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At least 469 records · Page 26

All sources NASA NTRS DOE OSTI

DOE OSTI2026

Feasibility of Nitrogen as a Carrier Gas for Inconel Cold Spray in Hydropower Application

Cold spray deposition of Inconel nickel alloys has emerged as a promising strategy for mitigating cavitation erosion in hydropower facilities. Most prior developments employ helium (He) as the carrier gas because it enables high particle velocities and the formation of dense coatings. However, He is nearly two orders of magnitude more expensive than nitrogen (N2), which limits its widespread adoption in the hydropower sector. Although He-based cold spray can be justified for high value repairs, the lower cost and broad availability of N2 make it an attractive alternative. This study assesses the feasibility of N2-based cold spray of Inconel 625 powders for hydropower applications. Cavitation erosion testing shows that He-based coating exhibits cavitation resistance of ~398% relative to the 304L stainless steel (SS304L) substrate. In contrast, N2-based coating shows substantially lower cavitation resistance, reaching only ~69% of the SS304L substrate, even when higher carrier gas temperature and pressure are applied. When the Inconel 625 powder size is reduced from 44 to 22 µm under N2-based cold spray conditions, cavitation resistance increases significantly to ~148% of the SS304L substrate. Additional improvement can be obtained by incorporating fine chromium carbide powders into the feedstock, resulting in cavitation resistance of ~172% of the SS304L substrate. Overall, with optimized feedstock design, N2-based cold spray offers a practical and cost-effective approach for producing cavitation resistant coatings on hydropower components, although He-based cold spray continues to deliver higher cavitation resistance.

Wang, Tianhao↗

NASA NTRS1972

Investigation of characteristics of feed system instabilities

The relationship between the structural and feed system natural frequencies in structure-propulsion system coupled longitudinal oscillations (pogo) is investigated. The feed system frequencies are usually very dependent upon the compressibility (compliance) of cavitation bubbles that exist to some extent in all operating turbopumps. This document includes: a complete review of cavitation mechanisms; development of a turbopump cavitation compliance model; an accumulation and analysis of all available cavitation compliance test data; and a correlation of empirical-analytical results. The analytical model is based on the analysis of flow relative to a set of cascaded blades, having any described shape, and assumes phase changes occur under conditions of isentropic equilibrium. Analytical cavitation compliance predictions for the J-2 LOX, F-1 LOX, H-1 LOX and LR87 oxidizer turbopump inducers do not compare favorably with test data. The model predicts much less cavitation than is derived from the test data. This implies that mechanisms other than blade cavitation contribute significantly to the total amount of turbopump cavitation.

Vaage, R. D.↗

NASA NTRS2011

Water Flow Testing and Unsteady Pressure Analysis of a Two-Bladed Liquid Oxidizer Pump Inducer

The unsteady fluid dynamic performance of a cavitating two-bladed oxidizer turbopump inducer was characterized through sub-scale water flow testing. While testing a novel inlet duct design that included a cavitation suppression groove, unusual high-frequency pressure oscillations were observed. With potential implications for inducer blade loads, these high-frequency components were analyzed extensively in order to understand their origins and impacts to blade loading. Water flow testing provides a technique to determine pump performance without the costs and hazards associated with handling cryogenic propellants. Water has a similar density and Reynolds number to liquid oxygen. In a 70%-scale water flow test, the inducer-only pump performance was evaluated. Over a range of flow rates, the pump inlet pressure was gradually reduced, causing the flow to cavitate near the pump inducer. A nominal, smooth inducer inlet was tested, followed by an inlet duct with a circumferential groove designed to suppress cavitation. A subsequent 52%-scale water flow test in another facility evaluated the combined inducer-impeller pump performance. With the nominal inlet design, the inducer showed traditional cavitation and surge characteristics. Significant bearing loads were created by large side loads on the inducer during synchronous cavitation. The grooved inlet successfully mitigated these loads by greatly reducing synchronous cavitation, however high-frequency pressure oscillations were observed over a range of frequencies. Analytical signal processing techniques showed these oscillations to be created by a rotating, multi-celled train of pressure pulses, and subsequent CFD analysis suggested that such pulses could be created by the interaction of rotating inducer blades with fluid trapped in a cavitation suppression groove. Despite their relatively low amplitude, these high-frequency pressure oscillations posed a design concern due to their sensitivity to flow conditions and test scale. The amplitude and frequency of oscillations varied considerably over the pump s operating space, making it difficult to predict blade loads.

