1 · 10(exp 6) < Re(sub d) < 3·10(exp 6), could be assessed in the hypersonic Ludwieg tube, HLB, of TU Braunschweig, Germany. Transition is observed at rather low, subcritical roughness values in the order of 20 μm for a roughness patch placed about the geometric center of the capsule model. These experiments varied fluctuation levels of the freestream. The authors assume that the observed transitions that occur downstream of the subcritical roughness patch are due to freestream disturbances in the tunnel, which interact with small roughness heights. Additional experiments in the HLB facility with patches of larger roughness height support the relevance of transient growth theory for low-to-medium roughness heights, relative to boundary layer thickness. The effects of Reynolds numbers and total flow enthalpy on transition with isolated roughness were investigated in the HIEST facility of JAXA, Japan. Here, a model insert with roughness elements of varying height for tripping transition to turbulence was employed. The results are compared to known trip effectiveness correlations for isolated roughness. Overall, the transient growth correlation seems to represent roughness-induced transition behavior on the ACE and HLB entry capsule shapes with roughness over the entire capsule surface. These experiment are however for perfect gases. Comparable experiments on roughness induced transition in a high-enthalpy facility are still needed to confirm the validity of transient-growth correlation for vehicle design.
An investigation of forced-convection heat transfer and associated pressure drops was conducted with air flowing through electrically heated Inconel tubes having various degrees of square-thread-type roughness, an inside diameter of 1/2 inch, and a length of 24 inches. were obtained for tubes having conventional roughness ratios (height of thread/radius of tube) of 0 (smooth tube), 0.016, 0.025, and 0.037 over ranges of bulk Reynolds numbers up to 350,000, average inside-tube-wall temperatures up to 1950deg R, and heat-flux densities up to 115,000 Btu per hour per square foot. Data The experimental data showed that both heat transfer and friction increased with increase in surface roughness, becoming more pronounced with increase in Reynolds number; for a given roughness, both heat transfer and friction were also influenced by the tube wall-to-bulk temperature ratio. Good correlation of the heat-transfer data for all the tubes investigated was obtained by use of a modification of the conventional Nusselt correlation parameters wherein the mass velocity in the Reynolds number was replaced by the product of air density evaluated at the average film temperature and the so-called friction velocity; in addition, the physical properties of air were evaluated at the average film temperature. The isothermal friction data for the rough tubes, when plotted in the conventional manner, resulted in curves similar to those obtained by other investigators; that is, the curve for a given roughness breaks away from the Blasius line (representing turbulent flow in smooth tubes) at some value of Reynolds number, which decreases with increase in surface roughness, and then becomes a horizontal line (friction coefficient independent of Reynolds number). A comparison of the friction data for the rough tubes used herein indicated that the conventional roughness ratio is not an adequate measure of relative roughness for tubes having a square-thread-type element. The present data, as well as those of other investigators, were used to isolate the influence of ratios of thread height to width, thread spacing to width, and the conventional roughness ratio on the friction coefficient. A fair correlation of the friction data was obtained for each tube with heat addition when the friction coefficient and Reynolds number were defined on the basis of film properties; however, the data for each tube retained the curve characteristic of that particular roughness. The friction data for all the rough tubes could be represented by a single line for the complete turbulence region by incorporating a roughness parameter in the film correlation. No correlation was obtained for the region of incomplete turbulence.
Metal additive manufacturing has enabled geometrically complex internal cooling channels for turbine and heat exchanger applications, but the process gives rise to large-scale roughness whose size is comparable to the channel height (which is 500 $\mathrm {\mu }$ m). These super-rough channels pose previously unseen challenges for experimental measurements, data interpretation and roughness modelling. First, it is not clear if measurements at a particular streamwise and spanwise location still provide accurate representation of the mean (time- and plane-averaged) flow. Second, we do not know if the logarithmic layer survives. Third, it is unknown how well previously developed rough-wall models work for these large-scale roughnesses. To answer the above practical questions, we conduct direct numerical simulations of flow in additively manufactured super-rough channels. Three rough surfaces are considered, all of which are obtained from computed tomography scans of additively manufactured surfaces. The roughness’ trough to peak sizes are 0.1 $h$ , 0.3 $h$ and 0.8 $h$ , respectively, where $h$ is the intended half-channel height. Each rough surface is placed opposite a smooth wall and the other two rough surfaces, leading to six rough-wall channel configurations. Two Reynolds numbers are considered, namely $Re_\tau =180$ and $Re_\tau =395$ . We show first that measurements at one streamwise and spanwise location are insufficient due to strong mean flow inhomogeneity across the entire channel, second that the logarithmic law of the wall survives despite the mean flow inhomogeneity and third that the established roughness sheltering model remains accurate.
