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DOE OSTI2021

Convection in Scaled Turbine Internal Cooling Passages With Additive Manufacturing Roughness

Abstract Additive manufacturing processes, such as direct metal laser sintering (DMLS), enable the creation of novel turbine cooling internal passages and systems. However, the DMLS method produces a significant and unique surface roughness. Previous work in scaled passages analyzed pressure losses and friction factors associated with the rough surfaces, as well as investigated the velocity profiles and turbulent flow characteristics within the passage. In this study, the heat transfer characteristics of scaled additively manufactured surfaces were measured using infrared (IR) thermography. Roughness panels were CNC machined from plates of aluminum 6061 to create near isothermal roughness elements when heated. Fluid resistance differences between the aluminum roughness panels and roughness panels constructed from ABS plastic using the same roughness patterns from McClain et al. (2020, “Flow in a Simulated Turbine Blade Cooling Channel With Spatially Varying Roughness Caused by Additive Manufacturing Orientation,” ASME Turbo Expo 2020, Turbomachinery Technical Conference and Exposition, Virtual Conference, Sept. 21–25, GT2020-16069) were investigated. Finally, the overall thermal performance enhancements and friction losses were assessed through the calculation of surface averaged “global thermal performance” ratios. The global thermal performance characterizations indicate results in-line with those found for traditional commercial roughness and slightly below traditional internal passage convection enhancement methods such as swirl chambers, dimples, and ribs. The passages investigated in this study do not include compressibility effects or the long-wavelength artifacts and channel geometric deviations observed by Wildgoose et al. (2020, “Impact of Additive Manufacturing on Internal Cooling Channels with Varying Diameters and Build Directions,” ASME Turbo Expo 2020, Turbomachinery Technical Conference and Exposition, Virtual Conference, Sept. 21–25, GT2020-15049). However, the results of this study indicate that, based on the roughness augmentation alone, artificial convective cooling enhancers such as turbulators or dimples may still be required for additively manufactured turbine component cooling.

Engineering↗

NASA NTRS1987

Rough-wall turbulent boundary layers in the transition regime

An experimental investigation of turbulent boundary layers over two-dimensional spanwise groove and three-dimensional sandgrain roughnesses in the transition regime between hydraulically smooth and fully rough conditions is presented. It is found that a self-preserving state can be reached in boundary layers developing over both d-type groove and sandgrain roughnesses, and that the drag of a k-type rough wall can be reduced by lowering the spanwise aspect ratio of the roughness elements. The two roughness Reynolds numbers defining the boundaries of the transition regime of the k-type roughnesses are shown to decrease with increasing roughness-element spanwise aspect ratio, and the upper critical transition Reynolds number is shown to determine the roughness behavior in both the transition and fully rough regime.

Bandyopadhyay, Promode R.↗

NASA NTRS1958

A Low-Speed Experimental Investigation of the Effect of a Sandpaper Type of Roughness on Boundary-Layer Transition

An investigation was made in the Langley low-turbulence pressure tunnel to determine the effect of size and location of a sandpaper type of roughness on the Reynolds number for transition. Transition was observed by means of a hot-wire anemometer located at various chordwise stations for each position of the roughness. These observations indicated that when the roughness is sufficiently submerged in the boundary layer to provide a substantially linear variation of boundary-layer velocity with distance from the surface up to the top of the roughness, turbulent "spots" begin to appear immediately behind the roughness when the Reynolds number based on the velocity at the top of the roughness height exceeds a value of approximately 600. At Reynolds numbers even slightly below the critical value (value for transition), the sandpaper type of roughness introduced no measurable disturbances into the laminar layer downstream of the roughness. The extent of the roughness area does not appear to have an important effect on the critical value of the roughness Reynolds number.

