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At least 37 records · Page 2

Relating flow resistance to equivalent roughness

Describing flow resistance using the physical properties of an underlying surface is a recalcitrant problem in overland flow models. If discharge measurements are available, an equivalent roughness (e.g., Manning’s n) can be calibrated to represent the effects of surface properties within the domain with a single numerical value. Alternatively, the flow resistance can be estimated from discharge and velocity measured at a point, typically a runoff plot outlet. However, such experimental estimates are often inconsistent with the equivalent roughness determined from calibration to discharge, even if both derive from the same dataset. For example, if Manning’s equation is used to parameterize flow resistance, the Manning’s n obtained by calibrating a model to discharge differs from the value of n calculated from measured flow and velocity at the hillslope outlet. Here, this discrepancy is resolved by deriving a correction factor relating experimentally-determined flow resistance to the equivalent roughness. The derived correction factor is tested for four commonly-used resistance formulations using 129 rainfall simulator experiments. The correction factor is necessary to reproduce measured velocities, and yields minor improvements in discharge prediction. Plain Language Summary: Accurate runoff prediction is needed for land and water management in dryland regions, where sporadic and limited rainfall necessitate efficient water use and drought mitigation strategies. The skill of runoff models is known to be hindered by out ability to estimate flow resistance, which is the quantity that describes how energy is lost from flowing water to the underlying surface. Typically, models represent flow resistance with an equivalent roughness, e.g., Manning’s n, that is adjusted until the model can reproduce available discharge observations at watershed scale. However, the flow resistance measured in plot-scale experiments (1–10 m) often exceeds equivalent roughness coefficients by a factor of 10. This means that the direct use of plot-scale experimental data to parameterize runoff models could cause errors in discharge and runoff velocity predictions. Here, we resolve these differences by deriving an analytic correction factor that relates flow resistance to the equivalent roughness required for models to reproduce experimental velocity and discharge data. This correction factor is tested using rainfall simulator data from 129 experiments performed in the US Southwest covering a wide range of precipitation intensities, soil textures and vegetation types. Use of the correction factor substantially improves model prediction of flow velocity, which is needed for reproducing the timing of flood events and the estimation of erosion.

54 ENVIRONMENTAL SCIENCES

Predicting roughness effects in additively manufactured coolant channels with helical enhancements

Additive manufacturing (AM) is a promising technique for fabrication of complex geometries such as those expected to be utilized in the blanket, first wall, and divertor. In the case of cooling, metallic AM may be exploited to embed geometric enhancements (ribs, rifling, etc.) to improve cooling performance. However, due to the roughness of these unfinished internal AM surfaces, prediction of thermal hydraulic performance in such channels is difficult. In this work, we consider a methodology for predicting pressure drop and heat transfer in AM channels containing helical enhancements (e.g. helical ribs, twisted tapes) that allows the incorporation of roughness data through conventional pipe flow correlations. This methodology is tested using experimental friction factor and heat transfer coefficient data from high-pressure helium coolant flow measurements in AM stainless steel tubes fabricated by laser powder bed fusion. Both a featureless AM tube and one containing helical ribs were considered alongside a conventionally manufactured smooth tube. The AM surface roughness is obtained by profilometry and used to predict an equivalent sand-grain roughness, with this equivalent roughness confirmed through AM featureless tube measurements. Under the proposed methodology, this roughness information is incorporated into predictions of friction factor and Nusselt number for the rifled tube. Furthermore, these predictions agree well with experimental data across a large range of Reynolds numbers, encouraging the use of this methodology for thermal hydraulic analysis of similar systems and design of future coolant channel geometries.

