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NASA NTRS1986

Existence of needle crystals in local models of solidification

The way in which surface tension acts as a singular perturbation to destroy the continuous family of needle-crystal solutions of the steady-state growth equations is analyzed in detail for two local models of solidification. All calculations are performed in the limit of small surface tension or, equivalently, small velocity. The basic mathematical ideas are introduced in connection with a quasilinear, isotropic version of the geometrical model of Brower et al., in which case the continuous family of solutions dissappears completely. The formalism is then applied to a simplified boundary-layer model with an anisotropic kinetic attachment coefficient. In the latter case, the solvability condition for the existence of needle crystals can be satisfied whenever the coefficient of anisotropy is arbitrarily small but nonzero.

Langer, J. S.↗

NASA NTRS1995

Dynamics of Vapour Bubbles in Nucleate Boiling: Basic Equations of Bubble Evolution - 1

We consider the behaviour of a vapour bubble formed at a nucleation site on a heated horizontal wall. There is no forced convection of an ambient liquid, and the bubble is presumably separated from the wall by a thin liquid microlayer. The energy conservation law results in a variational equation for the mechanical energy of the whole system consisting of the bubble and liquid. It leads to a set of two strongly nonlinear equations which govern bubble expansion and motion of its centre of mass. A supplementary equation to find out the vapour temperature follows from consideration of heat transfer to the bubble, both from the bulk of surrounding liquid and through the microlayer. The average thickness of the microlayer is shown to increase monotonously with time as the bubble meniscus spreads along the wall. Bubble expansion is driven by the pressure head between vapour inside and liquid far away from the bubble, with due allowance for surface tension and gravity effects. It is resisted by inertia of liquid being placed into motion as the bubble grows. The inertia originates also a force that presses the bubble to the wall. This force is counteracted by the buoyancy and an effective surface tension force that tends to transform the bubble into a sphere. The analysis brings about quite a new formulation of the familiar problem of bubble growth and detachment under conditions of nucleate pool boiling.

Buyevich, Yu A.↗

NASA NTRS1974

A feasibility study of developing toroidal tanks for a spinning spacecraft

The use of toroidal tanks in an advanced Pioneer, spin-stabilized Jupiter orbiter was investigated. Fluid behavior in spinning toroids was evaluated and the need for a propellant acquisition system was established. A common surface tension acquisition system design was selected from four candidates for gas-free liquid feed to a single outlet in both MMH and N2O4 tanks. Fabrication of toroidal tanks using either titanium or aluminum alloys is feasible. Integration of two toroidal tanks with surface tension systems in place of four spherical tanks provides spacecraft weight, packaging, structural mounting, thermal control and stability advantages.

Anderson, J. E.↗

DOE OSTI2020

An experimental investigation of the effectiveness of Ar-CO 2 shielding gas mixture for the wire arc additive process

Wire arc additive manufacturing (AM) is the process by which a large, metallic structure is built layer-by-layer using a welding arc to melt a wire feedstock. A novel opportunity exists to alter the shielding gas composition to fabricate distinct geometrical features without altering the other AM parameters. In this paper, shielding gases with varied concentrations of Argon (Ar) and CO 2 was used to deposit three distinct geometric shapes (walls, infill, and overhang) using a wire-based additive manufacturing system utilizing the gas metal arc welding (GMAW) surface tension transfer (STT) process. Computer-aided design (CAD) models were sliced with a custom-built slicer, and the sliced algorithm was converted into optimal robotic toolpaths. A custom virtual instrument (VI) was built in LabVIEW to compare the temperature profiles on the surface during each deposition process. After each deposition, the geometric features were scanned, and the surface waviness value was evaluated. Tensile and Charpy impact coupons were extracted from the wall geometries in the longitudinal and transverse directions and tested. The results indicated that a higher CO 2 content produced higher melt pool temperatures to an extent, while lower contents of CO 2 resulted in a dimensionally accurate geometry. The data also indicated that the 2%/98% CO 2 /Ar blend produced scatter in tensile strength and the analysis of variance (ANOVA) shows significant difference. However, the intermediate range of CO 2 (5–10%) resulted in uniform tensile properties. Altogether, these results indicate that a 5%/95% CO 2 /Ar blend is the ideal shielding gas for lowering process temperatures and improving mechanical properties in wire arc additive manufacturing using the gas metal arc welding surface tension transfer process. Additionally, varying concentrations of Ar/CO 2 can be used within the same part in order to modify the local properties or process parameters such as strength, toughness, temperature, or dimensional features. This may improve overall manufacturing quality without sacrificing specific properties.