Von Doenhoff, Albert E↗

NASA NTRS2004

Clouds Versus Carbon: Predicting Vegetation Roughness by Maximizing Productivity

Surface roughness is one of the dominant vegetation properties that affects land surface exchange of energy, water, carbon, and momentum with the overlying atmosphere. We hypothesize that the canopy structure of terrestrial vegetation adapts optimally to climate by maximizing productivity, leading to an optimum surface roughness. An optimum should exist because increasing values of surface roughness cause increased surface exchange, leading to increased supply of carbon dioxide for photosynthesis. At the same time, increased roughness enhances evapotranspiration and cloud cover, thereby reducing the supply of photosynthetically active radiation. We demonstrate the optimum through sensitivity simulations using a coupled dynamic vegetation-climate model for present day conditions, in which we vary the value of surface roughness for vegetated surfaces. We find that the maximum in productivity occurs at a roughness length of 2 meters, a value commonly used to describe the roughness of today's forested surfaces. The sensitivity simulations also illustrate the strong climatic impacts of vegetation roughness on the energy and water balances over land: with increasing vegetation roughness, solar radiation is reduced by up to 20 W/sq m in the global land mean, causing shifts in the energy partitioning and leading to general cooling of the surface by 1.5 K. We conclude that the roughness of vegetated surfaces can be understood as a reflection of optimum adaptation, and it is associated with substantial changes in the surface energy and water balances over land. The role of the cloud feedback in shaping the optimum underlines the importance of an integrated perspective that views vegetation and its adaptive nature as an integrated component of the Earth system.

Olsen, Lola M.↗

NASA NTRS2009

Determining Surface Roughness in Urban Areas Using Lidar Data

An automated procedure has been developed to derive relevant factors, which can increase the ability to produce objective, repeatable methods for determining aerodynamic surface roughness. Aerodynamic surface roughness is used for many applications, like atmospheric dispersive models and wind-damage models. For this technique, existing lidar data was used that was originally collected for terrain analysis, and demonstrated that surface roughness values can be automatically derived, and then subsequently utilized in disaster-management and homeland security models. The developed lidar-processing algorithm effectively distinguishes buildings from trees and characterizes their size, density, orientation, and spacing (see figure); all of these variables are parameters that are required to calculate the estimated surface roughness for a specified area. By using this algorithm, aerodynamic surface roughness values in urban areas can then be extracted automatically. The user can also adjust the algorithm for local conditions and lidar characteristics, like summer/winter vegetation and dense/sparse lidar point spacing. Additionally, the user can also survey variations in surface roughness that occurs due to wind direction; for example, during a hurricane, when wind direction can change dramatically, this variable can be extremely significant. In its current state, the algorithm calculates an estimated surface roughness for a square kilometer area; techniques using the lidar data to calculate the surface roughness for a point, whereby only roughness elements that are upstream from the point of interest are used and the wind direction is a vital concern, are being investigated. This technological advancement will improve the reliability and accuracy of models that use and incorporate surface roughness.

Holland, Donald↗

DOE OSTI2021

Calculated Roughness Changes due to Clear-Cutting At Savannah River Site

At the Savannah River Site (SRS), multiple facilities are routinely producing and working with radiological constituents which require safety basis modeling by the National Nuclear Safety Administration. The models used to determine the safety basis employ roughness length as an input parameter which describes the roughness of the ground surface which influences momentum exchange near the surface and the subsequent generation of mechanical turbulence. Because roughness length is dependent on surface characteristics, including vegetation, any changes to the surface would have a subsequent impact on the roughness length and require a new safety basis analysis to be performed. An analysis of measurements prior to and after the dear-cuts and thinning was performed and roughness lengths were calculated for each of sixteen wind sectors. Not all sectors contained dear-cuts, so this provides comparison of natural variations in roughness. Based on the results of the estimated changes, consideration will be given to how these changes may affect atmospheric dispersion modeling. It was found that clear-cutting activities generally led to a reduction in roughness. Reductions in roughness length also occurred in some of the wind sectors containing only undisturbed forest, but those in sectors with dear-cuts were found to be slightly greater in magnitude than natural variation. Only in one instance was the change in roughness length found to exceed a decrease of 10%, indicating that there is no significant safety basis to the site as a whole based on previous clear-cutting activities.

