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All sourcesNASA NTRSDOE OSTI
NASA NTRSDate not supplied

An Approach for Practical Grid-Resolved Roughness Aerothermodynamic Simulations for Woven Heatshield Surfaces

An approach for simulating the aerothermal environment over a patterned roughness surface within an otherwise axisymmetric flow is developed. The patterned roughness is simplified into a sinusoidal shape that captures the basic features of a charred 3MDCP ablator. Two orientations of this pattern, which are equally flight relevant due to the forming process, enable periodic boundary conditions along the edges of a grid spanning a single roughness element. This simplified three-dimensional grid represents the minimum problem size for a patterned roughness simulation, which enables computationally efficient grid-resolved roughness simulations. This approach is validated by simulating the Langley Mach 6 measurements made on a similar sinusoidal surface, which results in convective heating within 5% of the experimental data. Applying this approach to Mars Sample Return (MSR) Earth Entry System (EES) flight cases, considering simulations with both 11 species air and 30 species air with ablation products, results in heating augmentation that is slightly lower than the widely-used Dahm correlation approach, with the difference being dependent on pattern orientation. This result provides the only insight into the behavior of the roughness augmentation at the high temperature reacting flow conditions present for EES flight cases, which are not captured by available ground test measurements. For shear augmentation, the simulations revealed that the surface-parallel pressure component is dominant. For arc-jet tests targeted to flight values for shear, the higher arc-jet pressures required to match flight values for shear result in up to a 400% increase in the rough wall shear value, which is not captured by the Dahm correlation. This indicates that, to avoid significant over-testing, grid-resolved roughness simulations are required to determine arc-jet conditions that produce flight shear levels in rough-wall scenarios.

Christopher O Johnston↗
NASA NTRS2014

Ice Roughness in Short Duration SLD Icing Events

Ice accretion codes depend on models of roughness parameters to account for the enhanced heat transfer during the ice accretion process. While mitigating supercooled large droplet (SLD or Appendix O) icing is a significant concern for manufacturers seeking future vehicle certification due to the pending regulation, historical ice roughness studies have been performed using Appendix C icing clouds which exhibit mean volumetric diameters (MVD) much smaller than SLD clouds. Further, the historical studies of roughness focused on extracting parametric representations of ice roughness using multiple images of roughness elements. In this study, the ice roughness developed on a 21-in. NACA 0012 at 0deg angle of attack exposed to short duration SLD icing events was measured in the Icing Research Tunnel at the NASA Glenn Research Center. The MVD's used in the study ranged from 100 micrometer to 200 micrometers, in a 67 m/s flow, with liquid water contents of either 0.6 gm/cubic meters or 0.75 gm/cubic meters. The ice surfaces were measured using a Romer Absolute Arm laser scanning system. The roughness associated with each surface point cloud was measured using the two-dimensional self-organizing map approach developed by McClain and Kreeger (2013) resulting in statistical descriptions of the ice roughness.

Icing↗
NASA NTRS2015

Convective Enhancement of Icing Roughness Elements in Stagnation Region Flows

To improve existing ice accretion simulation codes, more data regarding ice roughness and its effects on convective heat transfer are required. To build on existing research on this topic, this study used the Vertical Icing Studies Tunnel (VIST) at NASA Glenn Research to model realistic ice roughness in the stagnation region of a NACA 0012 airfoil. Using the VIST, a test plate representing the leading 2% chord of the airfoil was subjected to flows of 7.62 m/s (25 ft/s), 12.19 m/s (40 ft/s), and 16.76 m/s (55 ft/s). The test plate was fitted with 3 surfaces, each with a different representation of ice roughness: 1) a control surface with no ice roughness, 2) a surface with ice roughness with element height scaled by 10x and streamwise rough zone width from the stagnation point scaled by 10x, and 3) a surface with ice roughness with element height scaled by 10x and streamwise rough zone width from the stagnation point scaled by 25x. Temperature data from the tests were recorded using an infrared camera and thermocouples imbedded in the test plate. From the temperature data, a convective heat transfer coefficient map was created for each case. Additional testing was also performed to validate the VIST's flow quality. These tests included five-hole probe and hot-wire probe velocity traces to provide flow visualization and to study boundary layer formation on the various test surfaces. The knowledge gained during the experiments will help improve ice accretion codes by providing heat transfer coefficient validation data and by providing flow visualization data helping understand current and future experiments performed in the VIST.

