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Results for “SURFACE ROUGHNESS EFFECT”

Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 379 records · Page 21
All sourcesNASA NTRSDOE OSTI
DOE OSTI2020

Understanding Laser Powder Bed Fusion Surface Roughness

Abstract Surface roughness is a well-known consequence of additive manufacturing methods, particularly powder bed fusion processes. To properly design parts for additive manufacturing, a comprehensive understanding of the inherent roughness is necessary. While many researchers have measured different surface roughness resultant from a variety of parameters in the laser powder bed fusion process, few have succeeded in determining causal relationships due to the large number of variables at play. To assist the community in understanding the roughness in laser powder bed fusion processes, this study explored several studies from the literature to identify common trends and discrepancies amongst roughness data. Then, an experimental study was carried out to explore the influence of certain process parameters on surface roughness. Through these comparisons, certain local and global roughness trends have been identified and discussed, as well as a new framework for considering the effect of process parameters on surface roughness.

Engineering↗
NASA NTRS1982

Radar scattering laws for the lunar surface

Bistatic radar observations of quasi-specular scatter from the lunar surface at 13 and 116 cm wavelengths have been expressed in terms of probability densities of the underlying surface slope distributions. These show best agreement with a Hagfors scattering function, although other forms having predominantly Gaussian or exponential characteristics also occur. Estimates of root mean square (rms) surface slope derived from these function range from 4 deg rms in maria to at least 8 deg rms in highlands. These are values appropriate to 25 m horizontal scales and represent averages over tens of square kilometers of surface area. The effective scattering roughness varies with wavelength, most strongly in maria, where its behavior is consistent with that expected from an immature, i.e., unsaturated cratered surface. There is very little variation in scattering roughness with wavelength in highlands area.

Simpson, R. A.↗
DOE OSTI2023

Direct Numerical Simulation of Transitional and Turbulent Flows Over Multi-Scale Surface Roughness—Part I: Methodology and Challenges

Abstract High-fidelity simulation of transitional and turbulent flows over multi-scale surface roughness presents several challenges. For instance, the complex and irregular geometrical nature of surface roughness makes it impractical to employ conforming structured grids, commonly adopted in large-scale numerical simulations due to their high computational efficiency. One possible solution to overcome this problem is offered by immersed boundary methods, which allow wall boundary conditions to be enforced on grids that do not conform to the geometry of the solid boundary. To this end, a three-dimensional, second-order accurate boundary data immersion method (BDIM) is adopted. A novel mapping algorithm that can be applied to general three-dimensional surfaces is presented, together with a newly developed data-capturing methodology to extract and analyze on-surface flow quantities of interest. A rigorous procedure to compute gradient quantities such as the wall shear stress and the heat flux on complex non-conforming geometries is also introduced. The new framework is validated by performing a direct numerical simulation (DNS) of fully developed turbulent channel flow over sinusoidal egg-carton roughness in a minimal-span domain. For this canonical case, the averaged streamwise velocity profiles are compared against results from the literature obtained with a body-fitted grid. General guidelines on the BDIM resolution requirements for multi-scale roughness simulation are given. Momentum and energy balance methods are used to validate the calculation of the overall skin friction and heat transfer at the wall. The BDIM is then employed to investigate the effect of irregular homogeneous surface roughness on the performance of an LS-89 high-pressure turbine blade at engine-relevant conditions using DNS. This is the first application of the BDIM to realize multi-scale roughness for transitional flow in transonic conditions in the context of high-pressure turbines. The methodology adopted to generate the desired roughness distribution and to apply it to the reference blade geometry is introduced. The results are compared to the case of an equivalent smooth blade.

Engineering↗
NASA NTRS2007

The Effect of an Isogrid on Cryogenic Propellant Behavior and Thermal Stratification

All models for thermal stratification available in the presentation are derived using smooth, flat plate laminar and turbulent boundary layer models. This study examines the effect of isogrid (roughness elements) on the surface of internal tank walls to mimic the effects of weight-saving isogrid, which is located on the inside of many rocket propellant tanks. Computational Fluid Dynamics (CFD) is used to study the momentum and thermal boundary layer thickness for free convection flows over a wall with generic roughness elements. This presentation makes no mention of actual isogrid sizes or of any specific tank geometry. The magnitude of thermal stratification is compared for smooth and isogrid-lined walls.

