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NASA NTRSDate not supplied

Metal Additive Manufacturing Process Selection and Development Lifecycle for Propulsion Components

Metal additive manufacturing (AM) is a generic term that captures a variety of fabrication processes. Each of these manufacturing process has unique advantages and challenges for use in aerospace propulsion applications. The most commonly used AM processes include Powder Bed Fusion (PBF), Directed Energy Deposition (DED), and solid-state processes as in Cold Spray, Ultrasonic Additive Manufacturing, and Additive Friction Stir Deposition. While detailed research has been conducted among many of the AM processes to mature processing parameters and material properties, navigating which processes are best to select is difficult as it is based on specific component requirements. The focus of this presentation is to provide an overview of considerations for each of metal AM process selection for aerospace components based on various key attributes. These key attributes include geometric considerations, metallurgical characteristics, cost basis, post-processing and maturity of the processes. The data for these trade selections are based on studies that NASA as performed internally and with academic and industry partners. These studies include multiple AM build experiments to evaluate (1) geometric variations and constraints within the processes, (2) alloy characterization and mechanical testing, (3) pathfinder component development and hot-fire evaluations, and (4) certification approaches. This presentation summarizes these results and is meant to introduce specific examples which show what to consider when designing a metal AM component for aerospace propulsion applications.

Paul Gradl↗
NASA NTRSDate not supplied

Wall-Modeled Large-Eddy Simulations of a Swept Wing with Leading-Edge Ice

The aerodynamic performance of a swept wing derived from the Common Research Model wing with high-fidelity and smooth leading-edge ice shapes is evaluated using wall-modeled large-eddy simulations. Two mesh paradigms are considered within the Launch, Ascent, and Vehicle Aerodynamics framework: structured hybrid curvilinear body-fitted/immersed-boundary and unstructured Voronoi. The curvilinear approach models the effect of the ice on the flow through penalty terms and the Voronoi strategy includes the ice representation directly in the mesh.Aerodynamic loads, surface pressure profiles, and skin-friction streamlines are compared against experimental results collected at the Wichita State University wind tunnel at a Mach number of 0.18 and a Reynolds number per mean aerodynamic chord of 1.6 million. For the curvilinear simulations with high-fidelity ice, results are sensitive to spanwise mesh resolution near the leading edge, where insufficient spanwise resolution leads to a spanwise running vortexaft of the high-fidelity ice, which is partially removed with increasing spanwise resolution. For the Voronoi simulations with high-fidelity ice, refining the mesh led to good convergence towards the experimental results with the best case demonstrating a maximum discrepancy of three lift counts relative to the experiment across a range of angles of attack from about 5 to 24 degrees, validating the shrink-wrapping procedure used for the ice. For the smooth ice, the curvilinear approach consistently under-predicted the upper surface suction leading to an under-prediction in lift, but did not demonstrate the pronounced over-prediction in upper surface suction near the leading edge observed in the Voronoi simulations.

AATT↗
NASA NTRS1977

Internal friction quality-factor Q under confining pressure

It has been found in previous studies that small amounts of adsorbed volatiles can have a profound effect on the internal friction quality-factor Q of rocks and other porous media. Pandit and Tozer (1970) have suggested that the laboratory-measured Q of volatile-free rocks should be similar to the in situ seismic Q values of near-surface lunar rocks which according to Latham et al. (1970) are in the range of 3000-5000. Observations of dramatic increases in Q with outgassing up to values approaching 2000 in the seismic frequency range confirm this supposition. Measurements under confining pressures with the sample encapsulated under hard vacuum are reported to aid in the interpretation of seismic data obtained below the lunar surface. It has been possible to achieve in the experiments Q values just under 2000 at about 1 kbar for a terrestrial analog of lunar basalt. It was found that a well-outgassed sample maintains a high Q whereas one exposed to moisture maintains a low Q as the confining pressure is raised to 2.5 kbar. This result suggests that volatiles can indeed affect Q when cracks are partially closed and the high lunar seismic Q values reported are concomitant with very dry rock down to depths of at least 50 km.

