Engineering Papers⌕ Search

SEARCH · Engineering Papers

Results for “friction experiments”

Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 613 records · Page 34
All sourcesNASA NTRSDOE OSTI
NASA NTRS2009

Compressibility Considerations for kappa-omega Turbulence Models in Hypersonic Boundary Layer Applications

The ability of kappa-omega models to predict compressible turbulent skin friction in hypersonic boundary layers is investigated. Although uncorrected two-equation models can agree well with correlations for hot-wall cases, they tend to perform progressively worse - particularly for cold walls - as the Mach number is increased in the hypersonic regime. Simple algebraic models such as Baldwin-Lomax perform better compared to experiments and correlations in these circumstances. Many of the compressibility corrections described in the literature are summarized here. These include corrections that have only a small influence for kappa-omega models, or that apply only in specific circumstances. The most widely-used general corrections were designed for use with jet or mixing-layer free shear flows. A less well-known dilatation-dissipation correction intended for boundary layer flows is also tested, and is shown to agree reasonably well with the Baldwin-Lomax model at cold-wall conditions. It exhibits a less dramatic influence than the free shear type of correction. There is clearly a need for improved understanding and better overall physical modeling for turbulence models applied to hypersonic boundary layer flows.

Rumsey, C. L.↗
NASA NTRS2017

Assessment of State-of-the-Art Dust Emission Scheme in GEOS

The GEOS modeling system has been extended with state of the art parameterization of dust emissions based on the vertical flux formulation described in Kok et al 2014. The new dust scheme was coupled with the GOCART and MAM aerosol models. In the present study we compare dust emissions, aerosol optical depth (AOD) and radiative fluxes from GEOS experiments with the standard and new dust emissions. AOD from the model experiments are also compared with AERONET and satellite based data. Based on this comparative analysis we concluded that the new parameterization improves the GEOS capability to model dust aerosols originating from African sources, however it lead to overestimation of dust emissions from Asian and Arabian sources. Further regional tuning of key parameters controlling the threshold friction velocity may be required in order to achieve more definitive and uniform improvement in the dust modeling skill.

Darmenov, Anton↗
DOE OSTI2022

Physics-Informed and Data-Driven Prediction of Residual Stress in Three-Dimensional Machining

Efficient and reliable prediction of machining-induced residual stress (RS) is a key requirement for truly integrated computational materials engineering (ICME). Currently available process modeling approaches, including empirical, analytical, and numerical methodologies lack predictive power and require substantial calibration and validation data. Moreover, most model-based approaches consider only two-dimensional (2D) (i.e., orthogonal), cutting processes. Meanwhile, industrial processes such as milling, turning, and drilling are inherently three-dimensional (3D). The present work attempts to bridge the gap between 2D and 3D through careful consideration of the process physics, including geometric, kinematic, and size-effect constraints to realize robust prediction of how RS develops in 3D machining. Using a novel in-situ experimental technique and digital image correlation (DIC) to determine equivalent Hertzian contact widths, contact pressures, and friction coefficients, the proposed methodology leverages a discretized conversion algorithm that includes multi-pass shakedown effects. This paper presents a semi-analytical model to predict machining-induced RS in 3D turning operations, which are used representatively for 3D processes more generally. Rather than follow a ‘brute force’ 3D FEM approach or conduct countless experiments to train a purely data-driven machine learning algorithm, the proposed approach builds on previous 2D modeling work. Through careful consideration of the process physics, including complex geometry/kinematic considerations of 3D turning, the authors demonstrated an experimentally calibrated approach, as well as validation based on published RS data. Model predictions and previously published measurement data of RS depth profiles for turning of Inconel 718 were compared for a range of process parameters. Correlation between the proposed 3D model and validation data was found to be within the margin of experimental error for most conditions. The proposed model appears to capture the overall behavior of 3D RS depth profiles with acceptable accuracy, particularly the key metrics of near-surface stress, peak stress magnitude and location, as well as overall stress profile depth. This report presents a physics-informed, data-driven approach for efficient calibration of a 2D model for machining-induced RS through DIC analysis of in-situ characterized subsurface displacement fields.