Oliveira, Justin↗
NASA NTRS1986

The SIR-B observations of microwave backscatter dependence on soil moisture, surface roughness, and vegetation covers

An experiment was conducted from an L-band SAR aboard Space Shuttle Challenger in October 1984 to study the microwave backscatter dependence on soil moisture, surface roughness, and vegetation cover. The results based on the analyses of an image obtained at 21-deg incidence angle show a positive correlatlion between scattering coefficient and soil moisture content, with a sensitivity comparable to that derived from the ground radar measurements reported by Ulaby et al. (1978). The surface roughness strongly affects the microwave backscatter. A factor of two change in the standard deviation of surface roughness height gives a corresponding change of about 8 dB in the scattering coefficient. The microwave backscatter also depends on the vegetation types. Under the dry soil conditions, the scattering coefficient is observed to change from about -24 dB for an alfalfa or lettuce field to about -17 dB for a mature corn field. These results suggest that observations with a SAR system of multiple frequencies and polarizations are required to unravel the effects of soil moisture, surface roughness, and vegetation cover.

Wang, J. R.↗
NASA NTRS2013

Influence of Ice Particle Surface Roughening on the Global Cloud Radiative Effect

Ice clouds influence the climate system by changing the radiation budget and large-scale circulation. Therefore, climate models need to have an accurate representation of ice clouds and their radiative effects. In this paper, new broadband parameterizations for ice cloud bulk scattering properties are developed for severely roughened ice particles. The parameterizations are based on a general habit mixture that includes nine habits (droxtals, hollow/solid columns, plates, solid/hollow bullet rosettes, aggregate of solid columns, and small/large aggregates of plates). The scattering properties for these individual habits incorporate recent advances in light-scattering computations. The influence of ice particle surface roughness on the ice cloud radiative effect is determined through simulations with the Fu-Liou and the GCM version of the Rapid Radiative Transfer Model (RRTMG) codes and the National Center for Atmospheric Research Community Atmosphere Model (CAM, version 5.1). The differences in shortwave (SW) and longwave (LW) radiative effect at both the top of the atmosphere and the surface are determined for smooth and severely roughened ice particles. While the influence of particle roughening on the single-scattering properties is negligible in the LW, the results indicate that ice crystal roughness can change the SW forcing locally by more than 10 W m(exp −2) over a range of effective diameters. The global-averaged SW cloud radiative effect due to ice particle surface roughness is estimated to be roughly 1-2 W m(exp −2). The CAM results indicate that ice particle roughening can result in a large regional SW radiative effect and a small but nonnegligible increase in the global LW cloud radiative effect.

clouds↗
NASA NTRSDate not supplied

Computational Study of Low-Speed Boundary-Layer Laminar-Turbulent Transition over a 30º Swept Plate in a Channel

Reliable boundary-layer laminar-turbulent transition predictions are critical for the design of aircraft that use natural or controlled laminar flow to achieve low drag and better fuel efficiency. During cruise flight through low turbulence, the three-dimensional boundary layer over swept surfaces can transition prematurely due to stationary crossflow instabilities induced by surface roughness. Parabolized stability equations analyses have been successfully used to explain the different phases of the transition process under well controlled perturbations such as steps or discrete roughness elements. However, methodologies are still lacking to model the boundary layer receptivity to distributed random roughness, and the following non-linear instability stages leading to transition. For engineering applications, several semi-empirical methods based on linear amplification factors or local helicity have found growing adoption, but their reliability is limited by their level of simplification and the sparsity of data they are based on. To address this gap, a new study of the effect of distributed random surface roughness on crossflow transition was started, using a 30◦ swept plate as a test vehicle. The plate, which is mounted in the 2 Foot × 3 Foot Low-Speed Boundary-Layer Channel at the NASA Langley Research Center, has been tested with micro-scale roughness of varied geometry near the leading edge. In order to analyze the flow in the test section and prepare Direct Numerical Simulations with resolved roughness, Reynolds-Averaged Navier-Stokes (RANS) simulations of the flow over the plate installed in the wind tunnel test section were performed using the Langtry-Menter transition model with stationary crossflow extension. This paper presents the results of these simulations, with comparison to the experiment.

ARMD↗
NASA NTRS1952

The excitation of unstable perturbations in a laminar friction layer

With the aid of the method of small oscillations which was used successfully in the investigation of the stability of laminar velocity distributions in the presence of two-dimensional perturbations, the excitation of the unstable perturbations for the Hartree velocity distributions occurring in plane boundary-layer flow for decreasing and increasing pressure is calculated as a supplement to a former report. The results of this investigation are to make a contribution toward calculation of the transition point on cylindrical bodies.