Schwarz, Jordan B.↗

NASA NTRS2016

Effects of Alternate Leading Edge Cutback on the Space Shuttle Main Engine Low Pressure Fuel Pump

A higher order cavitation oscillation observed in the SSME low pressure fuel pump has been eliminated in water flow testing of a modified subscale replica of the inducer. The low pressure pump was modified by removing the outboard sections of two opposing blades of the four-bladed inducer, blending the "cutback" regions into the blades at the leading edge and tip, and removing material on the suction sides to decrease the exposed leading edge thickness. The leading edge tips of the cutback blades were moved approximately 25 degrees from their previous locations, thereby increasing one blade to blade spacing, decreasing the second, while simultaneously moving the cutback tips downstream. The test was conducted in MSFC's inducer test loop at scaled operating conditions in degassed and filtered water. In addition to eliminating HOC across the entire scaled operating regime, rotating cavitation was suppressed while the range of both alternate blade and asymmetric cavitation were increased. These latter phenomena, and more significantly, the shifts between these cavitation modes also resulted in significant changes to the head coefficient at low cavitation numbers. Reverse flow was detected at a slightly larger flow coefficient with the cutback inducer and suction capability was reduced by approximately 1 velocity head at and above approximately 90% of the reference flow coefficient. These performance changes along with more intense reverse flow are consistent with poor flow area management and increased incidence in the cutback region. Although the test demonstrated that the inducer modification was successful at eliminating the higher order cavitation across the entire scaled operating regime, different, previously unobserved, cavitation oscillations were introduced and significant performance penalties were imposed.

Mulder, Andrew↗

DOE OSTI2016

Negative Pressures and Spallation in Water Drops Subjected to Nanosecond Shock Waves

Abstract Not Provided

CHEM, MATSCI, PHYS, XFEL↗

DOE OSTI2013

On the spatial stability of a liquid jet in the presence of vapor cavities

A dispersion equation describing the effect of temperature differences on the stability of three-dimensional cylindrical liquid jets in the presence of vapor cavities is presented by the use of linear stability analysis. The mathematical model and its solving method are verified by comparing them with the data in the literature, and then the effect of temperature differences between jet and surrounding gas on the spatial stability of liquid jet is investigated. Some conclusions can be drawn from the results of this investigation: (1) the temperature difference destabilizes the liquid jet when the jet liquid is cooler than the surrounding gas, (2) the smallest atomized droplet without taking into account the effect of temperature differences is significantly larger than that when the effect of temperature differences is taken into account, (3) the effect of temperature differences on the stability of liquid jet has little relationship with azimuthal wave modes, (4) cavitation destabilizes the liquid jet when the value of the bubble volume fraction is not greater than 0.1 (0 ≤ α ≤ 0.1), and the temperature difference can weaken this effect of cavitation on the stability of liquid jet, and (5) cavitation is responsible for generating smaller droplets, the effect of cavitation on the critical wave number with and without taking into account the effect of temperature differences is quite different, and temperature difference is likely to fully restrain the effect of cavitation on the critical wave number; however, cavitation is again responsible for generating smaller droplets despite the effect of temperature differences when the bubble volume fraction α = 0.1. These findings may explain some observations of practical atomizer performance.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗

DOE OSTI2017

Internal Nozzle Flow Simulations of Gasoline-Like Fuels under Diesel Operating Conditions