Describing flow resistance from the properties of an underlying surface is a challenge in surface hydrology. Runoff models must specify a resistance formulation or “roughness scheme”—describing the functional relationship between flow resistance and flow depth/velocity—and its parameters. Uncertainty in runoff predictions derives from both the selected roughness scheme (e.g., Darcy Weisbach, Manning's, or laminar flow equations), and its parameterization with a roughness coefficient (e.g., Manning's n). Both choices are informed by model calibration to data, usually discharge, and, if available, velocity. In this study, a Saint Venant Equation-based runoff model is calibrated to discharge and velocity data from 112 rainfall simulator experiments. The results are used to identify the optimal roughness scheme among four widely-used options for each experiment, and to explore whether surface properties can be used to select the optimal roughness scheme and its coefficient. Among the tested roughness schemes, a transitional flow equation provided the best fit to the plurality of experiments. The most suitable roughness scheme for a given experiment was not related to measured surface properties. Regression models predicted the calibrated roughness coefficients with adjusted values between 0.48 and 0.54, depending on the roughness scheme used. Litter cover was the best predictor of the roughness coefficient, followed by soil cover and average canopy gap size. The results suggest that selection of an optimal roughness scheme based on surface properties alone remains difficult, but that once a scheme is selected, roughness coefficients can be estimated from surface properties.
The flow behind streamwise arrays of roughness elements was examined with a hot-wire probe. The roughness elements had heights of approximately 20% and 40% of the boundary layer thickness and different spacings and orientations of these roughness elements were tested. The circular roughness elements were spaced two diameters apart or four diameters apart from center to center. Transition moved upstream only when the roughness elements were spaced four diameters apart. The rectangular roughness elements were oriented so that they were at a 45-degree angle relative to the leading edge of the plate. Tandem rectangular elements either had the same orientation or opposing orientation. Mean mass-flux and total-temperature profiles of the flow field downstream of the roughness elements were examined for mean-flow distortion. Mass-flux fluctuation profiles showed that a 45-kHz odd-mode disturbance was present downstream of the shorter circular roughness elements. The dominant instability downstream of the taller circular roughness elements was a 65–85 kHz even-mode disturbance. Mass-flux fluctuation profiles showed that the dominant mode downstream of the tandem rectangular roughness elements with the same orientation was similar to that of a single roughness element and centered at a frequency of approximately 55 kHz. The 55-kHz instability appeared to correspond to increased spanwise shear, and thus was determined to be an odd-like mode. The dominant instability downstream of the tandem roughness elements with opposing orientation was centered at a frequency of 65 kHz and did not transition in the measurement region.
Abstract Design for cooling effectiveness in turbine blades relies on accurate models for dynamic losses and heat transfer of internal cooling passages. Metal additive manufacturing (AM) has expanded the design space for these configurations, but can give rise to large-scale roughness features. The range of roughness length scales in these systems makes morphology resolved computational fluid dynamics (CFD) impractical. However, volumetric roughness models can be leveraged, as they have computational costs orders of magnitude lower. In this work, a discrete element roughness model (DERM), based on the double-averaged Navier–Stokes equations, is presented and applied to additively manufactured rough channels, representative of gas turbine blade cooling passages. Unique to this formulation of DERM is a generalized sheltering-based treatment of drag, a two-layer model for spatially averaged Reynolds stresses, and explicit treatment of dispersion. Six different AM rough surface channel configurations are studied, with roughness trough to peak sizes ranging from 15% to 60% nominal channel passage half-width, and the roughness Reynolds number ranges from Rek = 60 to 300. DERM predictions for spatially and temporally averaged mean flow quantities are compared to previously reported direct numerical simulation results. Good agreement in the mean velocity profiles, stress balances, and drag partitions are observed. While DERM models are typically calibrated to specific deterministic roughness morphologies at comparatively small roughness Reynolds numbers, the present more generalized DERM formulation has wider applicability. Here, it is demonstrated that the model can accommodate random roughness of large scale, typical of AM.
Detailed size measurements of surface roughness associated with leading edge ice accretions are presented to provide information on characteristics of roughness and trends of roughness development with various icing parameters. Data was obtained from icing tests conducted in the Icing Research Tunnel (IRT) at NASA Lewis Research Center (LeRC) using a NACA 0012 airfoil. Measurements include diameters, heights, and spacing of roughness elements along with chordwise icing limits. Results confirm the existence of smooth and rough ice zones and that the boundary between the two zones (surface roughness transition region) moves upstream towards stagnation region with time. The height of roughness grows as the air temperature and the liquid water content increase, however, the airspeed has little effect on the roughness height. Results also show that the roughness in the surface roughness transition region grows during a very early stage of accretion but reaches a critical height and then remains fairly constant. Results also indicate that a uniformly distributed roughness model is only valid at a very initial stage of the ice accretion process.