Icing↗
NASA NTRS2016

Characterization of Ice Roughness Variations in Scaled Glaze Icing Conditions

Because of the significant influence of surface tension in governing the stability and breakdown of the liquid film in flooded stagnation regions of airfoils exposed to glaze icing conditions, the Weber number is expected to be a significant parameter governing the formation and evolution of ice roughness. To investigate the influence of the Weber number on roughness formation, 53.3-cm (21-in.) and 182.9-cm (72-in.) NACA 0012 airfoils were exposed to flow conditions with essentially the same Weber number and varying stagnation collection efficiency to illuminate similarities of the ice roughness created on the different airfoils. The airfoils were exposed to icing conditions in the Icing Research Tunnel (IRT) at the NASA Glenn Research Center. Following exposure to the icing event, the airfoils were then scanned using a ROMER Absolute Arm scanning system. The resulting point clouds were then analyzed using the self-organizing map approach of McClain and Kreeger (2013) to determine the spatial roughness variations along the surfaces of the iced airfoils. The roughness characteristics on each airfoil were then compared using the relative geometries of the airfoil. The results indicate that features of the ice shape and roughness such as glaze-ice plateau limits and maximum airfoil roughness were captured well by Weber number and collection efficiency scaling of glaze icing conditions. However, secondary ice roughness features relating the instability and waviness of the liquid film on the glaze-ice plateau surface are scaled based on physics that were not captured by the local collection efficiency variations.

Roughness Formation↗
NASA NTRS2016

The Effect of Roughness Model on Scattering Properties of Ice Crystals.

We compare stochastic models of microscale surface roughness assuming uniform and Weibull distributions of crystal facet tilt angles to calculate scattering by roughened hexagonal ice crystals using the geometric optics (GO) approximation. Both distributions are determined by similar roughness parameters, while the Weibull model depends on the additional shape parameter. Calculations were performed for two visible wavelengths (864 nm and 410 nm) for roughness values between 0.2 and 0.7 and Weibull shape parameters between 0 and 1.0 for crystals with aspect ratios of 0.21, 1 and 4.8. For this range of parameters we find that, for a given roughness level, varying the Weibull shape parameter can change the asymmetry parameter by up to about 0.05. The largest effect of the shape parameter variation on the phase function is found in the backscattering region, while the degree of linear polarization is most affected at the side-scattering angles. For high roughness, scattering properties calculated using the uniform and Weibull models are in relatively close agreement for a given roughness parameter, especially when a Weibull shape parameter of 0.75 is used. For smaller roughness values, a shape parameter close to unity provides a better agreement. Notable differences are observed in the phase function over the scattering angle range from 5deg to 20deg, where the uniform roughness model produces a plateau while the Weibull model does not.

Weibull density functions↗
NASA NTRSDate not supplied

A Model for Ice Accretion Roughness Evolution and Spatial Variations

Over the past decade, multiple investigations of ice accretion roughness and spatial variations have been performed in the Icing Research Tunnel (IRT) at the NASA Glenn Research Center. The early investigations used models of NACA 0012 airfoils with different chord sizes and focused on temporal scaling and primary cloud scaling parameters such as stagnation point collection efficiency. Subsequent investigations included the effects of model sweep, airfoil shape, airfoil lifting condition, and freestream static temperature. To develop a predictive model for roughness evolution in generalized icing situations, the maximum roughness values for the airfoils and conditions used in the angle of attack and freestream temperature investigations were scaled to eliminate the temporal variations. LEWICE simulations were employed to identify the local collection efficiency at the locations of maximum roughness, and a two-dimensional panel-method code was used to identify the local static pressure at the location of the maximum roughness. Because of the stochastic nature of ice accretion roughness, a physics-directed approach was employed to develop a multi-dimensional correlation based on the local pressure coefficient, the local total temperature, the cloud properties, and the cloud exposure time. The resulting correlation predictions are compared to ice shapes measured in the IRT for both a 21-in. NACA 0012 airfoil model and a 60-in. HAARP-II model. The resulting predictions indicate that the local freezing fraction must be included in the roughness predictive model. Implications regarding icing heat transfer predictions using the resulting roughness model are also discussed.