Additive manufacturing

Surface roughness and dimensional evaluation of laser powder bed fusion additively manufactured shell and tube heat exchangers

The growing interest in additively manufactured (AM) heat exchangers drove the need to understand how this construction technique impacts heat exchanger performance. Two primary factors driven by AM that influence heat exchanger performance are surface roughness and geometry. To better understand these parameters, a range of shell and tube heat exchangers constructed using laser powder bed fusion were evaluated. Of those evaluated, the surface roughness throughout a fourteen-tube, zero-baffle heat exchanger was measured using computed tomography. Between the inner and outer tubes, the inner tube surfaces had a greater surface roughness than the outer by 8.07 μm, while the surfaces at the top of the build volume had higher surface roughness values than the bottom. Dimensionally, the inner tube diameters of this heat exchanger were 0.15% different from the design value, while the outer diameters were within a 0.84 % difference. Manual measurements across seven other heat exchangers yielded a maximum 1.15% difference between the design and measured diameters. Across the build volume for all heat exchangers studied, the tube diameters at the top were larger than at the bottom by a maximum of 1.24% difference. Inconsistent melting throughout the individual parts and the build volume, as well as particle splatter and thermal gradient variation were attributed to the surface roughness and dimensional changes seen. These results strengthen the knowledge of dimensional and surface roughness considerations when designing AM heat exchangers.

36 MATERIALS SCIENCE

Roughness effects on radiant heat transfer between interacting surfaces.

The radiative transfer between interacting plates with rough surfaces is analyzed on the basis of Beckman's (1963) rough-surface bidirectional reflectance model and, for comparison, on the basis of a direction-dependent specular reflection property model and an approximate rough surface model which assumes a diffuse distribution of the scattered energy. It is found that the overall heat transfer obtained with the Beckman model is only slightly (1.5%) less than that obtained with the direction-dependent specular reflection model. Furthermore, constant property specular reflection analysis gave results within 3% of the rough surface values. The region of uncertainty for the rough surface flux increases, however, as optical roughness increases.

Houchens, A. F.

Surface roughness effect on finite oil journal bearings

A theoretical study of the performance of finite oil journal bearings is made, considering the surface roughness effect. The total load supporting ability under such a condition derives from the hydrodynamic as well as asperity contact pressure. These two components of load are calculated separately. The average Reynolds equation for partially lubricated surfaces is used to evaluate hydrodynamic pressure. An analytical expression for average film thickness is obtained and introduced to modify the average Reynolds equation. The resulting differential equation is then solved numerically by finite difference methods for mean hydrodynamic pressure, which in turn gives the hydrodynamic load. Assuming the surface height distribution as Gaussian, the asperity contact pressure is found. The effect of surface roughness parameter, surface pattern, eccentricity ratio, and length to diameter ratio on hydrodynamic load and on side leakage is investigated. It is shown that hydrodynamic load increases with increasing surface roughness when both journal and bearing surfaces have identical roughness structures or when the journal only has a rough surface. The trend of hydrodynamic load is reversed if the journal surface is smooth and the bearing surface is rough.

Majumdar, B. C.

Passive microwave sensing of soil moisture content: Soil bulk density and surface roughness

Microwave radiometric measurements over bare fields of different surface roughnesses were made at the frequencies of 1.4 GHz, 5 GHz, and 10.7 GHz to study the frequency dependence as well as the possible time variation of surface roughness. The presence of surface roughness was found to increase the brightness temperature of soils and reduce the slope of regression between brightness temperature and soil moisture content. The frequency dependence of the surface roughness effect was relatively weak when compared with that of the vegetation effect. Radiometric time series observation over a given field indicated that field surface roughness might gradually diminish with time, especially after a rainfall or irrigation. This time variation of surface roughness served to enhance the uncertainty in remote soil moisture estimate by microwave radiometry. Three years of radiometric measurements over a test site revealed a possible inconsistency in the soil bulk density determination, which turned out to be an important factor in the interpretation of radiometric data.

Wang, J. R.