54 ENVIRONMENTAL SCIENCES↗

NASA NTRS1976

Roughness induced transition criteria for space shuttle-type vehicles

Tripping effectiveness of surface roughness on a delta wing shuttle orbiter model at 20 deg angle of attack is compared to that on plane and axisymmetrical bodies with and without longitudinal pressure gradients. The experimental data presented are compared on the basis of effective roughness Reynolds number since this parameter is not sensitive to flow conditions downstream of the roughness. The discussion covers the effective roughness Reynolds number as a function of roughness position Reynolds number, effective size ratio as a function of pressure gradient and distance from vehicle nose, and effect of spanwise roughness position on roughness effectiveness. It is shown that conventional criteria for sizing roughness elements which promote transition in two-dimensional zero-pressure gradient flows are insufficient for high-pressure gradient flows and three-dimensional flows. Roughness much smaller than that given by conventional criteria can cause transition and significantly increase the heating load.

Morrisette, E. L.↗

NASA NTRS1986

Drag reducing outer-layer devices in rough wall turbulent boundary layers

The ability of outer-layer devices to reduce wall shear stress over a substantial streamwise distance in rough-wall turbulent boundary layers has been studied experimentally. The devices examined are a pair of thin flat ribbons placed in tandem as well as those having symmetric airfoil sections. The wall conditions examined are smooth, d- and k-type transverse-groove and sandgrain roughnesses. The wall drag is found to be reduced from the respective normal levels in all rough walls. All k-type rough walls exhibit a similar level of relative wall drag reduction which is also smaller than that in a smooth-wall. The d-type rough walls exhibit a transitional behaviour - the relative wall drag reduction drops from the smooth wall level to that of the k-type roughness with increasing roughness Reynolds number. However, the absolute reductions in the local wall shear stress are similar in both the rough and smooth walls. On the other hand, the relative reductions are lower in the rough walls because of a higher reference drag which is caused by the unique presence of a pressure component on which the devices are not as effective.

Bandyopadhyay, P. R.↗

NASA NTRS1987

A parameterization of the effect of surface roughness on microwave emission

A simple model is developed to represent the net effect of surface roughness on the microwave emission from soils. The reflectivity of a rough soil surface is defined in a theoretical model that includes both coherent and incoherent reflectivities in terms of the statistical properties of the rough surface, i.e., the surface height standard deviation and its horizontal correlation length. It is shown that the rough surface reflectivity obtained from this theoretical model can be presented in a form that is simply the reflectivity of a smooth surface attenuated by a 'rough thickness'. It is found that the rough thickness can be parameterized as a function of the statistical slope ratio of a rough surface by a simple power-law relationship. Since the slope of a rough surface can be determined experimentally, the rough thickness can be quantitatively estimated from the parametric representation. Model calculations show that this simple model can provide reasonably accurate results of predicted brightness temperatures that agree well with field measurements within experimental uncertainty.

Mo, Tsan↗

NASA NTRS1995

Heat Transfer Variation on Protuberances and Surface Roughness Elements

In order to determine the effect of surface irregularities on local convective heat transfer, the variation in heat transfer coefficients on small (2-6 mm diam) hemispherical roughness elements on a flat plate has been studied in a wind funnel using IR techniques. Heat transfer enhancement was observed to vary over the roughness elements with the maximum heat transfer on the upstream face. This heat transfer enhancement increased strongly with roughness size and velocity when there was a laminar boundary layer on the plate. For a turbulent boundary layer, the heat transfer enhancement was relatively constant with velocity, but did increase with element size. When multiple roughness elements were studied, no influence of adjacent roughness elements on heat transfer was observed if the roughness separation was greater than approximately one roughness element radius. As roughness separation was reduced, less variation in heat transfer was observed on the downstream elements. Implications of the observed roughness enhanced heat transfer on ice accretion modeling are discussed.

Henry, Robert C.↗

NASA NTRS2008

Boundary Layer Receptivity due to Roughness and Freestream Sound for Supersonic Flows over Axisymmetric Cones