Icing↗
NASA NTRS2024

Impact of Random Micron-Sized Surface Roughness on Stationary Crossflow Instabilities

This study examines the effect of random micron-sized distributed roughness on stationary crossflow (SCF) instabilities. The roughness parameters are varied by creating nanoparticle coatings of various formulations and applying them to inserts that cover approximately the first 14% of the swept flat-plate model. In addition to the baseline configuration (no added roughness, root-mean-square (RMS) ≈ 0.4 µm ), 5 panels with RMS roughness values of 4.8 up to 17 µm and correlation lengths ranging from 92 to 876 µm were tested. Despite the significant roughness levels tested, the transition location was found to be only mildly impacted by the additional roughness. However, the SCF amplitudes and wavelength content were found to vary substantially depending on the roughness input. The results were somewhat unexpected, in that the panel with the highest roughness RMS level did not result in the largest initial amplitudes, nor did the panel with the most energy in the SCF wavelength range. Rather, the panel with the most energy in the smaller wavelengths resulted in the largest SCF amplitude. There were, however, significant variations in the results when the panels were rotated by 180 ◦ , indicating that the important factor for some of the panels may be isolated peaks that occur near the neutral point.

stationary crossflow instabilities↗
DOE OSTI2020

Revealing the Predominant Surface Facets of Rough Cu Electrodes under Electrochemical Conditions

Metal electrodes with rough surfaces are frequently found to convert CO or CO 2 to hydrocarbons and oxygenates with high selectivity and at high reaction rates in comparison with their smooth counterparts. The atomic-level morphology of a rough electrode is likely one key factor responsible for its comparatively high catalytic selectivity and activity. However, few methods are capable of probing the atomic-level structure of rough metal electrodes under electrocatalytic conditions. As a result, the nuances in the atomic-level surface morphology that control the catalytic characteristics of these electrodes have remained largely unexplored. Because the C≡O stretching frequency of atop-bound CO (CO atop ) depends on the coordination of the underlying metal atom, the IR spectrum of this reaction intermediate on the copper electrode could, in principle, provide structural information about the catalytic surface during electrolysis. However, other effects, such as dynamic dipole coupling, easily obscure the dependence of the frequency on the surface morphology. Further, in the limit of low CO atop coverage, where coupling effects are small, the C≡O stretching frequencies of CO atop on Cu(111) and Cu(100) facets are virtually identical. Therefore, on the basis of the C≡O stretching frequency, it is not straightforward to distinguish between these two ubiquitous surface facets, which exhibit vastly different CO reduction activities. Herein, we show that key features of the atomic-level surface morphology of rough copper electrodes can be inferred from the potential dependence of the line shape of the C≡O stretching band of CO atop . Specifically, we compared two types of rough copper thin-film electrodes that are routinely employed in the context of surface-enhanced infrared absorption spectroscopy (SEIRAS). We found that copper films that are electrochemically deposited on Si-supported Au films (CuAu–Si) are poor catalysts for the reduction of CO to ethylene in comparison to copper films (Cu–Si) that are electrolessly deposited onto Si crystals. As quantified by differential electrochemical mass spectrometry (DEMS), the onset potential for ethylene is ~200 ± 65 mV more cathodic for CuAu–Si than that for Cu–Si. To reveal the origin of the disparate catalytic properties of Cu–Si and CuAu–Si, we probed the surfaces of the electrodes with cyclic voltammetry (CV) and SEIRAS. The CV characterization suggests that the (111) surface facet predominates on CuAu–Si, whereas the (100) facet is more common on Cu–Si. SEIRAS reveals that the line shape of the C≡O stretching of CO atop is composed of two bands that are attributable to CO atop on terrace and defect sites. The different surface structures manifest themselves in the form of starkly different potential dependences of the line shape of the C≡O stretching mode of CO atop on the two types of electrodes. With a simple Boltzmann model that considers the different adsorption energies of CO atop on terrace and defect sites, and the resulting CO atop populations on terrace and defect sites, we deduced that the observed electrode-specific potential dependence of the line shape is consistent with the presence of different predominant terrace sites on the two types of films. This strategy for assessing the atomic-level morphology is not restricted to SEIRAS but could also be applied to the C≡O stretching bands recorded with surface-enhanced Raman spectroscopy (SERS), which is suitable for probing a wide range of rough copper electrodes. Therefore, with this work, we establish the potential dependence of the C≡O stretching band of CO atop as a probe of the atomic-level surface structure of rough metal electrodes under electrochemical conditions. When it is coupled with complementary techniques, this methodology provides essential structural information for further improvement in the reaction selectivity of rough metal electrodes.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2020