The transition process induced by the interaction of an isolated roughness with acoustic disturbances in the free stream is numerically investigated for a boundary layer over a flat plate with a blunted leading edge at a free stream Mach number of 3.5. The roughness is assumed to be of Gaussian shape and the acoustic disturbances are introduced as boundary condition at the outer field. The governing equations are solved using the 5'h-~rder accurate weighted essentially non-oscillatory (WENO) scheme for space discretization and using third- order total-variation-diminishing (TVD) Runge- Kutta scheme for time integration. The steady field induced by the two and three-dimensional roughness is also computed. The flow field induced by two-dimensional roughness exhibits different characteristics depending on the roughness heights. At small roughness heights the flow passes smoothly over the roughness, at moderate heights the flow separates downstream of the roughness and at larger roughness heights the flow separates upstream and downstream of the roughness. Computations also show that disturbances inside the boundary layer is due to the direct interaction of the acoustic waves and isolated roughness plays a minor role in generating instability waves.
Heat exchangers are used in many industries to transfer thermal energy between two or more objects with an associated thermal and hydraulic performance indicated by thermal effectiveness and pressure drop respectively. Many investigations have aimed to enhance the thermal effectiveness of heat exchangers by introducing turbulent flow inducers that increase the heat transfer rate at the expense of increasing pressure drop. Flow inducers like surface roughness can be controlled with advanced manufacturing methods like additive manufacturing for heat exchanger production. Selecting and manufacturing an optimal surface roughness for heat exchangers requires a more comprehensive approach that accounts for the surface roughness effect on the thermal and hydraulic performance of a sample. Since fabricating samples with additive manufacturing to a desired surface roughness can be an extensive experimental process, this study will fundamentally investigate the effect of surface roughness on the thermal and velocity boundary layers for various surface roughness profiles with physics-based computational modeling. To accurately model the surface roughness effect on thermohydraulic performance, correlations like roughness ratio, friction factor, and Nusselt number are investigated. This study expects to indicate correlations for different flow regimes which can successfully predict the effect of surface roughness on thermohydraulic performance. Results generated from modeling surface roughness effect with unique correlations are then compared to experimental data obtained from literature for validation. The results of this study will provide insight to understand the thermal fluid physics associated with surface roughness and design guidelines for heat exchangers produced with additive manufacturing.
This study examines the effect of random micron-sized distributed roughness on stationary crossflow instabilities. The roughness parameters are varied by creating nanoparticle coatings of various formulations and applying them to inserts that cover approximately the first 14% of the model. In addition to the baseline configuration (no added roughness, root-mean-square (RMS) ≈ 0.42 𝜇m), panels with RMS roughness values of 4.8 and 8.6 𝜇m were tested, with correlation lengths of 1029 and 385 𝜇m, respectively. Despite the significant roughness levels tested, the transition location was found to be only mildly impacted by the additional roughness, and the roughness panel with lower RMS amplitude caused a larger upstream movement of transition, on average. However, the stationary crossflow amplitudes and wavelength content were found to vary substantially depending on the roughness input. In particular, the panel with higher RMS roughness amplitude resulted in significantly larger amplitudes in the 7.5-9 mm wavelength range at the farthest upstream measurement station, while the lower roughness panel resulted in mildly larger amplitudes at 10 mm and wavelengths larger than 15 mm. Nonlinear Parabolized Stability Equations (PSE) computations were performed to attempt to estimate the initial amplitudes of the stationary crossflow instabilities. Wavelength spectra were matched at the most upstream measurement location, but large discrepancies exist between the predicted and measured growth behavior farther downstream, thus, more work is required to improve confidence in initial amplitude estimates.
This study examines the effect of random micron-sized distributed roughness on stationary crossflow instabilities. The roughness parameters are varied by creating nanoparticle coatings of various formulations and applying them to inserts that cover approximately the first 14% of the model. In addition to the baseline configuration (no added roughness, root-mean-square (RMS) ≈ 0.42 𝜇m), panels with RMS roughness values of 4.8 and 8.6 𝜇m were tested, with correlation lengths of 1029 and 385 𝜇m, respectively. Despite the significant roughness levels tested, the transition location was found to be only mildly impacted by the additional roughness, and the roughness panel with lower RMS amplitude caused a larger upstream movement of transition, on average. However, the stationary crossflow amplitudes and wavelength content were found to vary substantially depending on the roughness input. In particular, the panel with higher RMS roughness amplitude resulted in significantly larger amplitudes in the 7.5-9 mm wavelength range at the farthest upstream measurement station, while the lower roughness panel resulted in mildly larger amplitudes at 10 mm and wavelengths larger than 15 mm. Nonlinear Parabolized Stability Equations (PSE) computations were performed to attempt to estimate the initial amplitudes of the stationary crossflow instabilities. Wavelength spectra were matched at the most upstream measurement location, but large discrepancies exist between the predicted and measured growth behavior farther downstream, thus, more work is required to improve confidence in initial amplitude estimates.
