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At least 613 records · Page 34

Flow Visualization of Intrusive and Non-Intrusive Configurations for Lunar- and Martian-Relevant Plume-Surface Interaction

Flow visualization of a heated, inert-gas plume impinging onto a rigid surface was performed in lunar- and Martian-relevant pressure conditions. The experimental campaign was part of a broader effort to improve predictive models and capabilities for plume-surface interactions in spacecraft landing environments relevant to the Moon and Mars. The experiments used the planar laser-induced fluorescence (PLIF) technique to visualize the flow of the jet over both a full-space configuration using a flat impingement plate and a half-space configuration where the jet flow was bisected by a splitter edge mounted to the impingement plate. The latter configuration has been previously used to study erosion mechanisms in plume-surface interactions because the technique enables cross-sectional optical access for visualizing the plume-induced crater. However, this approach has some uncertainty regarding the influence of the splitter edge on the flow field. The present work evaluates the differences in flow structures and characteristics between the flat plate and splitter plate experimental configurations at eight unique test conditions with and without the splitter edge where the vacuum chamber pressure, nozzle mass flow rate, and height of the nozzle were varied. Several features are identified which differ between the flat plate and splitter plate comparison cases, and these are summarized in this paper. The results presented provide insights to the differences between intrusive and non-intrusive experimental configurations for plume-surface interaction studies that can be used to further validate predictive models and inform future ground and flight test results.

PLIF↗

Analysis of Launch Vehicle Liftoff Debris: Historical Perspective from Space Shuttle and Application to Artemis I

Human exploration-class launch vehicles are inherently prone to debris due to the extreme environments generated during pre-launch operations, liftoff, and flight. The use of cryogenic propellants often requires thermal protection system (TPS) coatings, typically foam, to maintain the propellant conditions in the tank and prevent an accumulation ice on the external surface of the vehicle. Some ice growth is to be expected at umbilical interfaces, vents, flanges, or brackets where it is difficult to apply TPS. This ice may come loose at any time due to wind on the launch pad, structural vibration and acoustics after rocket ignition, or aerodynamic forces during flight. This phenomena is especially apparent on vehicles with no TPS, such as the Saturn V rockets used in the Apollo Program, see Figure 1. During propellant tanking, the thermal contraction of the underlying substrate may generate cracks in the TPS (Figure 1). Chunks of TPS can release due to the expansion of ingested gas from cryopumping or from aerodynamic forces if the crack creates an offset surface. Most foams will also have a certain amount of “popcorning” where small pieces of foam will pop off during flight because of the differential between the static surface pressure and the pressure of the gas trapped in the foam cell structure. There are a number of other coating or closeout materials that may be shed from the vehicle and become debris. During pre-launch operations and liftoff, the vehicle may also be exposed to debris originating from the launch pad or ground support equipment. This debris is separate from foreign object debris, or FOD, which is not intended to be present and is strictly controlled through operations and maintenance procedures. In this case, debris is generated from hardware and materials that are necessary for launch and are subject to the intense vibration, acoustics, and direct plume impingement of the launch environment. Examples include ice from umbilicals, tape and tie wraps that protect cables, and rust or corrosion from the launch platform. While NASA has historically been aware of debris as a potential issue that could cause a failure resulting in loss of mission, loss of vehicle, or loss of crew, the likelihood and severity of that risk was not always well understood or given sufficient weight in program and flight decisions. After the Space Shuttle Columbia accident (STS-107), the investigation found that foam TPS debris shed from the external tank was the proximate cause of the damage to the orbiter wing. Six previous observations of debris released from the foam ramp that covered the bipod connecting the forward end of the orbiter to the external tank resulted in minor changes or were determined to be accepted flight risks. Two occurrences of bipod ramp foam loss were not identified until the STS-107 investigation. Despite the damage inflicted by these debris strikes, the Shuttle Program Requirements Control Board deemed the vehicle safe to fly. During the Return to Flight effort following the Columbia disaster, NASA Engineering developed a process for the assessment of debris transport, impact, and damage tolerance to support independent assessments of risk by NASA Safety and Mission Assurance (S&MA). Under this system, each element (vehicle or ground system) defines a catalog of all expected debris based on launch history, component testing, or analysis. Debris transport analysis (DTA) is conducted using the debris catalog characteristics and potential flow transport mechanisms (e.g., vehicle aerodynamics, gravity, wind, plume-driven). The predicted debris impact locations and velocities are provided to the hardware owners, who use available test data and analysis to determine whether each component can withstand the impacts. In cases where the element hardware may be severely damaged or fail, the options are to mitigate the debris source through some change in design or operation, or to work with S&MA to try to characterize the probability of the impact and damage for program risk acceptance. Because of the differences in debris characteristics and transport, the DTA has been divided between the Liftoff and Ascent regimes. The development and application of Liftoff DTA methodology from the Shuttle Program to the current Artemis Program is the subject of this paper. Liftoff DTA covers the time from the start of pre-launch operations at the launch pad, up until the vehicle clears the launch tower and there is no longer any interaction with ground systems. Debris transport during this period is broadly classified as either gravity, wind, and plume-entrained (GWPE) or plume driven (PD). GWPE debris is generally lower speed, travelling in a forward-to-aft direction. PD transport includes flow features from the rocket ignition transient, as well as plume impingement and recirculation that occur as the vehicle lifts off the launch platform. In these cases, the debris typically moves in an aft-to-forward direction at higher speeds. The applicable transport mechanisms must be considered for each piece of debris depending on the material, and release location and time. For example, rust or metallic debris from the tower could fall (GWPE) and impact the vehicle before landing on the launch platform deck where it could be also be transported by plume impingement (PD). However, falling ice (GWPE) from an umbilical is unlikely to survive impact with the vehicle or launch platform and be available for PD transport. Modeling of debris transport is accomplished using a set of DTA tools which simulate debris trajectories subject to a reference frame acceleration (i.e., gravity) and aerodynamic drag. Where the trajectory encounters a solid surface, the debris is allowed to rebound with a specified coefficient of restitution. The drag is calculated by interpolating the fluid state at each point in the debris trajectory from high-fidelity computational fluid dynamics (CFD) simulations of the launch vehicle and pad. The CFD data may either be static (steady state or time averaged), typically for GWPE transport, or dynamic (time-accurate) for PD flow features like the ignition transient. Examples of the CFD flow field solutions for the Space Launch System (SLS) rocket and launch pad are shown in Figure 2. Typical SLS debris trajectory predictions from DTA are illustrated in Figure 3. The final version of this paper will include a more detailed examination of the Liftoff DTA process developed during the Shuttle Program, and how it has been augmented and applied to the SLS rocket under the Artemis Program. Comparisons with debris observations from the Artemis I launch will demonstrate validation of the tools and methodology.