42 ENGINEERING↗
NASA NTRS1976

Reduction of losses in low-frequency /2 MHz/ surface-wave delay line by outgassing

Surface waves are attenuated by a fluid or gas surrounding the surface of propagation, an effect caused by frictional losses determined by the fluid or gas viscosity and by the emission of compression waves into the environment. The paper reports a large reversible reduction in attenuation of surface waves at frequencies as low as 2 MHz by outgassing treatments of some materials, suggesting that at such frequencies vacuum encapsulation is a desirable procedure. Outgassing experiments were performed on a delay line constructed from high-density p.z.t.-8 (lead-zirconate-titanate). The delay line configuration was a slab waxed onto a metal base with coaxial connectors mounted near and connected by gold-wire leads to the interdigital finger sets. Output signal enhancements by as much as 8 dB were achieved after overnight evacuation at 10 to the -2 torr at room temperature.

Tittmann, B. R.↗
DOE OSTI2023

Galvanic corrosion of AZ31B joined to dual-phase steel with and without Zn layer by ultrasonic and friction stir welding

Galvanic corrosion of AZ31B joined with bare or Zn-coated DP590 steel by ultrasonic spot welding or linear friction stir welding was quantitatively studied by pre-defining anode and cathode in the lap joint samples. Corrosion volume and depth from Mg anode surfaces exposed to 0.1 M sodium chloride solution was analyzed as functions of cathode surface type and welding method. Characterization of as-welded joints was performed to identify any microstructural feature of the bonding zone that could impact galvanic corrosion behavior. COMSOL modeling with modified user subroutine was conducted to simulate the progression of Mg corrosion in the same joint and electrode configurations used for the corrosion experiments. The experimental results indicated that Zn-coated cathode surface can reduce Mg galvanic corrosion significantly as galvanic polarization and cathodic current on Zn-coated surface remained relatively low for Mg in the weld joints. COMSOL modeling described the growth of Mg galvanic corrosion in a reasonable manner but showed limitation by underestimating the corrosion volume as it did not capture self-corrosion.

36 MATERIALS SCIENCE↗
NASA NTRS1992

Nucleation and growth of rolling contact failure of 440C bearing steel

A 'two-body' elasto-plastic finite element model of 2-dimensional rolling and rolling-plus-sliding was developed to treat the effect of surface irregularities. The model consists of a smooth cylinder in contact with a semi-infinite half-space that is either smooth or fitted with one of 0.4 microns deep or 7 microns deep groove, or a 0.4 microns high ridge-like asperity. The model incorporates elastic-linear-kinematic hardening-plastic (ELKP) and non-linear-kinematic hardening-plastic (NLKP) material constitutive relations appropriate for hardened bearing steel and the 440C grade. The calculated contact pressure distribution is Hertzian for smooth body contact, and it displays intense, stationary, pressure spikes superposed on the Hertzian pressure for contact with the grooved and ridged surface. The results obtained for the 0.4 microns deep groove compare well with those reported by Elsharkawy and Hamrock for an EHD lubricated contact. The effect of translating the counterface on the half space as opposed to indenting the half space with the counter face with no translation is studied. The stress and strain values near the surface are found to be similar for the two cases, whereas they are significantly different in the subsurface. It is seen that when tiny shoulders are introduced at the edge of the groove in the finite element model, the incremental plasticity and residual stresses are significantly higher in the vicinity of the right shoulder (rolling direction is from left to right) than at the left shoulder. This may explain the experimental observation that the spall nucleation occurs at the exit end of the artificially planted indents. Pure rolling calculations are compared with rolling + sliding calculations. For a coefficient of friction, mu = 0.1, the effect of friction is found to be small. Efforts were made to identify the material constitutive relations which best describe the deformation characteristics of the bearing steels in the initial few cycles. Elastic-linear-kinematic hardening-plastic (ELKP) material constitutive relations produce less net plastic deformation in the initial stages for a given stress, than seen in experiments. A new set of constitutive relations: non-linear-kinematic hardening-plastic (NLKP) was used. This material model produces more plasticity than the ELKP model and shows promise for treating the net distortions in the early stages. Techniques for performing experimental measurements that can be compared with the finite element calculations were devised. The measurements are being performed on 9mm-diameter, 440C steel cylindrical rolling elements in contact with 12.5 mm-diameter, 52100 steel balls in a 3-ball-rod fatigue test machine operating at 3600 RPM. Artificial, 7 microns deep, indents were inserted on the running track of the cylindrical rolling elements and profilometer measurements of these indents made, before and after the rolling. These preliminary measurements show that the indents are substantially deformed plastically in the process of rolling. The deformations of the groove calculated with the finite element model are comparable to those measured experimentally.

