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At least 523 records · Page 29

Nonintrusive optical single-particle counter for measuring the size and velocity of droplets in a spray

A technique for measuring nonintrusively, and in real time, the size and velocity of droplets in a spray is presented. A small beam identifies the center of a larger beam, thus defining a region of almost uniform intensity, and only droplets crossing through such a center are measured. The size is obtained from the absolute scattered light and the velocity from the modulated signal produced by the interferometric pattern. A self-calibrating algorithm is also discussed. Results are presented for a spray of predictable chracteristics.

Hess, C. F.↗

Life modeling of atmospheric and low pressure plasma-sprayed thermal-barrier coating

The cycles-to-failure vs cycle duration data for three different thermal barrier coating systems, which consist of atmospheric pressure plasma-sprayed ZrO2-8 percent Y2O3 over similarly deposited or low pressure plasma sprayed Ni-base alloys, are presently analyzed by means of the Miller (1980) oxidation-based life model. Specimens were tested at 1100 C for heating cycle lengths of 1, 6, and 20 h, yielding results supporting the model's value.

Miller, R. A.↗

Mechanical property measurements of plasma-sprayed thermal-barrier coatings subjected to oxidation

Techniques have been developed for measuring the tensile properties of plasma-sprayed coatings which are used in thermal barrier applications. The measurements have included the average Young's modulus, bond strength and elongation at failure. The oxidation behavior of the bond coat plays an important role in the integrity and adhesion of plasma-sprayed thermal barrier coatings. This work studies the nature of the high temperature degradation on the mechanical properties of the coating. Furnace tests have been carried out on U-700 alloy with bond coats of NiCrAlY or NiCrAlZr and an overlay of ZrO2-8 percent Y2O3. Weight gain measurements on the coatings have been examined with relation to the adhesion strength and failure observations. The results from an initial study are reported in this work.

Berndt, C. C.↗

Failure during thermal cycling of plasma-sprayed thermal barrier coatings

The thermal cycling behavior of plasma-sprayed ZrO2-12 wt pct Y2O3 coatings was studied. Coatings were produced with and without bond coats of Ni-Cr-Al-Zr and in some cases the substrates were heated to above the optimum temperature prior to spraying. The coatings (attached to the substrate) were thermal cycled to 1200 C and their cracking behavior was followed by acoustic emission (AE) techniques. It was possible to examine the failure mechanisms by statistical analysis of the AE data and to evaluate the influence of preheating and bond coating. It is shown that the AE spectrum changes when a bond coat is used because of the presence of microcracks which, in turn, dissipate energy and improve the coating integrity. The preheating effect is reflected by a decrease in the peak count rate and an increase in the temperature at which AE activity is initiated.

Berndt, C. C.↗

Digital Image Processing application to spray and flammability studies

Digital Image Processing has been integrated into a new technique for measurements of fuel spray characteristics. The advantages of this technique are: a wide dynamic range of droplet sizes, accounting for nonspherical droplet shapes not possible with other spray assessment techniques. Finally, the technique has been applied to the study of turbojet engine fuel nozzle atomization performance with Jet A and antimisting fuel.

Hernan, M. A.↗

Structure of nonevaporating sprays. I - Initial conditions and mean properties

Structure measurements were completed within the dilute portion of axisymmetric nonevaporating sprays. Measurements included: mean velocities, velocity fluctuations, and Reynolds stress of the gas phase; and mean velocities, fluctuating velocities, mass flux, and diameter distributions of the drop phase. The measurements were used to evaluate three typical methods of analyzing sprays: (1) a locally homogeneous flow (LHF) analysis, where slip between the phases is neglected; (2) a deterministic separated flow (DSF) analysis, where slip is considered but effects of drop interactions with turbulence are ignored; and (3) a stochastic separated flow (SSF) analysis, where effects of both slip and turbulence are considered using random-walk computations for drop motion. Measurements of initial conditions of both phases near the injector, mean gas-phase properties, and liquid flux distributions are described herein. Best agreement between predictions and measurements was obtained with the SSF model, which provided a reasonable representation of turbulent dispersion of drops. A companion paper presents additional measurements of drop continuous phase properties.