Tittmann, B. R.↗
NASA NTRS2004

DSMC Simulations of Hypersonic Flows With Shock Interactions and Validation With Experiments

The capabilities of a relatively new direct simulation Monte Carlo (DSMC) code are examined for the problem of hypersonic laminar shock/shock and shock/boundary layer interactions, where boundary layer separation is an important feature of the flow. Flow about two model configurations is considered, where both configurations (a biconic and a hollow cylinder-flare) have recent published experimental measurements. The computations are made by using the DS2V code of Bird, a general two-dimensional/axisymmetric time accurate code that incorporates many of the advances in DSMC over the past decade. The current focus is on flows produced in ground-based facilities at Mach 12 and 16 test conditions with nitrogen as the test gas and the test models at zero incidence. Results presented highlight the sensitivity of the calculations to grid resolution, sensitivity to physical modeling parameters, and comparison with experimental measurements. Information is provided concerning the flow structure and surface results for the extent of separation, heating, pressure, and skin friction.

Moss, James N.↗
NASA NTRS2004

DSMC Simulations of Hypersonic Flows With Shock Interactions and Validation With Experiments

The capabilities of a relatively new direct simulation Monte Carlo (DSMC) code are examined for the problem of hypersonic laminar shock/shock and shock/boundary layer interactions, where boundary layer separation is an important feature of the flow. Flow about two model configurations is considered, where both configurations (a biconic and a hollow cylinder-flare) have recent published experimental measurements. The computations are made by using the DS2V code of Bird, a general two-dimensional/axisymmetric time accurate code that incorporates many of the advances in DSMC over the past decade. The current focus is on flows produced in ground-based facilities at Mach 12 and 16 test conditions with nitrogen as the test gas and the test models at zero incidence. Results presented highlight the sensitivity of the calculations to grid resolutions, sensitivity to physical modeling parameters, and comparison with experimental measurements. Information is provided concerning the flow structure and surface results for the extent of separation, heating, pressure, and skin friction.

Moss, James N.↗
NASA NTRS1996

Experimental and Analytical Study of Two-Phase Flow in Microgravity

Design of the two-phase flow systems which are anticipated to be utilized in future spacecraft thermal management systems requires a knowledge of two-phase flow and heat transfer parameters in reduced gravities. A program has been initiated by NASA to design a two-phase test loop and to perform a series of experiments to study the effect of gravity on the Critical Heat Flux (CHF) and onset of instability. The test loop is also instrumented to generate data for two-phase pressure drop. In addition to low gravity airplane trajectory testing, the experimental program consisted of a set of laboratory tests which were intended to generate data under the bounding conditions (+1 g and -1 g) in order to plan the test matrix. One set of airplane trajectory tests has been performed and several modifications to the test set-up have been identified. Preliminary test results have been used to demonstrate the applicability of the earth gravity models for prediction of the two-phase friction pressure drop.

McQuillen, John B.↗
NASA NTRS2003

Carbon-Based Wear Coatings: Properties and Applications

The technical function of numerous engineering systems - such as vehicles, machines, and instruments - depends on the processes of motion and on the surface systems. Many processes in nature and technology depend on the motion and dynamic behavior of solids, liquids, and gases. Smart surface systems are essential because of the recent technological push toward higher speeds, loads, and operating temperatures; longer life; lighter weight and smaller size (including nanotechnology); and harsh environments in mechanical, mechatronic, and biomechanical systems. If proper attention is not given to surface systems, then vehicles, machines, instruments, and other technical systems could have short lives, consume excessive energy, experience breakdowns, result in liabilities, and fail to accomplish their missions. Surface systems strongly affect our national economy and our lifestyles. At the NASA Glenn Research Center, we believe that proper attention to surface systems, especially in education, research, and application, could lead to economic savings of between 1.3 and 1.6 percent of the gross domestic product. Wear coatings and surface systems continue to experience rapid growth as new coating and surface engineering technologies are discovered, more cost-effective coating and surface engineering solutions are developed, and marketers aggressively pursue, uncover, and exploit new applications for engineered surface systems in cutting tools and wear components. Wear coatings and smart surface systems have been used widely in industrial, consumer, automotive, aerospace, and biomedical applications. This presentation expresses the author's views of and insights into smart surface systems in wear coatings. A revolution is taking place in carbon science and technology. Diamond, an allotrope of carbon, joins graphite, fullerenes, and nanotubes as its major pure carbon structures. It has a unique combination of extreme properties: hardness and abrasion resistance; adhesion and friction; thermal conductivity; chemical and thermal inertness; corrosion and wear resistance; radiation resistance and biocompatibility; electronic, acoustic, and electrochemical characteristics; and environmental compatibility. These properties make diamond attractive for a wide range of diverse applications. In particular, chemical-vapor-deposited (CVD) diamond coatings offer a broad potential, since size and cost are not as limiting. The production of large, superhard diamond films or sheets at low cost make designer materials possible. This presentation is divided into two sections: properties and applications of hard coatings. The first section is concerned with the fundamental properties of the surfaces of CVD diamonds and related materials. The surface properties of hard coatings with favorable coefficients of friction (less than or equal to 0.1) and dimensional wear coefficients (less than or equal to 10(exp -6) cubic millimeters/N.m) in specific environments are discussed. The second section is devoted to applications. Examples of actual, successful applications and of potential challenging applications of the coatings.such as CVD diamond, diamondlike carbon, and cubic boron nitride-are described. Cutting tools coated with CVD diamond are of immediate commercial interest. Other applications, such as microelectromechanical systems (MEMS), valves, and bearings of CVD diamond, are being developed, but at a slow pace. There is a continually growing interest in commercializing diamondlike carbon for wear parts applications, such as biomedical parts and implants, forming dies, transport guides, magnetic tapes and disks, valves, and gears. Cubic boron nitride films are receiving attention because they can be used on tools to machine ferrous materials or on wear parts in sliding contact with ferrous materials.