BOUNDARY LAYER TRANSITION - EFFECT OF SURFACE ROUG↗
NASA NTRS2004

Experimentation Toward the Analysis of Gear Noise Sources Controlled by Sliding Friction and Surface Roughness

In helicopters and other rotorcraft, the gearbox is a major source of noise and vibration (N&V). The two N&V excitation mechanisms are the relative displacements between mating gears (transmission errors) and the friction associated with sliding between gear teeth. Historically, transmission errors have been minimized via improved manufacturing accuracies and tooth modifications. Yet, at high torque loads, noise levels are still relatively high though transmission errors might be somewhat minimal. This suggests that sliding friction is indeed a dominant noise source for high power density rotorcraft gearboxes. In reality, friction source mechanism is associated with surface roughness, lubrication regime properties, time-varying friction forces/torques and gear-mesh interface dynamics. Currently, the nature of these mechanisms is not well understood, while there is a definite need for analytical tools that incorporate sliding resistance and surface roughness, and predict their effects on the vibro- acoustic behavior of gears. Toward this end, an experiment was conducted to collect sound and vibration data on the NASA Glenn Gear-Noise Rig. Three iterations of the experiment were accomplished: Iteration 1 tested a baseline set of gears to establish a benchmark. Iteration 2 used a gear-set with low surface asperities to reduce the sliding friction excitation. Iteration 3 incorporated low viscosity oil with the baseline set of gears to examine the effect of lubrication. The results from this experiment will contribute to a two year project in collaboration with the Ohio State University to develop the necessary mathematical and computer models for analyzing geared systems and explain key physical phenomena seen in experiments. Given the importance of sliding friction in the gear dynamic and vibro-acoustic behavior of rotorcraft gearboxes, there is considerable potential for research & developmental activities. Better models and understanding will lead to quiet and reliable gear designs, as well as the selection of optimal manufacturing processes.

Asnani, Vivake M.↗
NASA NTRS1979

Elastohydrodynamic film thickness measurements of artificially produced nonsmooth surfaces

Optical interferometry is used to measure the elastohydrodynamic (EHD) film thickness associated with artificially produced nonsmooth surfaces. The nonsmooth surfaces are produced by modifying the surfaces of highly-polished balls with irregularities in the form of multiple grooves and dents. By closely spacing these irregularities it is possible not only to produce depressions on the surface of the balls but also to generate pseudo asperities. The average roughness wavelength of this artificially-produced, nonsmooth, surface approximates the average fundamental roughness wavelength found on surfaces of some mechanical elements operating under concentrated contact. By comparing the measured film thickness profiles to the stylus traces of the irregularities, it was possible to observe the local deformations associated with micro-EHD pressure generation. In both pure rolling and pure sliding conditions the artificially-produced asperities are deformed and complete separation exists between them and the mating surface. Such findings demonstrate the importance of local surface topography and resulting micro-EHD effects on the film thickness between rough surfaces in concentrated contact. Sliding data are presented which demonstrate a severe constriction, caused by the irregularities, at the exit of the Hertzian region.

Cusano, C.↗
NASA NTRS1979

Elastohydrodynamic film thickness measurements of artificially-produced nonsmooth surfaces

Optical interferometry is used to measure the elastohydrodynamic (EHD) film thickness associated with artificially produced, nonsmooth surfaces. The nonsmooth surfaces are produced by modifying the surfaces of highly-polished balls with irregularities in the form of multiple grooves and dents. By closely spacing these irregularities, it is possible not only to produce depressions on the surface of the balls but also to generate pseudo asperities. The average roughness wavelength of this artificially-produced, nonsmooth surface approximates the average fundamental roughness wavelength found on surfaces of some mechanical elements operating under concentrated contact. By comparing the measured film thickness profiles to the stylus traces of the irregularities, it is possible to observe the local deformations associated with micro-EHD pressure generation. In both pure rolling and pure sliding conditions, the artificially-produced 'asperities' are deformed and complete separation exists between them and the mating surface. Such findings demonstrate the importance of local surface topography and resulting micro-EHD effects on the film thickness between rough surfaces in concentrated contact. In addition, sliding data are presented which demonstrate a severe constriction, caused by the irregularities, at the exit of the Hertzian region.