Solomon, A. S. P.↗

Modeling of dense sprays from LOX/H2 coaxial injectors under supercritical conditions

Assumptions commonly employed in the analytical description of a thin spray become unacceptable as the droplet density and droplet volume displacement become large. Changes in the semiempirical models describing drop-drop or drop-gas interactions as well as in the basic modeling approach itself may be necessary. A number of efforts undertaken to improve such models of the atomization-evaporation process to render them applicable in the dense-spray, supercritical regime are described. The improvements include those for variable drop density, supercritical properties, stripping evaporation and drop reincorporation into the liquid stream. The models are developed for use with the ARICC three-phase finite difference combustion code. Selected results from a sample calculation are presented, demonstrating the enhanced realism achievable with the upgraded models.

Liang, P. Y.↗

Failure analysis of plasma-sprayed thermal barrier coatings

Thermally induced failure processes of plasma-sprayed thermal barrier coatings are examined. Cracking processes give rise to noise which was monitored by acoustic emission (AE) techniques. The sequential failure of coatings was examined from samples which were thermally cycled. Coatings of yttria-stabilized zirconia with and without a NiCrAlZr bond coat were plasma-sprayed onto U700 alloy rod. In some cases the substrate was intentionally overheated during deposition of the thermal protection system to check how this process variable influenced the AE response of the specimen. In this way a qualitative appraisal of how process variables affect coating integrity could be discerned in terms of cracking behavior. Results from up to seven consecutive thermal cycles are reported here. Coating failure was observed in all cases. Failure of the thermal protection system is progressive, since cracking and crack growth were observed prior to ultimate failure. Thus castastrophic failure occurs at some stage when there is a transformation from the microcrack to a macrocrack network.

Berndt, C. C.↗

Fabrication of ceramic substrate-reinforced and free forms by mandrel plasma spraying metal-ceramic composites

Components fabricated of, or coated with, ceramics have lower parasitic cooling requirements. Techniques are discussed for fabricating thin-shell ceramic components and ceramic coatings for applications in rocket or jet engine environments. Thin ceramic shells with complex geometric forms involving convolutions and reentrant surfaces were fabricated by mandrel removal. Mandrel removal was combined with electroplating or plasma spraying and isostatic pressing to form a metal support for the ceramic. Rocket engine thrust chambers coated with 0.08 mm (3 mil) of ZrO2-8Y2O3 had no failures and a tenfold increase in engine life. Some measured mechanical properties of the plasma-sprayed ceramic are presented.

Quentmeyer, R. J.↗

Film and interstitial formation of metals in plasma-sprayed ceramics

A method is described to electrodeposit noble metals such as platinum and ordinary metals such as copper on and within plasma-sprayed ceramic materials and ceramic fiber materials. Low-density ceramic fiber bodies were vacuum impregnated with plating solution and attached to an electrode. Light micrographs illustrating the density and location of deposited materials are presented and discussed. Voids in the plasma-sprayed ceramic were filled with deposits that vary from spherical to lens-shaped circular and have particle size corresponding to the full range of void size. Multiple coatings of ceramic and metal can be sequenced.

Hendricks, R. C.↗

Fracture toughness tests on plasma-sprayed coatings

Fracture toughness measurements have been performed on plasma-sprayed coatings. The intrinsic fracture toughness of plasma-sprayed coatings may be ascertained by means of a double cantilever beam (DCB) test. Emphasis is placed on calibration of the specimen geometry. Representative values for alumina coatings are presented.

Berndt, C. C.↗

Ignition characteristics of rich n-heptane fuel sprays in the transition region

Ignition studies were performed on monodisperse n-heptane sprays at atmospheric pressure over a range of equivalence ratios and droplet diameters. A capacitive discharge spark ignition system was used as the ignition source, providing independent control of spark energy and duration. Preliminary measurements were made to optimize spark duration and spark gap, optimum conditions being those at which the maximum frequency or probability of ignition was observed. Using the optimum electrode spacing and spark duration, the frequency of ignition was determined as a function of spark energy for three overall equivalence ratios (0.6, 0.8, and 1.0) and for initial droplet diameters of 25, 40, 50, 60, and 70 microns. An LDA system was used to determine the actual equivalence ratio at the spark gap, which varied from 1.5 to 4.7. The spark energy at which the frequency of ignition was 90 percent was defined as the minimum ignition energy. These data indicated that the ignitability of the sprays was enhanced as the equivalence ratio was increased, but was diminished as the droplet size was increased. The increase in minimum ignition energy with increasing droplet size and fixed equivalence ratio was nearly linear over the range of parameters studied. However, the effect became smaller with increasing equivalence ratio.