Miyoshi, Kazuhisa↗
NASA NTRS1993

Active suspension design for a Large Space Structure ground test facility

The expected future high performance requirements for Large Space Structures (LSS) enforce technology innovations such as active vibration damping techniques e.g., by means of structure sensors and actuators. The implementation of new technologies like that requires an interactive and integrated structural and control design with an increased effort in hardware validation by ground testing. During the technology development phase generic system tests will be most important covering verification and validation aspects up to the preparation and definition of relevant space experiments. For many applications using advanced designs it is deemed necessary to improve existing testing technology by further reducing disturbances and gravity coupling effects while maintaining high performance reliability. A key issue in this context is the improvement of suspension techniques. The ideal ground test facility satisfying these requirements completely will never be found. The highest degree of reliability will always be obtained by passive suspension methods taking into account severe performance limitations such as non-zero rigid body modes, restriction of degrees of freedom of motion and frequency response limitations. Passive compensation mechanisms, e.g., zero-spring-rate mechanisms, either require large moving masses or they are limited with respect to low-frequency performance by friction, stiction or other non-linear effects. With active suspensions these limitations can be removed to a large extent thereby increasing the range of applications. Despite an additional complexity which is associated with a potential risk in reliability their development is considered promising due to the amazing improvement of real-time control technology which is still continuing.

Lange, Thomas J. H.↗
NASA NTRS1999

Aeolian Sand Transport in the Planetary Context: Respective Roles of Aerodynamic and Bed-Dilatancy Thresholds