This study examines the effect of random micron-sized distributed roughness on stationary crossflow instabilities. The roughness parameters are varied by creating nanoparticle coatings of various formulations and applying them to inserts that cover approximately the first 14% of the model. In addition to the baseline configuration (no added roughness, root-mean-square (RMS) ≈ 0.42 𝜇m), panels with RMS roughness values of 4.8 and 8.6 𝜇m were tested, with correlation lengths of 1029 and 385 𝜇m, respectively. Despite the significant roughness levels tested, the transition location was found to be only mildly impacted by the additional roughness, and the roughness panel with lower RMS amplitude caused a larger upstream movement of transition, on average. However, the stationary crossflow amplitudes and wavelength content were found to vary substantially depending on the roughness input. In particular, the panel with higher RMS roughness amplitude resulted in significantly larger amplitudes in the 7.5-9 mm wavelength range at the farthest upstream measurement station, while the lower roughness panel resulted in mildly larger amplitudes at 10 mm and wavelengths larger than 15 mm. Nonlinear Parabolized Stability Equations (PSE) computations were performed to attempt to estimate the initial amplitudes of the stationary crossflow instabilities. Wavelength spectra were matched at the most upstream measurement location, but large discrepancies exist between the predicted and measured growth behavior farther downstream, thus, more work is required to improve confidence in initial amplitude estimates.
Surface roughness is known to have a substantial impact on the aerothermodynamic loading of high-speed vehicles, particularly via its influence on the laminar-turbulent transition process within the boundary layer. Numerical simulations are performed to investigate the effects of a distributed region of densely packed, sinusoidal shape roughness elements on a Mach 3.5 flat plate boundary layer for flow conditions corresponding to the planned conditions of an upcoming experiment in the Mach 3.5 Supersonic Low Disturbance Tunnel at the NASA Langley Research Center. Analysis of convective instabilities in the wake of the roughness patch was reported in a previous paper and the current work extends that analysis to instability amplification across the length of the roughness patch. Quasi-parallel stability analysis of the modified boundary layer flow over the patch indicates two dominant families of unstable disturbances, namely, a group of high frequency modes that amplify in localized regions along the roughness patch and another group of low frequency modes that have smaller peak amplification rates but amplify steadily both above the roughness patch and in the wake region behind it. The results suggest that the amplification factors associated with the high-frequency modes are sufficiently low, at least for the roughness patches considered in this paper, so that these modes are unlikely to have a major influence on the transition process. The amplification of the low-frequency modes within the region of the roughness patch is further quantified via direct numerical simulations. Results confirm the strongly destabilizing influence of the roughness patch on the first mode instabilities, yielding an N-factor increment of ΔN ≈ 3.6 for a roughness patch length of eight wavelengths.
L-band passive microwave remote sensing is currently considered a robust technique for global monitoring of soil moisture. However, soil roughness complicates the relationship between brightness temperature and soil moisture, with current soil moisture retrieval algorithms typically assuming a constant roughness parameter globally, leading to a potential degradation in retrieval accuracy. This current investigation established a tower-based experiment site in Victoria, Australia. P-band (~40-cm wavelength/0.75 GHz) was compared with L-band (~21-cm wavelength/1.41 GHz) over random and periodic soil surfaces to determine if there is an improvement in brightness temperature simulation and soil moisture retrieval accuracy for bare soil conditions, due to reduced roughness impact when using a longer wavelength. The results showed that P-band was less impacted by random and periodic roughness than L-band, evidenced by more comparable statistics across different roughness conditions. The roughness effect from smooth surfaces (e.g., 0.8-cm root-mean-square height and 11.1-cm correlation length) could be potentially ignored at both P- and L-band with satisfactory simulation and retrieval performance. However, for rougher soil (e.g., 1.6-cm root-mean-square height and 6.8-cm correlation length), the roughness impact needed to be accounted for at both P- and L-band, with P-band observations showing less impact than L-band. Moreover, a sinusoidal soil surface with 10-cm amplitude and 80-cm period substantially impacted the brightness temperature simulation and soil moisture retrieval at both P- and L-band, which could not be fully accounted for using the SMOS and SMAP default roughness parameters. However, when retrieving roughness parameters along with soil moisture, the ubRMSE at P-band over periodic soil was improved to a similar level (0.01-0.02 m3/m3) as that of smooth flat soil (0.01 m3/m3), while L-band showed higher ubRMSE over the periodic soil (0.03-0.04 m3/m3) than over smooth flat soil (0.01 m3/m3). Accordingly, periodic roughness effects were reduced by using observations at P-band.