Numerical investigation of multiphase flow through self-affine rough fractures

Multiphase flow through fractures has great significance in subsurface energy recovery and gas storage applications. Different fracture and flow properties affect flow through a fracture which is difficult to control in laboratory experiments. Here, we perform lattice Boltzmann simulations in an ensemble of synthetically generated fractures. Drainage simulations are performed at different capillary numbers, wettability, and viscosity ratios. We track the invading front and quantify breakthrough saturations and show that roughness and wettability have a strong effect on fluid invasion through a complex fracture. Invading a more viscous fluid results in more stable displacement regardless of the capillary number while at very low capillary numbers, fluid migration is dependent on the inherent structure of the fracture. We develop a fluid displacement phase diagram in a single rough fracture and compare our results from that in the literature. Finally, we extend the phase diagrams across multiple fractures and demonstrate the importance of natural fracture features of roughness and wettability in identifying stable versus unstable displacement regimes during multiphase flow through rough fractures. Our work presents an end-to-end numerical pathway for testing on experimental data and expanding numerical data sets for testing combinations of different physical phenomenon and make valuable predictions on fluid flow through rough fractures.

02 PETROLEUM

Competition between roughness and strength for scale-dependent surfaces

Rocks famously have scale-dependent strength, yet the actual dependence is notoriously hard to measure or incorporate into any theoretical framework. Natural rough surfaces present an opportunity to solve the problem. Surfaces sliding in shear evolve as protrusions collide. These asperities can deform or break, thus creating a new surface shape. In particular, natural surfaces have roughness at all scales as well as scale-dependent strength. Based on a scaling analysis, we have previously suggested that the scale-dependent aspect ratio of steady-state surfaces should be proportional to the scale-dependent shear strain at yield. If true, scale-dependent strength could easily be inferred from natural surfaces. Thus, moving beyond the scaling argument to a rigorous treatment of scale-dependent strength for multiscale rough surfaces in shear is important. However, analytic frameworks for analyzing multiscale problems are challenging, as conventional continuum mechanics typically involves a single value for a material property across scales. Here, in this work, we build on the formalism of Persson (2001) that presents a method to compute contact area for rough surfaces with a prescribed topographic spectrum using a stochastic differential equation. The Persson formalism allows for plastic yield under normal loading of otherwise elastic materials and leaves open the possibility of scale-dependent yield stress. In this study, we pursue this route to develop a theory and numerical results for the yielding of a rough, elastoplastic surface with scale-dependent yield stress. Here, we examine surfaces for which the power spectrum of the topography 𝐶 and yield stress 𝑌 follow power laws as a function of scale 𝜆, such that 𝐶∼𝜆 −𝑚 and 𝑌∼𝜆 −𝑛 , respectively. In this formal treatment of the problem, we focus on surfaces in contact and the resulting yield and do not impose shear. Numerical solutions show that the deviation from the elastic scaling solution is bounded as expected by the prior 1D heuristic scaling argument that anticipates the Hurst exponent as 1−𝑛. We also show that the plasticity is expected to erode the contacts if 𝑚 is lower than 𝑛−3, which corresponds to a Hurst exponent lower than 1−𝑛/2. This result is rigorously sound for 2D, i.e., realistic surfaces, and quantitatively different than the prior scaling argument. The theory now permits a correspondingly quantitative approach to interpreting natural surfaces.

elasticity

Identifying the Accuracy of Surface Roughness for Metal Additive Manufacturing Parts Captured with Computed Tomography Scanning

Conventional surface roughness measurement techniques require direct access to internal surfaces, often necessitating destructive sectioning of test articles. Computed tomography (CT) offers a non-destructive alternative for internal surface characterization, but its application in metrology remains unstandardized and sensitive to machine resolution and operator technique. This study investigates the feasibility of using CT scanning to quantify areal surface roughness in metal AM heat exchanger tubes with three distinct internal geometries: ribbed, discrete W, and featureless. CT-derived surface parameters were extracted using custom Python scripts and compared to measurements obtained from a focus variation microscope calibrated against a known standard. Results show that CT-based roughness measurements closely matched microscope values for the discrete W specimen, deviations between CT and microscope measurements were minimal—less than 1 µm—indicating reliable reconstruction. In contrast, the ribbed and featureless specimens, with lower roughness values showed greater discrepancies. The findings suggest that CT scanning can be a viable non-destructive metrology tool for AM parts with surface roughness above approximately 8 µm. For smoother surfaces, current CT capabilities may not provide sufficient accuracy, highlighting the need for resolution-aware workflows and further standardization in CT-based surface metrology.