Debris↗

X-ray spectrometer and methods for use

A spectrometer includes a crystal analyzer having a radius of curvature that defines a Rowland circle, a sample stage configured to support a sample such that the sample is offset from the Rowland circle, an x-ray source configured to emit unfocused x-rays toward the sample stage, and a position-sensitive detector that is tangent to the Rowland circle. A method performed via a spectrometer includes emitting, via an x-ray source, unfocused x-rays toward a sample that is mounted on a sample stage such that the sample is offset from the Rowland Circle, thereby causing the sample to emit x-rays that impinge on the crystal analyzer or transmit a portion of the unfocused x-rays to impinge on the crystal analyzer; scattering, via the crystal analyzer, the x-rays that impinge on the crystal analyzer; and detecting the scattered x-rays via a position-sensitive detector that is tangent to the Rowland circle.

Seidler, Gerald Todd↗

Cooling insert for a turbomachine

Integrated combustor nozzles and turbomachines are provided. An integrated combustor nozzle includes a cooling insert having a flange. The cooling insert further includes a first wall and a second wall that each define respective passages therein. The first wall and the second wall each extend from an open end defined within the flange to a closed end. The first wall and the second wall each include an impingement side spaced apart from a solid side. Each impingement side defines a plurality of impingement apertures configured to direct coolant from the respective passage towards a side wall of the combustion liner. The cooling inserts further includes a collection passageway that is defined between the solid sides of the first wall and the second wall.