42 ENGINEERING↗

NASA NTRS1986

Design of an advanced two-phase capillary cold plate

The functional principles and implementation of capillary pumped loop (CPL) two phase heat transport system for various elements of the Space Station program are described. Circulation of the working fluid by the surface-tension forces in a fine-pore capillary wick is the core principle of CPL systems. The liquid, usually NH3 at the moment, is changed into a vapor by heat absorption at one end of the loop, and the vapor is carrried back along the wick by the surface tension within the wick. NASA specifications and the results of mechanical and thermal tests for prototype cold plate and the capillary pump designs are outlined. The CPL is targeted for installation on free-flying platforms, attached payloads, and power subsystem thermal control systems.

Chalmers, D. R.↗

NASA NTRS1989

Design considerations for a micro-g superfluid helium fluid acquisition system

The general description, the operation, and the design of a superfluid helium (SFHe) fluid acquisition system (FAS) for use under microgravity conditions is presented. For the type of FAS considered here, where fine-mesh woven screens are used to retain flowing SFHe within a gallery arm (flow) channel, those forces which determine the flow dynamics are the micro-g accelerations, liquid surface tension, and tensile strength and cumulative pressure drops along a flow path that begins at the bulk liquid and ends at the entrance to a pump. For this case, the dimensionless number, N(T) is written as the ratio between the pressure drop across the screen and the surface tension forces at the screen for low fluid velocities. Static Bond number measurements have bene taken for SFHe using 325 x 2300 twilled Dutch screen and have indicated a screen pore hydraulic radius of 0.00031 cm.

Lee, J. M.↗

NASA NTRS1998

On Pulsating and Cellular Forms of Hydrodynamic Instability in Liquid-Propellant Combustion

An extended Landau-Levich model of liquid-propellant combustion, one that allows for a local dependence of the burning rate on the (gas) pressure at the liquid-gas interface, exhibits not only the classical hydrodynamic cellular instability attributed to Landau but also a pulsating hydrodynamic instability associated with sufficiently negative pressure sensitivities. Exploiting the realistic limit of small values of the gas-to-liquid density ratio p, analytical formulas for both neutral stability boundaries may be obtained by expanding all quantities in appropriate powers of p in each of three distinguished wave-number regimes. In particular, composite analytical expressions are derived for the neutral stability boundaries A(sub p)(k), where A, is the pressure sensitivity of the burning rate and k is the wave number of the disturbance. For the cellular boundary, the results demonstrate explicitly the stabilizing effect of gravity on long-wave disturbances, the stabilizing effect of viscosity (both liquid and gas) and surface tension on short-wave perturbations, and the instability associated with intermediate wave numbers for negative values of A(sub p), which is characteristic of many hydroxylammonium nitrate-based liquid propellants over certain pressure ranges. In contrast, the pulsating hydrodynamic stability boundary is insensitive to gravitational and surface-tension effects but is more sensitive to the effects of liquid viscosity because, for typical nonzero values of the latter, the pulsating boundary decreases to larger negative values of A(sub p) as k increases through O(l) values. Thus, liquid-propellant combustion is predicted to be stable (that is, steady and planar) only for a range of negative pressure sensitivities that lie below the cellular boundary that exists for sufficiently small negative values of A(sub p) and above the pulsating boundary that exists for larger negative values of this parameter.