The receptivity of supersonic boundary layers due to the interaction of a two-dimensional acoustic wave with a three-dimensional roughness is numerically investigated over a 5-degree sharp tipped straight cone at a free stream Mach number of 3.5 and a high Reynolds number of 10(exp 6)/inch. Both the steady and unsteady solutions are obtained by solving the full Navier-Stokes equations using the fifth-order accurate weighted essentially non-oscillatory (WENO) scheme for spatial discretization and using third-order total-variation-diminishing (TVD) Runge-Kutta scheme for temporal integration. The simulations are performed with different roughness heights and roughness locations. The steady computations with the roughness reveal that the perturbations induced by the roughness remain very close to the wall and do not penetrate to the outer part of the boundary layer. The effects of the roughness persist for about 10 boundary layer thicknesses downstream of each element. The unsteady simulation shows the generation of unstable three-dimensional first mode disturbances within a short distance from the roughness. However, the amplitudes of the instability waves are very small near the neutral point, on the order of 10(exp -4) compared to the free stream disturbances. The receptivity coefficients due to the roughness elements located very close to the tip are one order of magnitude smaller than those due to the roughness elements located closer to the neutral point.

Balakumar, P.↗

NASA NTRS2009

Simplified Approach to Predicting Rough Surface Transition

Turbine vane heat transfer predictions are given for smooth and rough vanes where the experimental data show transition moving forward on the vane as the surface roughness physical height increases. Consiste nt with smooth vane heat transfer, the transition moves forward for a fixed roughness height as the Reynolds number increases. Comparison s are presented with published experimental data. Some of the data ar e for a regular roughness geometry with a range of roughness heights, Reynolds numbers, and inlet turbulence intensities. The approach ta ken in this analysis is to treat the roughness in a statistical sense , consistent with what would be obtained from blades measured after e xposure to actual engine environments. An approach is given to determ ine the equivalent sand grain roughness from the statistics of the re gular geometry. This approach is guided by the experimental data. A roughness transition criterion is developed, and comparisons are made with experimental data over the entire range of experimental test co nditions. Additional comparisons are made with experimental heat tran sfer data, where the roughness geometries are both regular as well a s statistical. Using the developed analysis, heat transfer calculatio ns are presented for the second stage vane of a high pressure turbine at hypothetical engine conditions.

Boyle, Robert J.↗

NASA NTRS2010

Laminar-Turbulent Transition Behind Discrete Roughness Elements in a High-Speed Boundary Layer

Computations are performed to study the flow past an isolated roughness element in a Mach 3.5, laminar, flat plate boundary layer. To determine the effects of the roughness element on the location of laminar-turbulent transition inside the boundary layer, the instability characteristics of the stationary wake behind the roughness element are investigated over a range of roughness heights. The wake flow adjacent to the spanwise plane of symmetry is characterized by a narrow region of increased boundary layer thickness. Beyond the near wake region, the centerline streak is surrounded by a pair of high-speed streaks with reduced boundary layer thickness and a secondary, outer pair of lower-speed streaks. Similar to the spanwise periodic pattern of streaks behind an array of regularly spaced roughness elements, the above wake structure persists over large distances and can sustain strong enough convective instabilities to cause an earlier onset of transition when the roughness height is sufficiently large. Time accurate computations are performed to clarify additional issues such as the role of the nearfield of the roughness element during the generation of streak instabilities, as well as to reveal selected details of their nonlinear evolution. Effects of roughness element shape on the streak amplitudes and the interactions between multiple roughness elements aligned along the flow direction are also investigated.

Choudhari, Meelan M.↗

NASA NTRS2009

Simplified Approach to Predicting Rough Surface Transition

Turbine vane heat transfer predictions are given for smooth and rough vanes where the experimental data show transition moving forward on the vane as the surface roughness physical height increases. Consistent with smooth vane heat transfer, the transition moves forward for a fixed roughness height as the Reynolds number increases. Comparisons are presented with published experimental data. Some of the data are for a regular roughness geometry with a range of roughness heights, Reynolds numbers, and inlet turbulence intensities. The approach taken in this analysis is to treat the roughness in a statistical sense, consistent with what would be obtained from blades measured after exposure to actual engine environments. An approach is given to determine the equivalent sand grain roughness from the statistics of the regular geometry. This approach is guided by the experimental data. A roughness transition criterion is developed, and comparisons are made with experimental data over the entire range of experimental test conditions. Additional comparisons are made with experimental heat transfer data, where the roughness geometries are both regular and statistical. Using the developed analysis, heat transfer calculations are presented for the second stage vane of a high pressure turbine at hypothetical engine conditions.