Berry, Jonathan Dwight↗

X-ray spectrometer and methods for use

A spectrometer includes a crystal analyzer having a radius of curvature that defines a Rowland circle, a sample stage configured to support a sample such that the sample is offset from the Rowland circle, x-ray source configured to emit unfocused x-rays toward the sample stage, and a position-sensitive detector that is tangent to the Rowland circle. A method performed via a spectrometer includes emitting, via an x-ray source, unfocused x-rays toward a sample that is mounted on a sample stage such that the sample is offset from the Rowland Circle, thereby causing the sample to emit x-rays that impinge on the crystal analyzer or transmit a portion of the unfocused x-rays to impinge on the crystal analyzer; scattering, via the crystal analyzer, the x-rays that impinge on the crystal analyzer; and detecting the scattered x-rays via a position-sensitive detector that is tangent to the Rowland circle.

Seidler, Gerald Todd↗

Automotive Silicon Carbide Power Module Cooling With A Novel Modular Manifold And Embedded Heat Sink

The next generation of integrated power electronics packages will implement wide-bandgap devices with ultrahigh device heat fluxes. Although jet impingement has received attention for power electronics thermal management, it is not used in commercial electric vehicles (EVs) because of the associated pressure drop and reliability concerns. Here, in this paper, we present a modular thermal management system designed for automotive power electronics. The system achieves superior thermal performance to benchmarked EVs, while adhering to reliability standards and with low pumping power. The system utilizes a low-cost and lightweight plastic manifold to generate jets over an optimized heat sink, which is embedded in the direct-bonded-copper (DBC) substrate. The embedded heat sink concept leverages additive manufacturing to add elliptical pin fins to the DBC substrate. The heat sink geometry is optimized for submerged jet impingement using a unit-cell model and an exhaustive search algorithm. The model predictions are validated using unit-cell experiments. A full-scale power module model is then used to compare the DBC-embedded heat sink against direct DBC cooling and baseplate-integrated heat sinks for single-sided (SS) and double-sided (DS) cooling concepts. Using the SS and DS DBC-embedded cooling concepts, the models predict a thermal resistance that represents a reduction of 75% and 85% compared to the 2015 BMW i3, respectively, for the same water-ethylene glycol inverter flow rate. We have shown that an inverter with a 100-kilo-Watt-per-liter power density is achievable with the proposed design.

33 ADVANCED PROPULSION SYSTEMS↗

Computational Study of Additively Manufactured Internally Cooled Airfoils for Industrial Gas Turbine Applications

Internal cooling features such as pin-fins, impingement jets, and rib-turbulators are necessary to keep turbine components cool, but if sufficiently advanced can potentially also eliminate the need for film cooling on turbine blades particularly in industrial gas turbines where temperatures are not extreme. Furthermore, by leveraging additive manufacturing, other advanced designs such as lattice and incremental impingement configurations are possible and have recently been experimentally tested. While the performance of such configurations has been quantified through means of overall cooling effectiveness, it is not as clear why certain designs were better than others, or what the mechanisms were behind the observed external cooling patterns. The purpose of this study was to computationally analyze different advanced turbine blade internal cooling designs previously tested by the National Energy Technology Laboratory.

CFD↗

Thermal Optimization of a Silicon Carbide, Half-Bridge Power Module

This project describes the modeling process to design the packaging and heat exchanger for a half-bridge wide-bandgap (WBG) power semiconductor module. The module uses two silicon carbide, metal-oxide-semiconductor field-effect transistor (MOSFET) devices per switch position that are soldered to an aluminum nitride, direct-bond copper (DBC) substrate. A baseplate cooling configuration (e.g., no thermal grease) is used along with a water-ethylene glycol, jet-impingement-style heat exchanger. The heat exchanger was designed to be fabricated using prototyping equipment from the National Renewable Energy Laboratory, complies with automotive standards (for minimal channel sizes, flow rates, and coolant), and considers reliability aspects (i.e., erosion/corrosion). Device-scale computational fluid dynamics (CFD) is used first to design the slot jet impingement cooling configuration and compute the effective heat transfer coefficient (HTC) of the concept. The computed HTCs are then used as boundary conditions for a finite element study to optimize the package geometry (e.g., device layout and baseplate thickness) to minimize thermal resistance and minimize temperature variation between the module's four devices. Finally, a fluid manifold is designed to generate the slot jets and cool the devices. Module-scale CFD predicts a relatively low junction-to-fluid thermal resistance of 16.7 mm2 K/W, a 1.4 degrees C temperature variation between devices, and a total pressure drop of 5,860 Pa (0.85 psi) for the design. The thermal resistance of the module design is about 67% lower than the 2015 BMW i3 power electronics/modules thermal resistance.