Spray formation in internal combustion engines with direct injection is strictly correlated with internal nozzle flow characteristics, which are in turn influenced by fuel physical properties and injector needle motion. This paper pre-sents a series of 3D simulations that model the in-nozzle flow in a 5-hole mini-sac diesel injector. Two gasoline-like naphtha fuels, namely full-range and light naphtha, were tested under operating conditions typical of diesel applica-tions and were compared with n-dodecane, selected from a palette used as diesel surrogates. Validated methodolo-gies from our previous work were employed to account for realistic needle motion. The multi-phase nature of the problem was described by the mixture model assumption with the Volume of Fluid method. Cavitation effects were included by means of the Homogeneous Relaxation Model and turbulence closure was achieved with the Standard k-ε model in an Unsteady Reynolds-Averaged Navier-Stokes formulation. The results revealed that injector perfor-mance and propensity to cavitation are influenced by the fuel properties. Analyses of several physical quantities were carried out to highlight the fuel-to-fuel differences in terms of mass flow rate, discharge coefficients, and fuel vapor volume fraction inside the orifices. A series of parametric investigations was also performed to assess the fuel response to varied fuel injection temperature, injection pressure, and cross-sectional orifice area. For all cases, the strict correlation between cavitation magnitude and saturation pressure was confirmed. Owing to their higher volatil-ity, the two gasoline-like fuels were characterized by higher cavitation across all the simulated conditions. Occur-rence of cavitation was mostly found at the needle seat and at the orifice inlets during the injection event’s transient, when very small gaps exist between the needle and its seat. This behavior tended to disappear at maximum needle lift, where cavitation was absent for all fuels. Differences in mass flow rate between the naphtha fuels and n-dodecane were measured and ascribed to the different densities of the three fuels. Nevertheless, they were found to be smaller than expected, owing to the lower viscosity of the gasoline-like fuels. This beneficial influence of the lower viscosity was shown to be less effective at higher temperature, where the relative viscosity differences de-creased.

Torelli, R.↗

DOE OSTI2015

Pre-breakdown processes in a dielectric fluid in inhomogeneous pulsed electric fields

We consider the development of pre-breakdown cavitation nanopores appearing in the dielectric fluid under the influence of the electrostrictive stresses in the inhomogeneous pulsed electric field. It is shown that three characteristic regions can be distinguished near the needle electrode. In the first region, where the electric field gradient is greatest, the cavitation nanopores, occurring during the voltage nanosecond pulse, may grow to the size at which an electron accelerated by the field inside the pores can acquire enough energy for excitation and ionization of the liquid on the opposite pore wall, i.e., the breakdown conditions are satisfied. In the second region, the negative pressure caused by the electrostriction is large enough for the cavitation initiation (which can be registered by optical methods), but, during the voltage pulse, the pores do not reach the size at which the potential difference across their borders becomes sufficient for ionization or excitation of water molecules. And, in the third, the development of cavitation is impossible, due to an insufficient level of the negative pressure: in this area, the spontaneously occurring micropores do not grow and collapse under the influence of surface tension forces. This paper discusses the expansion dynamics of the cavitation pores and their most probable shape.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗

DOE OSTI2021

Localizing Clinical Patterns of Blast Traumatic Brain Injury Through Computational Modeling and Simulation