Gupta, V.↗
DOE OSTI2022

Hydro-Mechanical Measurements of Sheared Crystalline Rock Fractures With Applications for EGS Collab Experiments 1 and 2

We present hydro-mechanical measurements that characterize shear on natural fractures in schist, amphibolite, and rhyolite specimens from the enhanced geothermal system (EGS) Collab Project's Experiment 1 and 2 sites (E1 and E2) at the Sanford Underground Research Facility. We employed a triaxial direct shear method augmented with X-ray imaging to perform hydroshearing (injection-induced shearing) and mechanical shearing on naturally fractured specimens at in situ stress conditions. Measurements included fracture permeability, strength, stress-dependent aperture, shear dilation, and frictional strength. Results reveal that in situ natural fractures must be permeable, weak, and shear-oriented to be hydrosheared, and only a subset of the observable in situ fractures were suitable. When sheared, the fracture permeability typically increased by a factor of 10 or more and this increase was retained over time. However, shear slip did not always result in permeability increase. High phyllosilicate content associated with exceptionally weak fractures exhibited poor or even decreased permeability after stimulation. These measurements in combination with site data were used to conduct a slip-tendency analysis for different fracture sets, and we selected the top candidate natural fractures for hydroshearing at the EGS Collab sites. We also found that the lower in situ shear stress and stronger fractures at the E2 site make hydroshearing more challenging than at the E1 site. Overall, the methods and analysis used in our work can be applied to any geothermal project to identify in situ joint sets that are best suited for hydroshearing, which in turn can help to optimize well placement and energy production.

58 GEOSCIENCES↗
NASA NTRS1984

Effect of initial conditions on turbulent reattachment downstream of a backward-facing step

The reattachment of a fully turbulent, two-dimentional shear layer downstream of a backward-facing step has been studied experimentally. The work examines the effect of variations in inlet conditions on the process of reattachment. A series of experiments was conducted in a low-speed wind tunnel using specialized instrumentation suited to the highly turbulent reversing flow near reattachment. Accurate characterization of the time-mean features of the reattaching flows was possible. Assuming linear scaling normalized on distance from reattachment, distributions of normalized pressure coefficient and forward flow fraction, and time-averaged skin friction coefficient appear universal for two-dimensional reattachment, independent of initial conditions and step height, for given duct geometry (area ratio) and for high step-height Reyolds numbers with thin separating boundary layers. The results suggest universal flow structure in the reattachment zone.

Westphal, R. V.↗
NASA NTRSDate not supplied

Experimental Characterization of Surface Roughness and Geometric Evaluations of Thin-Wall Laser Powder Directed Energy Deposition

Additive Manufacturing (AM) has offered many new design and manufacturing opportunities for components across various industries. As AM evolves there is a need to better understand outputs of the process including geometric limitations and surface roughness based on specific application requirements. One possible application area of AM are components using thin-wall (<2 mm) microchannel heat exchangers for subsystems across aerospace, and industrial applications. AM offers the opportunity to significantly reduce the cost and lead time associated with fabricating these complex parts with internal features such as an array of cooling channels. Laser Powder Bed Fusion (L-PBF) has been continuously demonstrated as a technique to fabricate heat exchangers with internal geometric complexities. However, L-PBF is limited in the scale at which parts can be fabricated. Laser Powder Directed Energy Deposition (LP-DED) has been demonstrated as an AM technology to significantly increase the scale of which thin-wall microchannel heat exchangers could be manufactured. Successful deployment of the LP-DED technology requires critical understanding of the resulting features from the build process. Surface roughness is one of the critical areas that effects the friction factor and pressure drop within a heat exchanger and must be well understood. This presentation will provide an overview of the characterization work completed to understand the LP-DED process for thin-walls representative of hydrogen resistant alloy NASA HR-1 that would be used in a Hydrogen-environment application. An overview of the experiments conducted with varying LP-DED parameters, evaluation of various geometric channel and geometric build features and resulting surface finish will be provided along with a summary of conclusions from these experiments. Results indicate that powder size is a major contributor and surface roughness varies between closed channel shapes and external surfaces.