DIRECT ENERGY CONVERSION↗

Computational Icing Risk Analysis of the D8 "Double Bubble" Aircraft

A computational icing risk analysis utilizing LEWICE3D was performed for the D8 Double Bubble aircraft. A variety of discrete drop sizes spanning the Appendix C and O regimes were simulated. For computational efficiency a 50-bin global discretization was produced and projected onto the distributions of interest, eliminating redundant simulations. The trajectory and impingement characteristics for discrete drop diameters were analyzed to help understand the behavior of the water drops in the presence of a complex flow field. The collection efficiency results for the discrete drop diameters were then weighted by their contributions to the total water content of six different continuous distributions and subsequently superposed to approximate these curves. Results indicate that significant variation in impingement exists as a function of drop diameter for complex wing body geometries, and that current discretization practices may be insufficient to accurately predict water collection on certain regions of the aircraft. Results also indicate that the Appendix O distributions, specifically those with considerable water content at large drops, generates water collection patterns that are markedly different from distributions representative of Appendix C.

icing↗

A comparative study of mechanical and chemical durability of non-wetting superhydrophobic and lubricant-infused surfaces

Fabrication of bioinspired non-wetting superhydrophobic surfaces (SHS) and lubricant-infused surfaces (LIS) has been studied extensively on a variety of materials. In contrast, durability of the surfaces exposed to harsh mechanical and chemical environments has been the subject of little attention. This study considers the mechanical and chemical durability of SHS and LIS copper surfaces fabricated via facile electrodeposition and chemical etching methods. The as-fabricated surfaces demonstrate excellent non-wetting characteristics with water contact angle of 160° and sliding angle below 5°. The surfaces are subject to mechanical wear through scratch test and water jet impingement at 15 psi and 20 psi as well as accelerated corrosion following the ASTM-E407 standard. The performance of the electrodeposited and etched non-wetting surfaces is systematically assessed in terms of contact and sliding angles and corrosion rate in a simulated marine environment. All surfaces are shown to be robust to mechanical wear after scratch test, with excellent stability of contact and sliding angles, and up to two orders of magnitude reduced corrosion rate compared to bare copper surface. SHS retained steadfast non-wetting characteristics under high-pressure water jet tests compared to the other surfaces while LIS, regardless of texturing method, showed one to two orders of magnitude reduced corrosion rate compared to bare copper surface throughout water jet impingement and chemical durability tests. The study presents for the first time a systematic comparison of durability of SHS and LIS through a common set of fabrication and testing protocol and helps identify appropriate non-wetting surfaces and fabrication methods based on the use environment.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

Investigation of crossed-twin structure formation in magnesium and magnesium alloys

In this work, the effect of alloying addition on the propensity for twin-twin interactions to transform into crossed-twin structures in magnesium alloys is investigated. A full-field elasto-viscoplastic fast Fourier transform (EVP-FFT) framework combined with a discrete twin model and dislocation density-based hardening law for slip strengths is used to calculate the micromechanical fields in the crystalline matrix around the interacting twins. AZ31 and MgLi alloys are selected along with pure Mg to study the influence of plastic anisotropy in connection with alloying elements. These alloys were selected since their plastic anisotropy measure, which is defined as the ratio between the critical resolved shear stress for pyramidal $\langle$c +a$\rangle$ and basal $\langle$a$\rangle$ slip modes, spanned a wide range. To quantify the role of twin thicknesses, we probe a range of impinging twin thicknesses while fixing the recipient twin thickness. The analysis reveals that: (i) the local driving stress for crossed twin structure formation generated from the interaction of the two twins is lower in a low plastically anisotropic material, like a MgLi alloy, than a high plastically anisotropic material like pure Mg and (ii) the critical impinging twin thickness needed to form the crossed twin structure in pure Mg, AZ31 and MgLi alloys is ~0.5, ~0.75 and ~1.5 times the recipient twin thickness. We propose a relationship between the tendency for crossed twin structure formation and the experimentally observed higher ductility in MgLi alloys compared to pure Mg. Finally, one key implication of the findings is that crossed- twin structure formation can be hindered and the ductility of magnesium alloy thereby improved by properly choosing alloying elements that lower the slip strength for pyramidal $\langle$c + a$\rangle$ slip.