Blast traumatic brain injury is ubiquitous in modern military conflict with significant morbidity and mortality. Yet the mechanism by which blast overpressure waves cause specific intracranial injury in humans remains unclear. Reviewing of both the clinical experience of neurointensivists and neurosurgeons who treated service members exposed to blast have revealed a pattern of injury to cerebral blood vessels, manifested as subarachnoid hemorrhage, pseudoaneurysm, and early diffuse cerebral edema. Additionally, a seminal neuropathologic case series of victims of blast traumatic brain injury (TBI) showed unique astroglial scarring patterns at the following tissue interfaces: subpial glial plate, perivascular, periventricular, and cerebral gray-white interface. The uniting feature of both the clinical and neuropathologic findings in blast TBI is the co-location of injury to material interfaces, be it solid-fluid or solid-solid interface. This motivates the hypothesis that blast TBI is an injury at the intracranial mechanical interfaces. In order to investigate the intracranial interface dynamics, we performed a novel set of computational simulations using a model human head simplified but containing models of gyri, sulci, cerebrospinal fluid (CSF), ventricles, and vasculature with high spatial resolution of the mechanical interfaces. Simulations were performed within a hybrid Eulerian—Lagrangian simulation suite (CTH coupled via Zapotec to Sierra Mechanics). Because of the large computational meshes, simulations required high performance computing resources. Twenty simulations were performed across multiple exposure scenarios—overpressures of 150, 250, and 500 kPa with 1 ms overpressure durations—for multiple blast exposures (front blast, side blast, and wall blast) across large variations in material model parameters (brain shear properties, skull elastic moduli). All simulations predict fluid cavitation within CSF (where intracerebral vasculature reside) with cavitation occurring deep and diffusely into cerebral sulci. These cavitation events are adjacent to high interface strain rates at the subpial glial plate. Larger overpressure simulations (250 and 500kPa) demonstrated intraventricular cavitation—also associated with adjacent high periventricular strain rates. Additionally, models of embedded intraparenchymal vascular structures—with diameters as small as 0.6 mm—predicted intravascular cavitation with adjacent high perivascular strain rates. The co-location of local maxima of strain rates near several of the regions that appear to be preferentially damaged in blast TBI (vascular structures, subpial glial plate, perivascular regions, and periventricular regions) suggest that intracranial interface dynamics may be important in understanding how blast overpressures leads to intracranial injury.

59 BASIC BIOLOGICAL SCIENCES↗

DOE OSTI2022

Durability Study of a High-Pressure Common Rail Fuel Injection System Using Lubricity Additive-Dosed Gasoline-Like Fuel—Improved Endurance with Upgraded Hardware

Gasoline compression ignition (GCI) is a promising combustion technology that can help the commercial transportation sector achieve operational flexibility and meet upcoming criteria pollutant regulations. However, high-pressure fuel injection systems (>1000 bar) are needed to enable GCI and fully realize its benefits compared to conventional diesel combustion. This work is a continuation of previous durability studies that identified three key technical risks after running gasoline-like fuel through a heavy-duty, common rail injection system: (i) cavitation damage to the inlet check valve of the high-pressure pump, (ii) loss of injector fueling capacity, (iii) cavitation erosion of the injector nozzle holes. Upgraded hardware solutions were tested on a consistent 400- to 800-hour NATO durability cycle with the same gasoline-like fuel as previous studies. The upgraded pump showed no signs of abnormal wear or cavitation damage to the inlet check valve. In contrast to previous studies, there were no signs of pump performance degradation observed after 400 hours of testing. Material selection and design upgrades were also made to the injector which, only showed a 6.5% loss in fueling capacity after 800 hours of durability testing compared to 49.3% previously. Finally, geometric nozzle hole features such as higher inlet radius of curvature and higher K-factor were found to correlate with reduced cavitation erosion. However, mitigation of eccentric radial needle motion (i.e., wobble) is likely needed to further suppress cavitation. In general, the results from this study indicate there are viable hardware-based solutions for improving the endurance of high-pressure systems when running with gasoline-like fuel.

33 ADVANCED PROPULSION SYSTEMS↗

NASA NTRS1972

Empirical evaluation of pump inlet compliance

Cavitation compliance was determined experimentally from pulsing tests on a number of rocket turbopumps. The primary test data used for this study are those for the Rocketdyne H-1, F-1, and J-2 oxidizer and fuel pumps employed on Saturn vehicles. The study shows that these data can be correlated by a particular form of nondimensionalization, the key feature of which is to divide the operating cavitation number or suction specific speed by its value at head breakdown. An expression is obtained for a best-fit curve for these data. Another set of test data for the Aerojet LR87 and 91 pumps can be correlated by a somewhat different nondimensional pump performance parameter, specifically by relating the cavitation number to its position between the head breakdown point and the point of zero slope of the head coefficient versus cavitation number. Recommendations are given for the estimation of the cavitation compliance for new designs in the Rocketdyne family of pumps.