Margolis, Stephen B.↗

NASA NTRS2003

Residual Gas Effects on Detached Solidification in Microgravity

Many microgravity directional solidification experiments yielded ingots with portions that grew without contacting the ampoule wall, leading to greatly improved crystallographic perfection. Our long-term goal is to make such detached solidification reproducible, which requires a full understanding of the mechanisms underlying it. Our Moving Meniscus Model of steady-state detachment predicts that it depends strongly on the surface tension of the melt and the advancing contact angle with the ampoule wall. Detached solidification is more likely when the contact angle for the melt on the ampoule wall is high, i.e. non-wetting. It has been claimed that impurities increase the contact angle. The objective of the current project is to determine the influence of residual gases on the surface tension and contact angle of molten semiconductors on typical ampoule materials. We are focusing on determining the influence of oxygen on the contact angle of molten InSb on clean silica ('quartz'), including the advancing and retreating contact angles in addition to the usual equilibrium contact angle. We have created a gas flow system that allows us to control the oxygen partial pressure over a sessile drop of InSb on a horizontal quartz surface. The cell is slowly tilted while videotaping to reveal the contact angles on the two sides of the drop just prior to it rolling down the surface. Thus far, we have learned the following: (1) Molten InSb readily forms an oxide layer in the presence of the trace amounts of oxygen found in high purity argon; (2) This oxide contains a substantial amount of Ga, which presumably is a trace contaminant that is not detectable in the starting material; (3) The addition of 10% hydrogen to the argon gas is sufficient to reduce the oxide and produce a clean drop; (4) An infrared filter must precede the video camera in order to produce a sharp image of the drop for later image analysis; (5) Tilting the surface on which the drop rests causes the two sides of the drop to display different contact angles, reflecting contact line sticking; (6) Vibration strongly accelerates the approach of the drop to its final shape on a horizontal surface by helping to overcome sticking of the contact line; (7) Oscillation of the drop surface due to vibration appears to increase as the surface is inclined from horizontal. Presumably, the angle at which the drop rolls down the surface is also reduced by vibration. This observation is particularly significant, as the meniscus must move along the ampoule wall during detached solidification.

Regel, Liya L.↗

NASA NTRS1973

Study and design of cryogenic propellant acquisition systems. Volume 1: Design studies

An in-depth study and selection of practical propellant surface tension acquisition system designs for two specific future cryogenic space vehicles, an advanced cryogenic space shuttle auxiliary propulsion system and an advanced space propulsion module is reported. A supporting laboratory scale experimental program was also conducted to provide design information critical to concept finalization and selection. Designs using localized pressure isolated surface tension screen devices were selected for each application and preliminary designs were generated. Based on these designs, large scale acquisition prototype hardware was designed and fabricated to be compatible with available NASA-MSFC feed system hardware.

Burge, G. W.↗

NASA NTRS1988

Simulation of fundamental atomization mechanisms in fuel sprays

Growth of instabilities on the liquid/gas interface in the initial region of fuel sprays is studied by means of numerical simulations. The simulations are based on solutions of the variable-density incompressible Navier-Stokes equations, which are obtained with a new numerical algorithm. The simulations give good agreement with analytical results for the instabilities on a liquid cylinder induced by surface tension and wind-induced instabilities. The effects of boundary layers on the wind-induced instabilities are investigated. It is found that a boundary layer reduces the growth rate for a single interface, and a comparison with inviscid theory suggests that boundary layer effects may be significantly more important than surface tension effects. The results yield a better estimate than inviscid theory for the drop sizes as reported for diesel sprays. Results for the planar jet show that boundary layer effects hasten the growth of Squire's 'symmetric' mode, which is responsible for jet disintegration. This result helps explain the rapid atomization which occurs in swirl and air-blast atomizers.