36 MATERIALS SCIENCE↗

Fabrication and durability characterization of superhydrophobic and lubricant-infused surfaces

Hypothesis: Practical applications of non-wetting surfaces require good mechanical durability in the wet environments for which they are intended to be used. Durability of non-wetting surfaces is influenced by the surface features, interaction with the functionalization agent, and the lubricant properties that can be tuned independently to identify optimal combination. Experiments: In this study, superhydrophobic and lubricant-infused surfaces are fabricated on copper tubes using chemical etching and electrodeposition texturing techniques, six different functionalizing agents, and five different infused lubricants. Through 180 fabrication combinations and 102 durability tests, each parameter is systematically studied for contributions to initial non-wetting behavior and its durability in heated, wet environment, under high-energy water jet impingement, and under accelerated flow conditions. Findings: Among the adsorbing and curing functionalization agents investigated, n-Hexadecyl mercaptan that belongs to the sulfhydryl group and Sylgard-184, respectively, showed high durability in heated water immersion and under jet impingement tests. For lubricant-infused surfaces, lubricants with high surface tension demonstrated high durability in heated water immersion test, whereas durability in hydrodynamic conditions is closely correlated to lubricant viscosity. Results showed that a lubricant-infused surface will maintain its non-wetting properties in dropwise condensation conditions for approximately 1.5 years.

36 MATERIALS SCIENCE↗

Twinning pathways enabled by precipitates in $\mathrm{AZ91}$

While precipitates have been shown to substantially strengthen magnesium alloys by blocking the glide of dislocations inside the grain, the interactions between these precipitates and deformation twins, which commonly occur in these alloys, are much less understood. Here, in this work, an elasto-viscoplastic fast-Fourier-transform (EVP-FFT) model is used to study the interactions between plate-shaped basal precipitates and propagating $10\bar{1}2$ tensile twins in AZ91 Mg alloy. The results suggest that while precipitates may impede the propagation and thickening of twins, they can also cause stress localizations that can promote the formation of multiple new twins of the same or different crystallographic variants. We show that the location of the twin-precipitate interaction site, whether precipitate-central or precipitate-edge impingement, and the thickness of the precipitate can influence the propensity for twins to expand around the precipitate or nucleate a new twin on the other side of it. Depending on the twin-precipitate impingement site, we propose multiple twinning pathways that can help explain how twins can proliferate in the magnesium alloys in the presence of precipitates.

36 MATERIALS SCIENCE↗

A gas dynamic perspective on particle lifting in electrostatic discharge-like devices using multiphase particle-in-cell approach

Although particle–laden electrostatic discharges are widely used in laboratories as well as in industrial applications, the mechanism of particle lifting for particles initially at rest in such highly unsteady systems is not well understood. A multiphase gas–particle solver is developed using the multiphase particle-in-cell (MP-PIC) approach to emulate the interaction of a compressible shock-dominated gas phase with the dense particle phase. First, the two-way coupled solver is initially used to study the interaction of a planar traveling shock with a vertical curtain of particulates. The gas and particle phase evolution was found to be in good agreement with a similar experimental study in Ling et al. [Phys. Fluids 24, 113301 (2012)]. Second, the MP-PIC code is used to study the interaction of an expanding blast wave with a thick bed of particles. The simulation considered forces such as quasi-steady drag, pressure-gradient, added-mass, Saffman, and Magnus forces. We observe that the vertical liftoff particles close to the shock impingement point in this configuration are associated with the quasi-steady drag, pressure gradient, and added-mass forces. Also, the Saffman lift and Magnus forces contribute to lifting particles located radially farther away from the shock impingement point. In addition, the study finds a decrease in particle lifting efficiency with decreasing plasma kernel length and shock strength.