Danis, A. M.↗

Analysis of the effects of fuel spray characteristics on NO(x) formation

Results from experimental and analytical studies on NO(x) formation in a one-dimensional monodisperse spray combustion system are reported. In a previous investigation, an optimum droplet diameter was reported for minimizing NO(x) emissions. In this paper, the effects of enhanced prevaporization and droplet interactions in addition to droplet size effects on NO(x) formation are investigated by air preheating experiments. These phenomena have been incorporated into an analytical model which predicts NO(x) formed from the combustion of monodisperse fuel sprays. Both, experimental and computed results indicate the importance of the extent of prevaporization and droplet interactions on NO(x) production. Preflame vaporization controls the gas phase stoichiometry which has a significant effect on the volume of the hot gases surrounding a fuel droplet where NO(x) is formed. On the other hand, the release of fuel vapor from the droplet to the reaction zone is influenced by droplet interactions which reduce the volume of the hot gases and NO(x) production by bringing the flame closer to the droplet surface.

Sarv, H.↗

Spray Gun With Constant Mixing Ratio

Conceptual mechanism mounted in handle of spray gun maintains constant ratio between volumetric flow rates in two channels leading to spray head. With mechanism, possible to keep flow ratio near 1:1 (or another desired ratio) over range of temperatures, orifice or channel sizes, or clogging conditions.

Simpson, William G.↗

Numerical simulation of the flow field and fuel sprays in an IC engine

A two-dimensional model for axisymmetric piston-cylinder configurations is developed to study the flow field in two-stroke direct-injection Diesel engines under motored conditions. The model accounts for turbulence by a two-equation model for the turbulence kinetic energy and its rate of dissipation. A discrete droplet model is used to simulate the fuel spray, and the effects of the gas phase turbulence on the droplets is considered. It is shown that a fluctuating velocity can be added to the mean droplet velocity every time step if the step is small enough. Good agreement with experimental data is found for a range of ambient pressures in Diesel engine-type microenvironments. The effects of the intake swirl angle in the spray penetration, vaporization, and mixing in a uniflow-scavenged two-stroke Diesel engine are analyzed. It is found that the swirl increases the gas phase turbulence levels and the rates of vaporization.

Nguyen, H. L.↗

Plasma Spraying Of Dense, Rough Bond Coats

Simple modification of plasma torch facilitates spraying of coarse powders. Shape of nozzle changed to obtain decrease in velocity of gas and consequent increase in time particles spend in flame before impact on substrate. Increased residence time allows melting of coarser powders, spraying of which results in rougher bond surfaces.

Miller, Robert A.↗

Stability relationship for water droplet crystallization with the NASA Lewis icing spray

In order to produce small droplets for icing cloud simulation, high pressure air atomizing nozzles are used. For certain icing testing applications, median drop sizes as small as 5 mm are needed, which require air atomizing pressures greater than 3000 kPa. Isentropic expansion of the ambient temperature atomizing air to atmospheric pressure can result in air stream temperatures of -160 C which results in ice crystals forming in the cloud. To avoid such low temperatures, it is necessary to heat the air and water to high initial temperatures. An icing spray research program was conducted to map the temperatures below which ice crystals form. A soot slide technique was used to determine the presence of crystals in the spray.

Marek, C. John↗

Spray automated balancing of rotors: Methods and materials

The work described consists of two parts. In the first part, a survey is performed to assess the state of the art in rotor balancing technology as it applies to Army gas turbine engines and associated power transmission hardware. The second part evaluates thermal spray processes for balancing weight addition in an automated balancing procedure. The industry survey reveals that: (1) computerized balancing equipment is valuable to reduce errors, improve balance quality, and provide documentation; (2) slow-speed balancing is used exclusively, with no forseeable need for production high-speed balancing; (3) automated procedures are desired; and (4) thermal spray balancing is viewed with cautious optimism whereas laser balancing is viewed with concern for flight propulsion hardware. The FARE method (Fuel/Air Repetitive Explosion) was selected for experimental evaluation of bond strength and fatigue strength. Material combinations tested were tungsten carbide on stainless steel (17-4), Inconel 718 on Inconel 718, and Triballoy 800 on Inconel 718. Bond strengths were entirely adequate for use in balancing. Material combinations have been identified for use in hot and cold sections of an engine, with fatigue strengths equivalent to those for hand-ground materials.

Smalley, Anthony J.↗