Directed Energy Deposition↗
DOE OSTI2023

Water transport in reverse osmosis membranes is governed by pore flow, not a solution-diffusion mechanism

We performed nonequilibrium molecular dynamics (NEMD) simulations and solvent permeation experiments to unravel the mechanism of water transport in reverse osmosis (RO) membranes. The NEMD simulations reveal that water transport is driven by a pressure gradient within the membranes, not by a water concentration gradient, in marked contrast to the classic solution-diffusion model. We further show that water molecules travel as clusters through a network of pores that are transiently connected. Permeation experiments with water and organic solvents using polyamide and cellulose triacetate RO membranes showed that solvent permeance depends on the membrane pore size, kinetic diameter of solvent molecules, and solvent viscosity. This observation is not consistent with the solution-diffusion model, where permeance depends on the solvent solubility. Motivated by these observations, we demonstrate that the solution-friction model, in which transport is driven by a pressure gradient, can describe water and solvent transport in RO membranes.

42 ENGINEERING↗
NASA NTRS1981

A simple mechanism for blocking

Numerical experiments show that blocking in a barotropic atmosphere can occur as a resonant enhancement of Rossby lee waves forced by two stationary sources of potential vorticity. In particular, if an upstream source of stationary forcing enhances the northerly flow over orography, then blocking occurs downstream of the mountain. In an analytical study, we show that, in the presence of friction, Rossby lee waves generate a rectified current downstream of the mountain, which does not vanish in the limit of zero friction. The relevance of this study to observed generation of blocking in the Atlantic Ocean and immediately upstream of the Rockies is discussed.

Kalnay-Rivas, E.↗
NASA NTRS1983

Alteration of outer flow structures for turbulent drag reduction

Paper reviews large eddy behavior in turbulent boundary layers and presents a survey of turbulent wall layers subjected to abrupt changes in boundary conditions. From this survey several methods have been identified with potential for altering the turbulence production process in the outer region of the boundary layer and reducing the turbulent skin-friction drag over relatively long downstream distances; these include convex longitudinal surface curvature, large-eddy breakup devices, and Emmons spot alteration. Paper also presents results of an ongoing experimental study to parametrically evaluate large-eddy breakup devices as a turbulent drag reduction concept and reproduce the 20 percent net drag reductions found in large-eddy breakup experiments at Illinois Institute of Technology.

Hefner, J. N.↗
NASA NTRS1992

The hypersonic shock wave-turbulent boundary layer interaction generated by a sharp fin at Mach 8.2

A combined experimental and numerical study has been conducted on the hypersonic shock-wave turbulent-boundary layer interaction at Mach 8.2 generated by a single fin of angles alpha = 10 and 15 deg. Three models are considered: (1) the 3D compressible Reynolds-averaged Navier-Stokes (RANS) equations using the k-epsilon turbulence model, (2) the 3D RANS using the Rodi turbulence model, and (3) the conical RANS using the Baldwin-Lomax algebraic turbulence model. The computations are compared with various experimental data. The computations using models (1) and (2) show quantitatively very similar results and very good agreement with experimental data for surface pressure and skin friction. Comparison with boundary layer profiles of pitot pressure and yaw angle are also generally good, but the peak surface heat transfer is overestimated by up to 48 percent. The effect of the laminar boundary layer on the fin is restricted to the immediate vicinity of the fin surface. Conical calculations using model (3) show substantially poorer agreement with experiment.