Childs, Robert, E.↗

NASA NTRS2001

Influence of Solutocapillary Convection on Macrovoid Defect Formation in Polymeric Membranes

Macrovoids (MVs) are large (10-50 micrometers) pores often found in polymeric membranes prepared via phase-inversion techniques. They are generally considered undesirable, as they adversely affect the permeability properties and performance of polymeric membranes for microfiltration, ultrafiltration, and reverse osmosis. However, MVs can be useful in certain thin-film applications in which vapor transmission is necessary, or for use as reservoirs for enzymes or liquid membrane material. If more could be learned about the nature and causes of MV formation, it might be possible to devise techniques to control and/or prevent MV formation that are more effective than those currently employed. Two hypotheses for the MV growth mechanism have been advanced. Reuvers proposed that once initiated, MV growth can be attributed to diffusion of (primarily) solvent to the MV nuclei. Because this mechanism does not involve gross movement of the MV, the presence or absence of body forces such as buoyancy should not significantly affect MV growth. On the other hand, Shojaie et al. proposed that solutocapillary convection induced by a steep surface-tension gradient along the MV/bulk solution interface enhances mass transfer to the growing MV. This interfacial convection exerts a force that pulls the growing MV downward into the casting solution. Both buoyancy and viscous drag hinder MV growth by inhibiting this motion. Thus, removing the buoyancy force by casting in microgravity should augment MV growth according to this hypothesis. Whereas neither surface tension nor gravity has a significant effect on MV growth according to the first hypothesis, buoyancy forces should be important if the second hypothesis is correct. The overall goal of this research is to test these two hypotheses in order to improve our understanding of the MV growth processing solvent-cast polymeric membranes. Studying MV growth in low-gravity conditions is pivotal to our ability to discriminate between these two hypotheses.

Pekny, M. R.↗

DOE OSTI2025

Application of a Triple Bubbler Inside Molten Salt for Pyroprocessing Safeguards Purposes

The application of a triple bubbler system within molten salt environments, specifically a eutectic mixture of LiCl-KCl, is explored for nuclear safeguards purposes, focusing on nuclear material accountancy (NMA) and holdup accountancy in pyroprocessing techniques. Traditional holdup accountancy methods, which involve periodic sampling and lengthy lead times, are being supplemented by the development of actinide sensors using electrochemistry. However, these methods alone are insufficient to meet regulatory requirements set by agencies like NRC and IAEA. The triple bubbler device measures salt level, density, and surface tension simultaneously using three dip tubes of varying diameters and heights. This study investigates the accuracy and robustness of the triple bubbler in molten salt conditions at temperatures ranging from 450-550°C. The updated bubbler design, utilizing tantalum metal and larger tube geometry, demonstrated minimal plugging and maintained measurement accuracy within acceptable uncertainties: 0.611% for depth, 1.34% for density, and approximately 40% for surface tension. Results indicate that the triple bubbler system is effective for real-time, accurate measurements in pyroprocessing environments, making it a promising tool for ensuring compliance with nuclear safeguards and supporting nuclear non-proliferation efforts.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2025

Predictive dynamic wetting, fluid–structure interaction simulations for braze run-out

Brazing and soldering are metallurgical joining techniques that use a wetting molten metal to create a joint between two faying surfaces. Here, the quality of the brazing process depends strongly on the wetting properties of the molten filler metal, namely the surface tension and contact angle, and the resulting joint can be susceptible to various defects, such as run-out and underfill, if the material properties or joining conditions are not suitable. In this work, we implement a finite element simulation to predict the formation of such defects in braze processes. This model incorporates both fluid–structure interaction through an arbitrary Eulerian–Lagrangian technique and free surface wetting through conformal decomposition finite element modeling. Upon validating our numerical simulations against experimental run-out studies on a silver-Kovar system, we then use the model to predict run-out and underfill in systems with variable surface tension, contact angles, and applied pressure. Finally, we consider variable joint/surface geometries and show how different geometrical configurations can help to mitigate run-out. This work aims to understand how brazing defects arise and validate a coupled wetting and fluid–structure interaction simulation that can be used for other industrial problems.