The traditional view of aeolian sand transport generally estimates flux from the perspective of aerodynamic forces creating the airborne grain population, although it has been recognized that "reptation" causes a significant part of the total airborne flux; reptation involves both ballistic injection of grains into the air stream by the impact of saltating grains as well as the "nudging" of surface grains into a creeping motion. Whilst aerodynamic forces may initiate sand motion, it is proposed here that within a fully-matured grain cloud, flux is actually governed by two thresholds: an aerodynamic threshold, and a bed-dilatancy threshold. It is the latter which controls the reptation population, and its significance increases proportionally with transport energy. Because we only have experience with terrestrial sand transport, extrapolations of aeolian theory to Mars and Venus have adjusted only the aerodynamic factor, taking gravitational forces and atmospheric density as the prime variables in the aerodynamic equations, but neglecting reptation. The basis for our perspective on the importance of reptation and bed dilatancy is a set of experiments that were designed to simulate sand transport across the surface of a martian dune. Using a modified sporting crossbow in which a sand-impelling sabot replaced the bolt-firing mechanism, individual grains of sand were fired at loose sand targets with glancing angles typical of saltation impact; grains were projected at about 80 m/s to simulate velocities commensurate with those predicted for extreme martian aeolian conditions. The sabot impelling method permitted study of individual impacts without the masking effect of bed mobilization encountered in wind-tunnel studies. At these martian impact velocities, grains produced small craters formed by the ejection of several hundred grains from the bed. Unexpectedly, the craters were not elongated, despite glancing impact; the craters were very close to circular in planform. High-speed photography showed them to grow in both diameter and depth after the impactor had ricochetted from the crater site. The delayed response of the bed was "explosive" in nature, and created a miniature ejecta curtain spreading upward and outward for many centimeters for impact of 100-300 micron-diameter grains into similar material. Elastic energy deposited in the bed by the impacting grain creates a subsurface stress regime or "quasi-Boussinesq" compression field. Elastic recovery of the bed occurs by dilatancy; shear stresses suddenly convert the grains from closed to open packing, and grains are consequently able to eject themselves forcefully from the impact site. Random jostling of the grains causes radial homogenization of stress vectors and a resulting circular crater. There is a great temptation to draw parallels with cratering produced by meteorite impacts, but a rigorous search for common modelling ground between the two phenomena has not been conducted at this time. For every impact of an aerodynamically energized grain, there are several hundred grains ejected into the wind for the high-energy transport that might occur on Mars. Many of these grains will themselves become subject to the boundary layer's aerodynamic lift forces (their motion will not immediately die and add to the creep population), and these grains will become indistinguishable from those lifted entirely by aerodynamic forces. As each grain impacts the bed, it will eject even more grains into the flow. A cascading effect will take place, but because it must be finite in its growth, damping will occur as the number of grains set in motion causes mid-air collisions that prevent much of the impact energy from reaching the surface of the bed -thus creating a dynamic equilibrium in a high-density saltation cloud. It is apparent that for a given impact energy, the stress field permits a smaller volume of grains to convert to open packing as the size of the bed grains increases, or as the energy of the "percussive" grain decreases (by decrease in velocity or mass). Thus, the mass of the "repercussive" grain population that is ejected from the impact site becomes a function of the scale of the stress field in relation to the scale of the bed material (self-similarity being applicable if both bed size and energy are simultaneously adjusted). In other words, in a very high energy aeolian system where an aerodynamically raised grain can ballistically raise many more grains, the amount of material lifted into the wind becomes largely a function of a dilatancy threshold. If this threshold is exceeded, grains are repercussively injected into the saltation cloud. The "dilatancy threshold" may be defined in terms of the saltation percussive force required to convert the bed, through elastic response, from a closed to an open packing system. If open packing cannot be created, the grains cannot escape from the impact site, even though the elastic deformation and percussive force may be able to reorganize the grains with respect to one another. As the crossbow experiments showed, for an ever-increasing bed grain size, a point is reached when no material can be moved because the energy of the percussive grain is insufficient to dilate the relatively coarse bed. Although this seems to be stating the obvious -- that too little energy will not cause the bed to splash -- the consequences of exceeding the "splash threshold" by dilatancy are not so obvious for high-energy aeolian transport. It is noted that the force required to elastically dilate the bed has to overcome Coulombic grain attractions such as dipole-dipole coupling, dielectric, monopole, contact-induced dipole attractions, van der Waals forces, molecular monolayer capillary forces, as well as the mechanical interlocking frictional resistance of the grains. On Mars, it is predicted that the dilatancy threshold may be the prime control of grain flux. Additional information is contained in the original.

Marshall, J. R.↗
NASA NTRS1990

Micro Blowing Simulations Using a Coupled Finite-Volume Lattice-Boltzman n L ES Approach

Three dimensional large-eddy simulations (LES) of single and multiple jet-in-cross-flow (JICF) are conducted using the 19-bit Lattice Boltzmann Equation (LBE) method coupled with a conventional finite-volume (FV) scheme. In this coupled LBE-FV approach, the LBE-LES is employed to simulate the flow inside the jet nozzles while the FV-LES is used to simulate the crossflow. The key application area is the use of this technique is to study the micro blowing technique (MBT) for drag control similar to the recent experiments at NASA/GRC. It is necessary to resolve the flow inside the micro-blowing and suction holes with high resolution without being restricted by the FV time-step restriction. The coupled LBE-FV-LES approach achieves this objectives in a computationally efficient manner. A single jet in crossflow case is used for validation purpose and the results are compared with experimental data and full LBE-LES simulation. Good agreement with data is obtained. Subsequently, MBT over a flat plate with porosity of 25% is simulated using 9 jets in a compressible cross flow at a Mach number of 0.4. It is shown that MBT suppresses the near-wall vortices and reduces the skin friction by up to 50 percent. This is in good agreement with experimental data.