Knight, Doyle D.↗
DOE OSTI2026

Dynamic modeling of near isothermal compressor for Transcritical carbon dioxide cycle to support efficiency improvement

Compressors are the primary components of energy consumption in vapor compression systems, drawing considerable research effort to reduce carbon emissions and improve energy efficiency. This work presents an isothermal compressor that integrates the compression chamber with the gas cooler to achieve near-isothermal compression, resulting in up to 30% energy reduction compared to traditional isentropic compression, according to the experiment results. A detailed dynamic model for the isothermal compression cycle of carbon dioxide (CO 2 ) is first presented, coupled with a liquid-piston model for chamber design. The model is experimentally validated on a 3.5 kW prototype, yielding a 6.2% relative error in chamber pressure and a 0.5 K deviation in chamber temperature. The liquid piston exhibits reduced frictional heating and geometric adaptability relative to the mechanical piston. Leveraging these attributes, the study further evaluates approaches that enhance the heat transfer to achieve isothermal compression by increasing the effective heat transfer area during compression. As a result, simulations demonstrated up to a 5% improvement in the coefficient of performance over the baseline case through chamber design, providing guidelines for design of isothermal compression cycle.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
NASA NTRS1989

Simultaneous detection of separation and transition in surface shear layers

Flush-mounted hot-film gages have proved effective in detecting boundary-layer transition and in measuring skin friction but with limited success in detecting laminar separation and reattachment. The development of multielement micro hot-film sensors, and the recent discovery of the phase reversal phenomena associated with low-frequency dynamic shear stress signals across regions of laminar separation and turbulent reattachment, have made it possible to simultaneously and unambiguously detect these surface shear layer characteristics. Experiments were conducted on different airfoils at speeds ranging from low subsonic to transonic speeds to establish the technique for incompressible and compressible flow applications. The multielement dynamic shear stress sensor technique was successfully used to detect laminar separation, turbulent reattachment, as well as, shock induced laminar and turbulent separation.

Mangalam, Siva M.↗
NASA NTRS2003

Industry Needs Fulfilled by Patented NASA PS300 Solid Lubricant Technology

In 1999, the NASA Glenn Research Center was awarded a patent (#5866518) for a new high-temperature solid lubricant coating material, PS300. A combination of wear-resistant metals and ceramics with solid lubricant additives, PS300 reduces friction and wear in sliding contacts from below ambient to over 650 C. This lubricant is an outgrowth of over three decades of high-temperature tribological research and was specifically developed as a shaft lubricant to protect foil air bearings used in Oil-Free turbomachinery, like gas turbines. Foil bearings are lubricated by air at high speeds but experience sliding and wear during initial startup and shut down when a lubricating film of air has not yet developed. PS300 shaft coatings have successfully lubricated foil bearings for over 100 000 cycles without wearing out.

DellaCorte, Christopher↗
NASA NTRS2009

Uncertainty Analysis for the Evaluation of a Passive Runway Arresting System

This paper considers the stopping distance of an aircraft involved in a runway overrun incident when the runway has been provided with an extension comprised of a material engineered to induce high levels of rolling friction and drag. A formula for stopping distance is derived that is shown to be the product of a known formula for the case of friction without drag, and a dimensionless constant between 0 and 1 that quantifies the further reduction in stopping distance when drag is introduced. This additional quantity, identified as the Drag Reduction Factor, D, is shown to depend on the ratio of drag force to friction force experienced by the aircraft as it enters the overrun area. The specific functional form of D is shown to depend on how drag varies with speed. A detailed uncertainty analysis is presented which reveals how the uncertainty in estimates of stopping distance are influenced by experimental error in the force measurements that are acquired in a typical evaluation experiment conducted to assess candidate overrun materials.

Deloach, Richard↗
NASA NTRS1981

Flight experiments with a slender cone at angle of attack

The three-dimensional leeward separation about a 5 deg semi-angle cone at an 11 deg angle of attack was investigated in flight, in the wind tunnel, and by numerical computations. The test conditions were Mach numbers of 0.6, 1.5, and 1.8 at Reynolds numbers between 7 and 10 million based on free-stream conditions and a 30-inch wetted length or surface. The surface conditions measured included mean static and fluctuating pressures; skin friction magnitudes and separation line positions were obtained using obstacle blocks. The mean static pressures from flight and wind tunnel were in good agreement. The computed results gave the same distributions, but were slightly more positive in magnitude. The experimentally measured primary and secondary separation line locations compared closely with computed results. There were substantial differences in level and in trend between the surface root-mean-square pressure fluctuations obtained in flight and in the wind tunnel, due, it is thought, to a relatively high acoustic disturbance level in the tunnel compared with the quiescent conditions in flight.

Peake, D. J.↗