Understanding Laser Powder Bed Fusion Surface Roughness

Abstract Surface roughness is a well-known consequence of additive manufacturing methods, particularly powder bed fusion processes. To properly design parts for additive manufacturing, a comprehensive understanding of the inherent roughness is necessary. While many researchers have measured different surface roughness resultant from a variety of parameters in the laser powder bed fusion process, few have succeeded in determining causal relationships due to the large number of variables at play. To assist the community in understanding the roughness in laser powder bed fusion processes, this study explored several studies from the literature to identify common trends and discrepancies amongst roughness data. Then, an experimental study was carried out to explore the influence of certain process parameters on surface roughness. Through these comparisons, certain local and global roughness trends have been identified and discussed, as well as a new framework for considering the effect of process parameters on surface roughness.

Engineering↗
NASA NTRS1990

On the receptivity problem for Goertler vortices: Vortex motions induced by wall roughness

The receptivity problem for Goertler vortices induced by wall roughness is investigated. The roughness is modelled by small amplitude perturbations to the curved wall over which the flow takes place. The amplitude of these perturbations is taken to be sufficiently small for the induced Goertler vortices to be described by linear theory. The roughness is assumed to vary in the spanwise direction on the boundary layer lengthscale, while in the flow direction the corresponding variation is on the lengthscale over which the wall curvature varies. In fact the latter condition can be relaxed to allow for a faster streamwise roughness variation so long as the variation does not become as fast as that in the spanwise direction. The function which describes the roughness is assumed to be such that its spanwise and streamwise dependences can be separated; this enables progress by taking Fourier or Laplace transforms where appropriate. The cases of isolated and distributed roughness elements are investigated and the coupling coefficient which relates the amplitude of the forcing and the induced vortex amplitude is found asymptotically in the small wavelength limit. It is shown that this coefficient is exponentially small in the latter limit so that it is unlikely that this mode can be stimulated directly by wall roughness. The situation at 0(1) wavelengths is quite different and this is investigated numerically for different forcing functions. It is found that an isolated roughness element induces a vortex field which grows within a wedge at a finite distance downstream of the element. However, immediately downstream of the obstacle the disturbed flow produced by the element decays in amplitude. The receptivity problem at larger Goertler numbers appropriate to relatively large wall curvature is discussed in detail.

Denier, James P.↗
NASA NTRS1990

On roughness-induced transition - Facts, views, and speculations

Roughness is considered as a steady passive device, and it is shown that roughness-induced separation is specifically sensitive to unsteady environmental forcing. The two-dimensional isolated roughness causing local upstream and downstream separations is considered, along with flows associated with the two-dimensional roughness and their relevance to the problem of distributed roughness. The difference between the two-dimensional isolated roughness and a three-dimensional isolated roughness at all Reynolds numbers is underlined, and the mechanisms and parameter conditions of a sudden breakdown of hairpin eddies are discussed, as well as flows over distributed roughness.

Morkovin, Mark V.↗
NASA NTRS1991

The application of differential roughness to mitigate friction and wear

By definition, differential roughness occurs where the surface roughness of one region is distinctly different from that of an adjacent region. Differential roughness may occur on a sliding surface when the structure of an area of the surface is modified relative to the original material. Differential roughness may be used to effect a film thickness change so as to cause hydrodynamic or hydrostatic lubrication effects just as if the surfaces were machined. The advantage of differential roughness is that the effective offset of film thickness continues to exist even if there is gross wear. One can effect film thickness changes which are smaller than can be made directly. Furthermore, asperity tip load support is the same over both the high roughness and small roughness regions. The potential uses for differential roughness are seals, bearings, and pumps. Some examples are presented.