42 ENGINEERING↗

Modeling of the spray-induced wall stress acting on the ignition assistance device

This research introduces a novel wall-stress model called the Spray-Induced Wall Stress (SIWS) model, which considers the effects of spray-wall impingement and the resulting formation of wall stress within the Lagrangian spray modeling framework. The primary objective of this paper is to provide a mathematical description of the fundamental physics underlying the model. Subsequently, the proposed model is validated using existing experimental data. Here, the remainder of the study focuses on the practical application of the model to an ignition assistance device. Specifically, this device is installed in a compression ignition engine and designed to enhance ignition in aviation-fueled high-altitude aircraft propulsion systems. The research sheds light on the mechanical impulse caused by the high-speed impact of the spray jet, leading to the accumulation of mechanical stress on the rigid body of the ignition assistance device. Previous studies on fluid-structure interaction have only considered the interaction between the gas phase and the solid wall. However, the SIWS model incorporates the additional impact of the impinging liquid spray jet. Consequently, the simulated stress distribution on the ignition assistance device can be estimated by considering both the gas-phase-induced term and the spray-induced term simultaneously.

33 ADVANCED PROPULSION SYSTEMS↗

Extended Rice–Thomson analysis and atomistic simulations revealing grain boundary effects on fracture in refractory high-entropy alloys

Significance This work serves to extend the fundamental ductile vs. brittle fracture theory, specifically the Rice–Thomson criterion, by introducing a grain boundary ahead of an initiating crack which propagates at an oblique angle to impinge the boundary. Atomistic fracture simulations on two refractory complex concentrated alloys, the brittle NbMoTaW and the ductile Nb 45 Ta 25 Ti 15 Hf 15 , demonstrate qualitative correspondence with the extended Rice–Thomson criterion and experimental observations. Abstract Understanding how grain boundaries mediate fracture remains a critical challenge in designing ductile, high-performance refractory alloys. Here, we extend the Rice–Thomson criterion to account for the angle between cracks and the impinging grain boundaries (GBs), capturing the competition between intergranular fracture and dislocation-mediated plasticity. Using machine learning interatomic potentials, we performed molecular statics simulations to probe fracture mechanisms in nanocrystalline NbMoTaW and Nb 45 Ta 25 Ti 15 Hf 15 , each with two different grain sizes, revealing trends consistent with experimental observations and the extended Rice model. Comparison with averaged R-curves for bulk samples demonstrates that GBs enhance ductility in Nb 45 Ta 25 Ti 15 Hf 15 in both grain sizes investigated. In contrast, GBs only locally improve fracture resistance in NbMoTaW when cracks are temporarily pinned at GBs inclined at high angles from the crack, but generally promote brittle intergranular fracture. These contrasting behaviors are attributed to differences in GB cohesion, reflecting clear alloying trends that align with ab-initio calculations and trends observed experimentally. Our results bridge classical fracture theory, atomistic simulations, and experimental observations, providing a comprehensive understanding of the fracture mechanisms in nanocrystalline refractory complex concentrated alloys.

36 MATERIALS SCIENCE↗

High-Fidelity Simulation of the Light-to-Dense Stratification Transient in the HiRJET Facility

Density stratification in a large enclosure is a crucial phenomenon to heat transfer and sustainable passive heat removal of a sodium fast reactor during reactivity transients. However, engineering turbulence models were identified to have unsatisfactory performance in predicting propagation of a stratified front. Yet, the scarcity of high-resolution data for stratification hampers the development of models. To explor e applications of leveraging direct numerical simulation (DNS) data to support turbulence model development, this work conducted DNS using NekRS to study a long stratification transient in the High-Resolution Jet (HiRJET) experimental facility. Here, this work considers an experiment run where light fluid is injected into a tank containing a denser fluid with a relative density difference of 1.5%. Formation of the stratified layer is identified as impingement of the buoyant jet promoting mixing of the two fluids. Based on the transient statistics, transport of the concentration can be characterized by regions with dominating effects of turbulent mixing, buoyant dissipation, and molecular diffusion, respectively, as moving away from the elevation of jet impingement. Concentration near the stratified front also exhibits oscillation at Brunt-Väisälä frequency. Preliminary validation of the simulation showed encouraging agreement of the concentration distribution with the reference experiment.

buoyant mixing↗