Menon, S.↗
NASA NTRS1986

Evaluation of transfer films of Salox M on 440C for HPOTP bearing cage applications, task 119

The objective of the task was to evaluate the suitability of a bronze-filled polytetra fluoroethylene (Salox M) as the cage material in Space Shuttle Main Engine (SSME) high pressure oxygen turbo pump (HPOTP) bearings. The role of the cage pocket material will be to provide a transferred lubricating interface at the ball-race contact region. A series of experiments was conducted which involved block-on-ring tests (the block was the polytetrafluoroethylene (PTFE) -filled material and the ring was through-hardened 440C steel) and high speed traction tests of two 440C disks with one disk rubbed with a PTFE block to generate a transfer film. Measurements included post test visual observations of the condition of the 440C, wear rate measurements of the blocks, and traction measurements between the disks. It was observed that both Salox M and glass-filled PTFE (Armalon) transferred PTFE to 440C at cryogenic temperatures. Bronze is also transferred to uncoated 440C from the Salox M. At room temperature no PTFE transfer was observed in the high speed disk tests due to severe frictional heating, although bronze transfer still occurred with the bronze-PTFE Salox M material. Since the bearing will operate at cryogenic temperature, transfer films are very probable. Salox M wore slightly, although probably tolerably, more than glass-filled PTFE against 440C. However, Salox M is clearly less abrasive to 440C than is the glass-filled material. When the surface layer of PTFE is depleted from the glass-filled material, the glass fibers tend to seriously abrade the steel. This problem does not occur with Salox M. The surface roughness studies indicate that smooth balls are quite reasonable for transfer films. No significant difference in wear rates of the candidate cage materials was observed when the 440C surface finish was increased from 0.025 micron to 0.1 micron cla. At higher levels of roughness, the wear rate increased. Two surface coatings (MoS2 and TiN) were tested. The surface coatings tended to reduce the Salox M wear rate and reduce bronze transfer. PTFE transfer at cryogenic temperatures still occurred with the surface coatings. Two cage design concepts are presented utilizing Salox M material. One design involves a metal-reinforced Salox M cage, while the second design uses Salox M inserts in a metal structure.

Barber, S. A.↗
NASA NTRS2017

Dawn Spacecraft Performance at Ceres: Results of Hybrid Control for Ceres Mapping

Dawn is a low-thrust interplanetary spacecraft currently orbiting the dwarf planet Ceres, to better understand the early creation of the solar system. Launched in September 2007, Dawn arrived at Vesta in July 2011. After a 16-month successful science campaign at Vesta, Dawn departed for Ceres, arriving in early 2015. The Dawn spacecraft uses both reaction wheel assemblies (RWA) and a reaction control system (RCS) to provide 3-axis attitude control for the spacecraft. Reaction wheels were designed to be the primary system for attitude control, however two wheels have shown high friction anomalies and have been removed from service. The project has implemented a hybrid control algorithm using two reaction wheels and RCS thrusters. This hybrid control capability enabled Dawn to achieve very high science return, while significantly conserving remaining hydrazine propellant. With only two remaining healthy RWA’s, hybrid control became part of the baseline plan for Ceres science operations. The Dawn team developed specific operational approaches in which sequences were developed with careful consideration of science versus resource trades. Commanding and sequence planning also incorporated contingency planning, in the event that another reaction wheel may fail. Despite the differences in operational approach between Vesta and Ceres, both campaigns achieved very rich scientific data return. This paper highlights Dawn’s recent flight experience with hybrid attitude control during Ceres orbit operations. The discussion includes the approaches utilized by the Dawn team to address unique operational challenges presented by the hybrid approach, and reviews spacecraft performance under hybrid control in low orbit at Ceres. Additionally, methods used to optimize hydrazine use and thereby extend the science campaign will be presented. Finally, a preliminary assessment of an orbit transfer with two reaction wheels, during extended mission operations, is discussed.