Lebeck, Alan O.↗
NASA NTRS1992

Direct numerical simulation of instabilities in parallel flow with spherical roughness elements

Results from a direct numerical simulation of laminar flow over a flat surface with spherical roughness elements using a spectral-element method are given. The numerical simulation approximates roughness as a cellular pattern of identical spheres protruding from a smooth wall. Periodic boundary conditions on the domain's horizontal faces simulate an infinite array of roughness elements extending in the streamwise and spanwise directions, which implies the parallel-flow assumption, and results in a closed domain. A body force, designed to yield the horizontal Blasius velocity in the absence of roughness, sustains the flow. Instabilities above a critical Reynolds number reveal negligible oscillations in the recirculation regions behind each sphere and in the free stream, high-amplitude oscillations in the layer directly above the spheres, and a mean profile with an inflection point near the sphere's crest. The inflection point yields an unstable layer above the roughness (where U''(y) is less than 0) and a stable region within the roughness (where U''(y) is greater than 0). Evidently, the instability begins when the low-momentum or wake region behind an element, being the region most affected by disturbances (purely numerical in this case), goes unstable and moves. In compressible flow with periodic boundaries, this motion sends disturbances to all regions of the domain. In the unstable layer just above the inflection point, the disturbances grow while being carried downstream with a propagation speed equal to the local mean velocity; they do not grow amid the low energy region near the roughness patch. The most amplified disturbance eventually arrives at the next roughness element downstream, perturbing its wake and inducing a global response at a frequency governed by the streamwise spacing between spheres and the mean velocity of the most amplified layer.

Deanna, R. G.↗
NASA NTRS1995

Non-linear boundary-layer receptivity due to distributed surface roughness

The process by which a laminar boundary layer internalizes the external disturbances in the form of instability waves is known as boundary-layer receptivity. The objective of the present research was to determine the effect of acoustic excitation on boundary-layer receptivity for a flat plate with distributed variable-amplitude surface roughness through measurements with a hot-wire probe. Tollmien-Schlichting (T-S) mode shapes due to surface-roughness receptivity have also been determined, analyzed, and shown to be in agreement with theory and other experimental work. It has been shown that there is a linear relationship between the surface roughness and receptivity for certain roughness configurations with constant roughness wavelength. In addition, strong nonlinear receptivity effects exist for certain surface roughness configurations over a band where the surface roughness and T-S wavelength are matched. The results from the present experiment follow the trends predicted by theory and other experimental work for linear receptivity. In addition, the results show the existence of nonlinear receptivity effects for certain combinations of surface roughness elements.

Amer, Tahani Reffet↗
NASA NTRS1995

Non-linear boundary-layer receptivity due to distributed surface roughness

The process by which a laminar boundary layer internalizes the external disturbances in the form of instability waves is known as boundary-layer receptivity. The objective of the present research was to determine the effect of acoustic excitation on boundary-layer receptivity for a flat plate with distributed variable-amplitude surface roughness through measurements with a hot-wire probe. Tollmien-Schlichting mode shapes due to surface roughness receptivity have also been determined, analyzed, and shown to be in agreement with theory and other experimental work. It has been shown that there is a linear relationship between the surface roughness and receptivity for certain roughness configurations with constant roughness wavelength. In addition, strong non-linear receptivity effects exist for certain surface roughness configurations over a band where the surface roughness and T-S wavelength are matched. The results from the present experiment follow the trends predicted by theory and other experimental work for linear receptivity. In addition, the results show the existence of non-linear receptivity effects for certain combinations of surface roughness elements.