Ghahremani, F. G.↗

NASA NTRS1988

The use of multigrid techniques in the solution of the Elrod algorithm for a dynamically loaded journal bearing

A numerical solution to a theoretical model of vapor cavitation in a dynamically loaded journal bearing is developed, utilizing a multigrid iterative technique. The code is compared with a presently existing direct solution in terms of computational time and accuracy. The model is based on the Elrod algorithm, a control volume approach to the Reynolds equation which mimics the Jakobssen-Floberg and Olsson cavitation theory. Besides accounting for a moving cavitation boundary and conservation of mass at the boundary, it also conserves mass within the cavitated region via liquid striations. The mixed nature of the equations (elliptic in the full film zone and nonelliptic in the cavitated zone) coupled with the dynamic aspects of the problem create interesting difficulties for the present solution approach. Emphasis is placed on the methods found to eliminate solution instabilities. Excellent results are obtained for both accuracy and reduction of computational time.

Woods, Claudia M.↗

NASA NTRS1988

The solution of the Elrod algorithm for a dynamically loaded journal bearing using multigrid techniques

A numerical solution to a theoretical model of vapor cavitation in a dynamically loaded journal bearing is developed utilizing a multigrid iteration technique. The method is compared with a noniterative approach in terms of computational time and accuracy. The computational model is based on the Elrod algorithm, a control volume approach to the Reynolds equation which mimics the Jakobsson-Floberg and Olsson cavitation theory. Besides accounting for a moving cavitation boundary and conservation of mass at the boundary, it also conserves mass within the cavitated region via a smeared mass or striated flow extending to both surfaces in the film gap. The mixed nature of the equations (parabolic in the full film zone and hyperbolic in the cavitated zone) coupled with the dynamic aspects of the problem create interesting difficulties for the present solution approach. Emphasis is placed on the methods found to eliminate solution instabilities. Excellent results are obtained for both accuracy and reduction of computational time.

Woods, Claudia M.↗

NASA NTRS1989

The solution of the Elrod algorithm for a dynamically loaded journal bearing using multigrid techniques

Woods, C. M.↗

NASA NTRS2012

Investigation of Turbulent Tip Leakage Vortex in an Axial Water Jet Pump with Large Eddy Simulation

Detailed steady and unsteady numerical studies were performed to investigate tip clearance flow in an axial water jet pump. The primary objective is to understand physics of unsteady tip clearance flow, unsteady tip leakage vortex, and cavitation inception in an axial water jet pump. Steady pressure field and resulting steady tip leakage vortex from a steady flow analysis do not seem to explain measured cavitation inception correctly. The measured flow field near the tip is unsteady and measured cavitation inception is highly transient. Flow visualization with cavitation bubbles shows that the leakage vortex is oscillating significantly and many intermittent vortex ropes are present between the suction side of the blade and the tip leakage core vortex. Although the flow field is highly transient, the overall flow structure is stable and a characteristic frequency seems to exist. To capture relevant flow physics as much as possible, a Reynolds-averaged Navier-Stokes (RANS) calculation and a Large Eddy Simulation (LES) were applied for the current investigation. The present study reveals that several vortices from the tip leakage vortex system cross the tip gap of the adjacent blade periodically. Sudden changes in local pressure field inside tip gap due to these vortices create vortex ropes. The instantaneous pressure filed inside the tip gap is drastically different from that of the steady flow simulation. Unsteady flow simulation which can calculate unsteady vortex motion is necessary to calculate cavitation inception accurately even at design flow condition in such a water jet pump.