Smith, Brett A.↗
NASA NTRS1985

Investigation of instability, dynamic forces, and effect of dynamic loading on strength of cages for the bearings in the high pressure oxygen turbopumps for the space shuttle main engine

Experiments were performed to determine the effect of cyclic loading on bearing cage strength. A long term working tensile load of approximately 1300 N (300 lbs) was found to be the likely maximum. Higher loads caused a decrease in cage tensile strength after the 125,000 cycle testing period. Poisson's ratio in compression was found to be highly dependent upon the direction of the fiberglass plies. At room temperature the value was 0.15 with the plies and 0.68 across the plies. At -196 C (-321 F), the value with the plies was 0.20. The results of the analyses conducted have again demonstrated the critical need for improved lubrication in the high pressure oxygen turbopump bearings. Lubricant films with low shear strength and low friction coefficients promote cage stability and decrease ball/cage forces during marginal operating conditions. The analysis of the effect of combined bearing loads on ball/cage loads has identified a radial load of 3600 N (800 lbs) as the maximum for the current clearance of the balls and cage pockets. Liquid oxygen impinging on the cage in the direction of rotation was found to enhance cage stability.

Dufrane, K. F.↗
NASA NTRSDate not supplied

Modal Correlation of Complex Aerospace Joints Using Automated Variable Substitution

A critical task involved with being able to predict flight loads accurately in aerospace finite element models (FEMs) is the prior verification of the FEMs by conducting modal survey testing (MST). Experience comparing dynamic response of initial FEMs to MST data tends to demonstrate that FEMs can have unacceptable accuracy even when best modeling practices are followed. One inherent source of inaccuracy in linear dynamic FEMs is the modeling of nonlinear joints with mechanisms such as spherical bearings. These joints are usually designed to freely translate or rotate under the high levels of loading experienced in flight. Engineers who create linear FEMs conventionally model these joints without any stiffness in the mechanism degrees of freedom to meet this design intent. However, inaccuracy is observed during test validation of these FEMs, which usually relies on low-level force excitation orders of magnitude below flight load levels. This low-level modal test rarely overcomes the joint friction that is present, and thus the mechanism joints are able to react loads. This divide between the test results and the FEM creates a significant challenge to the engineer who is performing the correlation, in that the engineer has no basis for what stiffness value should be used to make the FEM match the test results. A compounding challenge is that complicated built-up aerospace structures commonly have multiple joints through a load path where each joint will “stick” and “slip” at different levels of force input. Explicitly matching the dynamics of a system containing these nonlinear mechanisms would require a nonlinear FEM, which is prohibitively costly for dynamic simulations of most aerospace systems. The objective of this paper is to present a workflow that can efficiently cycle through many iterations of a FEM, allowing a Monte Carlo style examination of the design space to identify candidate stiffness values for nonlinear mechanism joints. The outlined approach is specific to MSC Nastran and utilizes MSC Nastran’s symbolic substitution capabilities, coupled with the IMAT™ and Attune™ software packages developed by ATA Engineering, Inc. (ATA). The workflow is demonstrated with a case study from the correlation effort for The Boeing Company’s Crew Space Transportation (CST)-100 Starliner FEM. Keywords: Correlation, MSC Nastran, IMAT™, Attune™, Finite Element Model, Modal Testing

Correlation↗
NASA NTRS1973

Rock physics properties of some lunar samples

Linear strains and acoustic velocity data for lunar samples under uniaxial and hydrostatic loading are presented. Elastic properties are presented for 60335,20; 15555,68; 15498,23; and 12063,97. Internal friction data are summarized for a number of artificial lunar glasses with compositions similar to lunar rocks 12009, 12012, 14305, 15021, and 15555. Zero porosity model-rock moduli are calculated for a number of lunar model-rocks, with mineralogies similar to Apollo 12, 14, and 16 rocks. Model-rock calculations indicate that rock types in the troctolitic composition range may provide reasonable modeling of the lunar upper mantle. Model calculations involving pore crack effects are compatible with a strong dependence of rock moduli on pore strain, and therefore of rock velocities on nonhydrostatic loading. The high velocity of rocks under uniaxial loading appears to be compatible with, and may aid in, interpretation of near-surface velocity profiles observed in the active seismic experiment.