36 MATERIALS SCIENCE↗

NASA NTRS1997

Hydrodynamic Instability in an Extended Landau/Levich Model of Liquid-Propellant Combustion at Normal and Reduced Gravity

The classical Landau/Levich models of liquid-propellant combustion, despite their relative simplicity, serve as seminal examples that correctly describe the onset of hydrodynamic instability in reactive systems. Recently, these two separate models have been combined and extended to account for a dynamic dependence, absent in the original formulations, of the local burning rate on the local pressure and temperature fields. The resulting model admits an extremely rich variety of both hydrodynamic and reactive/diffusive instabilities that can be analyzed either numerically or analytically in various limiting parameter regimes. In the present work, a formal asymptotic analysis, based on the realistic smallness of the gas-to-liquid density ratio, is developed to investigate the combined effects of gravity and other parameters on the hydrodynamic instability of the propagating liquid/gas interface. In particular, an analytical expression is derived for the neutral stability boundary A(p)(k), where A(p) is the pressure sensitivity of the burning rate and k is the wavenumber of the disturbance. The results demonstrate explicitly the stabilizing effect of gravity on long-wave disturbances, the stabilizing effect of viscosity (both liquid and gas) and surface tension on short-wave perturbations, and the instability associated with intermediate wavenumbers for negative values of A(p). In the limiting case of weak gravity, it is shown that hydrodynamic instability in liquid-propellant combustion is a long-wave instability phenomenon, whereas at normal gravity, this instability is first manifested through O(1) wavenumber disturbances. it is also demonstrated that, in general, surface tension and the viscosity of both the liquid and gas phases each produce comparable stabilizing effects in the long-wavenumber regime, thereby providing important modifications to previous analyses in which one or more of these effects were neglected.

Margolis, S. B.↗

NASA NTRS1998

Hydrodynamic Instability in an Extended Landau/Levich Model of Liquid-Propellant Combustion at Normal and Reduced Gravity

The classical Landau/Levich models of liquid-propellant combustion, despite their relative simplicity, serve as seminal examples that correctly describe the onset of hydrodynamic instability in reactive systems. Recently, these two separate models have been combined and extended to account for a dynamic dependence, absent in the original formulations, of the local burning rate on the local pressure and temperature fields. The resulting model admits an extremely rich variety of both hydrodynamic and reactive/diffusive instabilities that can be analyzed either numerically or analytically in various limiting parameter regimes. In the present work, a formal asymptotic analysis, based on the realistic smallness of the gas-to-liquid density ratio, is developed to investigate the combined effects of gravity and other parameters on the hydrodynamic instability of the propagating liquid/gas interface. In particular, an analytical expression is derived for the neutral stability boundary A(sub p)(k), where A(sub p) is the pressure sensitivity of the burning rate and k is the wavenumber of the disturbance. The results demonstrate explicitly the stabilizing effect of gravity on long-wave disturbances, the stabilizing effect of viscosity (both liquid and gas) and surface tension on short-wave perturbations, and the instability associated with intermediate wavenumbers for critical negative values of A(sub p). In the limiting case of weak gravity, it is shown that hydrodynamic instability in liquid-propellant combustion is a long-wave instability phenomenon, whereas at normal gravity, this instability is first manifested through O(1) wavenumber disturbances. It is also demonstrated that, in general, surface tension and the viscosity of both the liquid and gas phases each produce comparable stabilizing effects in the large-wavenumber regime, thereby providing important modifications to previous analyses in which one or more of these effects were neglected.