36 MATERIALS SCIENCE

Influence of surface roughness and waviness on film thickness and pressure distribution in elastohydrodynamic contacts

The Christensen theory of a stochastic model for hydrodynamic lubrication of rough surfaces was extended to elastohydrodynamic lubrication between two rollers. Solutions for the reduced pressure at the entrance as a function of the ratio of the average nominal film thickness to the rms surface roughness, were obtained numerically. Results were obtained for purely transverse as well as purely longitudinal surface roughness for cases with or without slip. The reduced pressure was shown to decrease slightly by considering longitudinal surface roughness. The same approach was used to study the effect of surface roughness on lubrication between rigid rollers and lubrication of an infinitely wide slider bearing. Using the flow balance concept, the perturbed Reynolds equation, was derived and solved for the perturbed pressure distribution. In addition, Cheng's numerical scheme was modified to incorporate a single two-dimensional elastic asperity on the stationary surface. The perturbed pressures obtained by these three different models were compared.

Chow, L. S. H.

Effect of surface roughness on the microwave emission from soils

The effect of surface roughness on the brightness temperature of a moist terrain was studied through the modification of Fresnel reflection coefficient and using the radiative transfer equation. The modification involves introduction of a single parameter to characterize the roughness. It is shown that this parameter depends on both the surface height variance and the horizontal scale of the roughness. Model calculations are in good quantitative agreement with the observed dependence of the brightness temperature on the moisture content in the surface layer. Data from truck mounted and airborne radiometers are presented for comparison. The results indicate that the roughness effects are greatest for wet soils where the difference between smooth and rough surfaces can be as great as 50K.

Choudhury, B. J.

Effect of surface roughness on the microwave emission from soils

The effect of surface roughness on the brightness temperature of a moist terrain has been studied through the modification of Fresnel reflection coefficient and using the radiative transfer equation. The modification involves introduction of a single parameter to characterize the roughness. It is shown that this parameter depends on both the surface height variance and the horizontal scale of the roughness. Model calculations are in good quantitative agreement with the observed dependence of the brightness temperature on the moisture content in the surface layer. Data from truck mounted and airborne radiometers are presented for comparison. The results indicate that the roughness effects are great for wet soils where the difference between smooth and rough surfaces can be as great as 50 K.

Choudhury, B. J.

Turbulent boundary layer over solid and porous surfaces with small roughness

Skin friction and profiles of mean velocity, axial and normal turbulence intensity, and Reynolds stress in the untripped boundary layer were measured directly on a large diameter, axisymmetric body with: (1) a smooth, solid surface; (2) a sandpaper-roughened, solid surface; (3) a sintered metal, porous surface; (4) a smooth, perforated titanium surface; (5) a rough solid surface made of fine, diffusion bonded screening, and (6) a rough, porous surface of the same screening. Results obtained for each of these surfaces are discussed. It is shown that a rough, porous wall simply does not influence the boundary layer in the same way as a rough solid wall. Therefore, turbulent transport models for boundary layers over porous surfaces either with or without injection or suction, must include both surface roughness and porosity effects.

Kong, F. Y.

Effect of surface roughness on elastohydrodynamic line contact

A numerical solution of an elastohydrodynamic lubrication (EHL) contact between two long rough surface cylinders is obtained. A simultaneous solution of an elasticity equation and the Reynolds equation for two partially lubricated rough surfaces is used to obtain a theoretical solution of pressure distribution, elastohydrodynamic load and film thicknesses for given speeds. A theoretical solution is also found for lubricants with pressure dependent viscosity, material properties of cylinders, and surface roughness parameters. Elastic deformation is found from hydrodynamic and contact pressure using plane strain analysis, and results indicate that for a constant central film thickness, increasing the surface roughness decreases the EHL load and there is little variation in minimum film thicknesses as the surface roughness is increased.

Majumdar, B. C.