Cusano, C.↗
DOE OSTI2023

Heat Exchanger Design for Waste Heat Recovery using Additive Manufacturing

With anticipated increases in global energy use and their associated emissions, there are many efforts to improve the emissions and efficiency of many industrial processes through waste heat recovery (WHR). To maximize improvements, the heat exchangers in WHR power cycles must be designed and optimized for a given heat source. Meanwhile, additive manufacturing (AM) is a single part manufacturing technique that provides the opportunity to develop unique and complex heat exchanger designs. Consequently, this work centers on the modeling, design, optimization, and testing of AM shell and tube heat exchangers for WHR. Specifically, a modified one-dimensional (1+1-D) and three-dimensional (3-D) heat exchanger models were developed and validated, with the 1+1-D model serving as the basis for design optimization. After modifications to the design to allow for AM, heat exchanger geometry optimizations were completed, targeting increased effectiveness across a range of physical parameters. Of the designs considered, nine were additively manufactured using Ti5553, and then tested using an external heat source and working fluid. Experimentally, the nineteen-tube, zero-baffle heat exchanger displayed the best overall performance, with the effects of dimensional accuracy, surface roughness, and baffles in the other designs also indicated. Next, the experimental results were used as inputs for the 1+1-D model. Although the original model was able to predict fluid outlet temperatures within 5% differences, larger variations in the heat exchanger performance parameters, temperature differences, and pressure drop necessitated optimizing the pressure drop and heat transfer calculations within the model. Thus, the resulting improved model was able to predict the heat transfer rates, heat source temperature difference, and effectiveness within 15% differences, while showing improvements in the pressure drops and working fluid temperature differences. The improved model serves as the foundation for future work to improve the design and performance of AM heat exchangers.

Spickler, Bailey Ann↗
NASA NTRS1985

A fundamental study of the sticking of insect residues to aircraft wings

The aircraft industry has long been concerned with the increase of drag on airplanes due to fouling of the wings by insects. The present research studied the effects of surface energy and surface roughness on the phenomenon of insect sticking. Aluminum plates of different roughnesses were coated with thin films of polymers with varying surface energies. The coated plates were attached to a custom jig and mounted on top of an automobile for insect collection. Contact angle measurements, X-ray photoelectron spectroscopy and specular reflectance infrared spectroscopy were used to characterize the surface before and after the insect impact experiments. Scanning electron microscopy showed the topography of insect residues on the exposed plates. Moments were calculated in order to find a correlation between the parameters studied and the amount of bugs collected on the plates. An effect of surface energy on the sticking of insect residues was demonstrated.

Eiss, N. S., Jr.↗
NASA NTRS2022

Interaction of a Tunnel-like Acoustic Disturbance Field with a Blunt Cone Boundary Layer at Mach 8

The existing measurements of laminar-to-turbulent transition over circular cones in conventional (i.e., “noisy”) hypersonic wind tunnels have established that the transition location moves downstream when the nose radius is increased from zero. However, this initially downstream movement slows down and ultimately reverses beyond a critical value of the nose radius, and may be related to external forcing in the form of freestream disturbances and/or surface roughness. To understand the effects of freestream acoustic disturbances on transition reversal over a blunt body, hypersonic boundary-layer receptivity to broadband freestream acoustic disturbances from the nozzle wall of a digital conventional wind tunnel is investigated by both direct numerical simulations (DNS) and modal and nonmodal stability analysis. A Mach 8 flow over a 7 deg half-angle cone with a nose radius of 𝑅 𝑛 = 5.2mm and freestream Reynolds number of 12.2 × 10 6 m -1 is considered. The results show that the broadband tunnel noise in the free stream of a convectional hypersonic wind tunnel (i.e., outside of the nozzle-wall turbulent boundary layer) can be well represented by an acoustic model with an ansatz of slow acoustic waves. With successful calibration of the model parameters against the precursor tunnel DNS, such an acoustic ansatz can successfully reproduce both the frequency-wavenumber spectra and the temporal evolution of the broadband tunnel noise radiated from the nozzle wall. Additionally, the DNS of the Mach 8 blunt cone with tunnel-like acoustic input above the bow shock showed that the spectra of wall-pressure and heat-transfer fluctuations recovers the signature of the axisymmetric waves predicted by the nonmodal analysis. Furthermore, the azimuthal wavenumber and frequency spectrum of the temperature fluctuations as a function of the wall-normal distance show higher amplitudes for three-dimensional waves above the boundary-layer edge. The numerical schlieren contours show the inclined structures commonly observed in blunt cone experiments, demonstrating that they correspond to three-dimensional structures due to freestream disturbances in the presence of an entropy layer.

Boundary-layer transition↗
NASA NTRS2021

Effect of Broaching Machining Parameters, Residual Stresses and Cold Work on Fatigue Life of Ni-based Turbine Disk P/M Alloy at 650°C

A study was performed to examine the effect of various broaching machining parameters on high temperature fatigue lives of a nickel-based Low Solvus High Refractory (LSHR) powder metallurgy disk alloy. The work was done to gain a better understanding of the effect of various broaching variables on the integrity and the durability of these fracture critical components. The influence of tool wear and broaching speed were examined in terms of their effect on residual stresses, cold work and surface roughness. These variables were shown to have a substantial effect on fatigue lives and the failure mode. The relationships between these parameters and fatigue crack initiation mechanisms are detailed. Statistical analyses evaluating these relationships are presented.

fatigue↗