Margolis, Stephen B.↗

DOE OSTI2021

Modeling Molten Salt Spreading and Heat Transfer using MELTSPREAD – An Uncertainty Analysis

This report summarizes spreading and heat transfer results for molten salt pouring onto a flat stainless steel substrate that were calculated using MELTSPREAD to gain insight into bulk salt behavior during a molten salt spill accident. MELTSPREAD was developed at Argonne to model the one-dimensional flow and freezing behavior of molten corium and is being applied to model molten salts for the first time as part of this work. An uncertainty analysis of thermophysical properties and spill conditions was performed using MELTSPREAD to determine which properties and conditions have the greatest impact on model outcome. The model was run with and without the inclusion of decay heat. Eutectic FLiNaK was used as the salt composition because it is well-characterized and appropriate for model development. Small salt volumes were used for the initial model runs described in this report so that the model results can be compared to the results from ongoing experiments on molten salt spreading and heat transfer currently being conducted at Argonne at a benchtop scale. The spreading of a small volume of FLiNaK (50 mL) was found to be limited by the balance between the molten salt surface tension and gravity and not by freezing for the pour conditions and assumed mechanisms of heat transfer in the model. Heat transfer from the salt was highly inefficient to due to its low thermal conductivity, high heat capacity, and high heat of fusion and varying these properties had no effect on the spreading behavior. Changing the viscosity and density of the salt slightly affected the spreading behavior. Setting the salt surface tension to approximately zero to simulate the salt wetting the substrate had the greatest effect on the spreading behavior and this increased both the spreading velocity and overall spreading area. Including decay heat in the model had a significant effect on the long-term cooling behavior of the salt but had no effect on the overall spreading behavior. Future effort should involve modeling a larger volume of molten salt to represent a reactor case spill scenario because the spreading behavior of large volumes of salt may differ from the small volumes that were the focus of this document.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

NASA NTRS2009

Results of the Fluid Merging Viscosity Measurement International Space Station Experiment

The purpose of FMVM is to measure the rate of coalescence of two highly viscous liquid drops and correlate the results with the liquid viscosity and surface tension. The experiment takes advantage of the low gravitational free floating conditions in space to permit the unconstrained coalescence of two nearly spherical drops. The merging of the drops is accomplished by deploying them from a syringe and suspending them on Nomex threads followed by the astronaut s manipulation of one of the drops toward a stationary droplet till contact is achieved. Coalescence and merging occurs due to shape relaxation and reduction of surface energy, being resisted by the viscous drag within the liquid. Experiments were conducted onboard the International Space Station in July of 2004 and subsequently in May of 2005. The coalescence was recorded on video and down-linked near real-time. When the coefficient of surface tension for the liquid is known, the increase in contact radius can be used to determine the coefficient of viscosity for that liquid. The viscosity is determined by fitting the experimental speed to theoretically calculated contact radius speed for the same experimental parameters. Recent fluid dynamical numerical simulations of the coalescence process will be presented. The results are important for a better understanding of the coalescence process. The experiment is also relevant to liquid phase sintering, free form in-situ fabrication, and as a potential new method for measuring the viscosity of viscous glass formers at low shear rates.

Ethridge, Edwin C.↗

DOE OSTI2026

Department of Transportation PHMSA Aerosol Spray Project: Phase-0

This report discusses the work conducted at Sandia National Laboratories during the preliminary phase (Phase-0) of the Department of Transportation (DOT) Pipeline and Hazardous Materials Safety Administration (PHMSA) project tasked to better understand what happens to a high-pressure liquid canister or vessel during a fire in which an accidental instantaneous release occurs. Phase 0 had two main objects: (1) to establish a methodology for the high temperature and pressure spray vessel release and (2) to characterize the spray droplet formation. For this test series, diagnostic equipment such as the Malvern Spraytec, high-speed photometric cameras, pencil gauges, and thermocouples were used. Additionally, the effect of surface tension on the particle size distribution was evaluated with 1-liter of distilled water and with the same including the addition of 0.5% soap/water mixture. Results from this effort indicated that the plume formed from the instantaneous release in all conditions primarily included two distinct particle size distributions including 217-312µm and 0.53µm on average. Soapy water formed a higher concentration of smaller mist (0.53µm) than distilled water, potentially due to decreased surface tension with the added surfactant. Though results showed good correlation to certain particle size distributions it is encouraged to conduct additional tests like this with a wider range of liquids with different properties, which could affect the overall particle size distribution when released.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