Boyle, R. J.↗

NASA NTRS2013

Wake Instabilities Behind Discrete Roughness Elements in High Speed Boundary Layers

Computations are performed to study the flow past an isolated, spanwise symmetric roughness element in zero pressure gradient boundary layers at Mach 3.5 and 5.9, with an emphasis on roughness heights of less than 55 percent of the local boundary layer thickness. The Mach 5.9 cases include flow conditions that are relevant to both ground facility experiments and high altitude flight ("cold wall" case). Regardless of the Mach number, the mean flow distortion due to the roughness element is characterized by long-lived streamwise streaks in the roughness wake, which can support instability modes that did not exist in the absence of the roughness element. The higher Mach number cases reveal a variety of instability mode shapes with velocity fluctuations concentrated in different localized regions of high base flow shear. The high shear regions vary from the top of a mushroom shaped structure characterizing the centerline streak to regions that are concentrated on the sides of the mushroom. Unlike the Mach 3.5 case with nearly same values of scaled roughness height k/delta and roughness height Reynolds number Re(sub kk), the odd wake modes in both Mach 5.9 cases are significantly more unstable than the even modes of instability. Additional computations for a Mach 3.5 boundary layer indicate that the presence of a roughness element can also enhance the amplification of first mode instabilities incident from upstream. Interactions between multiple roughness elements aligned along the flow direction are also explored.

Choudhari, Meelan↗

NASA NTRS2018

Transition Induced by Tandem Rectangular Roughness Elements on a Supersonic Flat Plate

The flow behind two rectangular roughness elements with a height approximately 38-41 percent of the boundary layer thickness was examined with a hot-wire probe. The rectangular roughness elements are oriented so that one element was at a plus 45-degree angle relative to the leading edge of the plate. A second roughness element was placed 7.16 millimeters downstream of the first one with either the same orientation relative to the leading edge of the plate, or an opposing orientation of minus 45 degrees from the leading edge. Mean mass-flux and total-temperature profiles of the flow field downstream of the tandem roughness elements were examined for mean-flow distortion. Using streak strength as a measure of mean-flow distortion, the tandem roughness elements had approximately the same amount of distortion, regardless of their relative orientation. Mass-flux fluctuation profiles show that the dominant mode downstream of the tandem roughness elements with the same orientation was similar to that of a single roughness element and centered at a frequency of approximately 55 kilohertz (kHz). The dominant instability downstream of the tandem roughness elements with opposing orientation was centered at a frequency of 65 kHz and grew more slowly than the instabilities behind the single roughness element.

Chou, Amanda↗

NASA NTRS2022

Combined Bluntness and Roughness Effects on Cones at Hypersonic Speeds

This computational study investigates the effects of discrete roughness elements on a blunt cone at zero degrees angle of attack in a Mach 6 flow. Motivation was provided by experiments conducted in the Air Force Research Laboratory Mach 6 High Reynolds Number facility on a 7-degree half-angle cone with a roughness array located at 45 degrees from the apex on two nose tips of different blutness but equivalent roughness Reynolds number. Transition was only affected on the blunter cone, indicating that the transition onset is associated with the combined effects of bluntness and roughness. The present study investigates the 15.24 mm nose radius, 420 azimuthal wavenumber case via Navier-Stokes computations of the laminar base flow and instability analysis. Plane-marching parabolized stability equations (PSE) and inflow-resolvent analysis based on the three-dimensional, harmonic linearized Navier-Stokes equations (HLNSE) are used to calculate the amplification of disturbances along the roughness wake as well as over the roughness nearfield. Results show that the roughness shape can have a great impact on the characteristics of the most amplified wake instabilities. For the experimental configuration with cubic roughness elements of 15 μ m height, the flow is marginally unstable. For prismatic elements of 20 μ m height, the PSE predicts a logarithmic disturbance amplification ratio of N = 5.6 along its wake, but this ratio increases to N = 9.6 when the amplification over the roughness and separation regions is included in the inflow-resolvent analysis.

Boundary-layer transition↗

NASA NTRS2022

Combined Bluntness and Roughness Effects on Cones at Hypersonic Speeds

Boundary-layer transition↗