Hah, Chunill↗

DOE OSTI2011

Lung Tumors Treated With Percutaneous Radiofrequency Ablation: Computed Tomography Imaging Follow-Up

Purpose: To describe the morphologic evolution of lung tumors treated with radiofrequency ablation (RFA) by way of computed tomography (CT) images and to investigate patterns of incomplete RFA at the site of ablation. Materials and Methods: One hundred eighty-nine patients with 350 lung tumors treated with RFA underwent CT imaging at 2, 4, 6, and 12 months. CT findings were interpreted separately by two reviewers with consensus. Five different radiologic patterns were predefined: fibrosis, cavitation, nodule, atelectasis, and disappearance. The appearance of the treated area was evaluated at each follow-up CT using the predefined patterns. Results: At 1 year after treatment, the most common evolutions were fibrosis (50.5%) or nodules (44.8%). Differences were noted depending on the initial size of the tumor, with fibrosis occurring more frequently for tumors <2 cm (58.6% vs. 22.9%, P = 1 Multiplication-Sign 10{sup -5}). Cavitation and atelectasis were less frequent patterns (2.4% and 1.4%, respectively, at 1 year). Tumor location (intraparenchymatous, with pleural contact <50% or >50%) was not significantly correlated with follow-up image pattern. Local tumor progressions were observed with each type of evolution. At 1 year, 12 local recurrences were noted: 2 cavitations, which represented 40% of the cavitations noted at 1 year; 2 fibroses (1.9%); 7 nodules (7.4%); and 1 atelectasis (33.3%). Conclusion: After RFA of lung tumors, follow-up CT scans show that the shape of the treatment zone can evolve in five different patterns. None of these patterns, however, can confirm the absence of further local tumor progression at subsequent follow-up.

62 RADIOLOGY AND NUCLEAR MEDICINE↗

DOE OSTI2018

Magneto-acoustic Interfacial Reaction-Based Nanoparticle Synthesis: A Direct Path to Manufacturing Metal Matrix Nanocomposites

This work investigates a novel nanoparticle fabrication methodology: combined reaction and acoustic cavitation abrasion of a solid in contact with a liquid. Magneto-Acoustic Mixing Technology is used to produce nanometer- to micron-sized particles by chemical and acoustic mechanisms between diamond particles and a stainless steel surface in the presence of a metallic liquid (Mg), where it is found that particle–surface interactions and cavitation generate particles more efficiently together than independently, producing unique chemistries. The individual and combined influence of sonic power and chemical reaction on particle size, volume fraction, chemistry, magnetic properties, and applicability to metal matrix nanocomposite fabrication are studied.

77 NANOSCIENCE AND NANOTECHNOLOGY↗

DOE OSTI2025

Creep ductility limiting mechanisms in an additively manufactured Al-Ce-Ni-Mn-Zr alloy

Tensile creep response and cavitation damage evolution in an additively manufactured Al-7.5Ce-4.5Ni-0.4Mn-0.7Zr (wt%) alloy with peak-aging and overaging treatments were investigated in the 300–400 ºC range. Microstructural heterogeneity and its response to heat treatment and subsequent creep deformation were studied to understand the interplay between cavity formation, creep lifetime and ductility. Increasing the applied stress activated the nucleation of more cavities, an experimental observation that is well described using the vacancy accumulation model. Cavities nucleated prematurely due to localized plasticity in the denuded zones that formed at/near melt-pool or grain boundaries. Microstructure/deformation heterogeneity with consequent evolution of stress triaxiality, especially at lower stresses, causes accelerated cavitation, thus producing low creep ductility (∼ 0.2–2.4 %), compared to (∼12–21 %) ductility of the alloy measured by regular tensile tests at equivalent temperatures. A constrained diffusional cavity growth mechanism with continuous cavity nucleation during creep is established as the dominant mechanism, implying that cavitation involves vacancy diffusion, yet its growth rate is dictated by the minimum creep rate. In conclusion, the ductility-limiting creep and cavitation mechanisms discussed here provide new insight into the creep behavior of 3D-printed metallic alloys.

Additive manufacturing↗