Warren, N.↗
NASA NTRS1994

Rotordynamic forces in labyrinth seals: Theory and experiment

A theoretical and experimental investigation of the aerodynamic forces generated by a single gland labyrinth seal executing a simultaneous spinning/whirling motion has been conducted. A lumped parameter model for a single gland seal with coupling to an upstream cavity with leakage is developed along with an appropriate solution technique. From this theory, it is shown that the presence of the upstream cavity can, in some cases, augment the cross-stiffness and direct damping by a factor of four. The parameters that govern the coupling are presented along with predictions on their influence. A simple uncoupled model is used to identify the mechanisms responsible for cross force generation. This reduced system is nondimensionalized and the physical significance of the reduced parameters is discussed. Closed form algebraic formulas are given for some simple limiting cases. It is also shown that the total cross-force predicted by the uncoupled model can be represented as the sum of an ideal component due to an inviscid flow with entry swirl and a viscous part due to the change in swirl created by friction inside the gland. The frequency dependent ideal part is solely responsible for the rotordynamic direct damping. The facility designed and built to measure these frequency dependent forces is described. Experimental data confirm the validity and usefulness of this ideal/viscous decomposition. A method for calculating the damping coefficients based on the force decomposition using only the static measurements is presented. Experimental results supporting the predicted cross force augmentation due to the effect of upstream coupling are presented.

Millsaps, Knox T.↗
NASA NTRS1998

Transition in Turbine Flows

We have further developed our capabilities to analyze transition in turbine boundary layers from first principles by integrating the nonlinear parabolized stability equations (PSE) with improved initial and boundary conditions. With modified iteration schemes, we are able to proceed deeper into the transition region where skin friction coefficient and heat transfer coefficient significantly increase. Initial and boundary conditions at elevated turbulence levels can be derived by receptivity analysis. Test runs for ERCOFTAC test case T3A at 2.4\% turbulence level provide results in good agreement with the experimental data. The sharper minimum of the skin coefficient also shown by DNS results is likely due to the missing intermittency. The method has been applied to various experimentally studied turbine blades (UTRC, VKI, Zierke, Langston, Hippensteele, and others). The PSE results, though physically reasonable, do not agree as well as expected with the experimental findings. We have, therefore, performed an extensive search for the reasons of the seemingly systematic deviations. A first source of uncertainty has been found in the often insufficient documentation of the experiments (e.g. on blockage by end-wall boundary layers). However, variation of the relevant parameters does not lead to more satisfactory agreement. A second reason has been found in the "standard procedure" which considers a 2D flow at midspan and uses a panel code and subsequent boundary-layer code to obtain the laminar basic flow for the transition analysis. Comparison with the pressure distribution obtained with a 3D design code (RVC3D) shows significant three-dimensionality of the flow (e.g. in the UTRC experiments). The spanwise variation has been neglected in our original PSE code. To overcome this problem, we have developed the PSE/3D for fully 3D boundary layers to account for streamwise and spanwise variations. Since the design code does not provide the boundary-layer flow with sufficient resolution, we have generated the Euler solution and employed a 3D boundary-layer code to obtain the viscous basic flow. Although only the linear stability level of PSE/3D has been implemented so far, the discrepancies with the experiments change but do not disappear. We still find deviations between the computed and experimental variations of C(sub f), and St along the blade for laminar flow. The main reason can be seen by comparing the solution of the boundary-layer code with the viscous results of the design code. The conventional boundary-layer solution exhibits an asymptotic behavior appropriate in external aerodynamics but does not match the steep gradients of the inviscid flow through the passage and consequently provides biased results for C(sub f), and St. An attempt is currently being made to correct this deficiency. Before attempting to perform the transition analysis for the viscous flow provided by the design code, we have analyzed the implementation and "best possible" results. Code and results exhibit flaws that may negatively affect the design and are intolerable for transition analysis. Therefore, we have decided to develop a new code to obtain a reliable basis for stability and transition studies. We expect to report improved results by the time of the meeting.

Herbert, Thorwald↗
NASA NTRS1999

Radio Frequencies Emitted by Mobile Granular Materials: A Basis for Remote Sensing of Sand and Dust Activity on Mars and Earth

In recent laboratory experiments, measurements were made of microsecond radio-wave (RF) bursts emitted by grains of sand as they energetically circulated in a closed, electrically ungrounded chamber. The bursts appeared to result from nanoscale electrical discharging from grain surfaces. Both the magnitude and wave form of the RF pulses varied with the type of material undergoing motion. The release of RF from electrical discharging is a well-known phenomenon, but it is generally measured on much larger energy scales (e.g., in association with lightning or electrical motors). This phenomenon might be used to detect, on planetary surfaces, the motion and composition of sand moving over dunes, the turbulent motion of fine particles in dust storms, highly-energetic grain and rock collisions in volcanic eruptions, and frictional grinding of granular materials in dry debris flows, landslides, and avalanches. The occurrence of these discharges has been predicted from theoretical considerations Additional information is contained in the original.

Marshall, J.↗