Boundary-Layer Transition on Hollow Cylinders in Supersonic Free Flight as Affected by Mach Number and a Screwthread Type of Surface Roughness

The effects of Mach number and surface-roughness variation on boundary-layer transition were studied using fin-stabilized hollow-tube models in free flight. The tests were conducted over the Mach number range from 2.8 to 7 at a nominally constant unit Reynolds number of 3 million per inch, and with heat transfer to the model surface. A screwthread type of distributed two-dimensional roughness was used. Nominal thread heights varied from 100 microinches to 2100 microinches. Transition Reynolds number was found to increase with increasing Mach number at a rate depending simultaneously on Mach number and roughness height. The laminar boundary layer was found to tolerate increasing amounts of roughness as Mach number increased. For a given Mach number an optimum roughness height was found which gave a maximum laminar run greater than was obtained with a smooth surface.

James, Carlton S.

Investigation of the Attenuation of Plane Shock Waves Moving over very Rough Surfaces

Experimental measurements of the attenuation of plane shock waves moving over rough walls have been made in a shock tube. Measurements of the boundary-layer characteristics, including thickness and velocity distribution behind the shock, have also been made with the aid of new cal techniques which provide direct information on the local boundary-layer conditions at the rough walls. Measurements of shock speed and shock pressure ratio are presented for both smooth-wall and rough-wall flow over lengths of machined-smooth and rough strips which lined all four walls of the shock tube. A simplified theory based on Von Karman's expression for skin-friction coefficient for flow over rough walls, along with a wave-model concept and extensions to include time effects, is presented. In this theory, the shock-tube flow is assumed to be one-dimensional at all times and the wave-model concept is used to relate the local layer growth to decreases in shock strength. This concept assumes that local boundary-layer growths act as local mass-flow sinks, which give rise to expansion waves which, in turn, overtake the shock and lower its mass flow accordingly.

Huber, Paul W.

The Effect of Surface Irregularities on Wing Drag: Roughness - 3

Tests have been made in the N.A.C.A. 8-foot high-speed wind tunnel of the drag caused by roughness on the surface of an airfoil of N.A.C.A. 23012 section and 5-foot chord. The tests were made at speeds from 80 t o 500 miles per hour at lift coefficients from 0 to 0.30. For conditions corresponding to high-speed flight, the increase in the drag was 30 percent of the profile drag of the smooth airfoil for the roughness produced by spray painting and 63 percent for the roughness produced. by 0.0037-inch carborundum grains. About one-half the drag increase was caused by the roughness on the forward one-fourth of the airfoil. Sandpapering the painted surface with No. 400 sandpaper made it sufficiently smooth that the drag was no greater than when the surface was polished. In the lower part of the range investigated the drag due to roughness increased rapidly with Reynolds Number.

Hood, Manley J.

Effect of pattern transfer process on roughness of block copolymer patterns from directed self-assembly

Block copolymer-directed self-assembly (DSA) remains promising for improving pattern quality and reducing the stochastic variations that challenge high numerical aperture extreme ultraviolet lithography. Equally critical is refining pattern transfer methods for accurately transferring the rectified DSA features to the underlying substrate. We compare two atomic layer deposition (ALD)-based techniques: sequential infiltration synthesis (SIS) and dry liftoff, applied to polystyrene-block-poly(methyl methacrylate) (PS-b-PMMA) DSA patterns. Both methods utilize aluminum oxide hard masks, with one synthesized through infiltration into the PMMA domains and the other through conformal ALD coating. High-resolution scanning electron micrographs were analyzed to measure line edge, width, and placement roughness for both the line (PMMA) and space (PS) features. Although both methods yielded similar overall 3σ rms roughness, they differed significantly in the frequency-dependent power spectral density (PSD) profiles. SIS reduced line placement roughness at length scales associated with the polymer pitch, but increased space width roughness at low frequencies, whereas dry liftoff mimicked the frequency content of the original guiding pattern. This study underscores the importance of PSD evaluation in selecting optimal pattern transfer strategies for specific applications.

Block copolymers