Amer, Tahani Reffet↗
NASA NTRS1959

An Investigation of the Effect of a Highly Favorable Pressure Gradient on Boundary-Layer Transition as Caused by Various Types of Roughnesses on a 10-foot-Diameter Hemisphere at Subsonic Speeds

Tests were made on a 10-foot-diameter hemispherical nose at Reynolds numbers up to 10 x 10(exp 6) and at a maximum Mach number of about 0.1 to determine the effects of a highly favorable pressure gradient on boundary-layer transition caused by roughness. Both two-dimensional and three-dimensional roughness particles were used, and the transition of the boundary layer was determined by hot-wire anemometers. The roughness Reynolds number for transition R(sub k,t) caused by three-dimensional particles such as Carborundum grains, spherical particles, and rimmed craters was found. The results show that for particles immersed in the boundary layer, R(sub k,t) is independent of the particle size or position on the hemispherical nose and depends mainly on the height-to-width ratio of the particle. The values of R(sub k,t) found on the hemispherical nose compare closely with those previously found on a flat plate and on airfoils with roughness. For two-dimensional roughness, the ratio of roughness height to boundary-layer displacement thickness necessary to cause transition was found to increase appreciably as the roughness was moved forward on the nose. Also included in the investigation were studies of the spread of turbulence behind a single particle of roughness and the effect of holes such as pressure orifices.

Peterson, John B., Jr.↗
NASA NTRS2006

Aeolian Sediment Transport through Large Patches of Roughness in the Atmospheric Inertial Sublayer

Roughness influences the flux of wind driven sand transport. In this paper, we report on sediment transport measurements for four different surface roughness configurations composed of the same size (solid) roughness elements in the atmospheric inertial sublayer (ISL). Results of these tests indicate that sediment transport rates through patches of roughness in the atmospheric inertial sublayer are to a large extent controlled and scale proportionally with the roughness density (lambda = n b h/S, where n is number of elements of breadth b and height h in area S) of the surface. However, element size apparently increases the magnitude of the reduction beyond that attributable to lambda. A sediment transport model that incorporates the effect of shear stress partitioning appears to predict reasonably well the effect of roughness on sand transport in the cases where the roughness elements are less than or equal to 0.10 m in height. However, when the dimensions of the roughness itself are equivalent to or are greater than the range of saltation lengths (vertical and horizontal), additional interactions of the elements with the saltation cloud appear to reduce the transport efficiency.

Gillies, John A.↗
NASA NTRS2008

Temporal Stability of Surface Roughness Effects on Radar Based Soil Moisture Retrieval During the Corn Growth Cycle

A representative soil surface roughness parameterization needed for the retrieval of soil moisture from active microwave satellite observation is difficult to obtain through either in-situ measurements or remote sensing-based inversion techniques. Typically, for the retrieval of soil moisture, temporal variations in surface roughness are assumed to be negligible. Although previous investigations have suggested that this assumption might be reasonable for natural vegetation covers (Moran et al. 2002, Thoma et al. 2006), insitu measurements over plowed agricultural fields (Callens et al. 2006) have shown that the soil surface roughness can change considerably over time. This paper reports on the temporal stability of surface roughness effects on radar observations and soil moisture retrieved from these radar observations collected once a week during a corn growth cycle (May 10th - October 2002). The data set employed was collected during the Optimizing Production Inputs for Economic and Environmental Enhancement (OPE3) field campaign covering this 2002 corn growth cycle and consists of dual-polarized (HH and VV) L-band (1.6 GHz) acquired at view angles of 15, 35, and 55 degrees. Cross-polarized L baud radar data were also collected as part of this experiment, but are not used in the analysis reported on here. After accounting for vegetation effects on radar observations, time-invariant optimum roughness parameters were determined using the Integral Equation Method (IEM) and radar observations acquired over bare soil and cropped conditions (the complete radar data set includes entire corn growth cycle). The optimum roughness parameters, soil moisture retrieval uncertainty, temporal distribution of retrieval errors and its relationship with the weather conditions (e.g. rainfall and wind speed) have been analyzed. It is shown that over the corn growth cycle, temporal roughness variations due to weathering by rain are responsible for almost 50% of soil moisture retrieval uncertainty depending on the sensing configuration. The effects of surface roughness variations are found to be smallest for observations acquired at a view angle of 55 degrees and HH polarization. A possible explanation for this result is that at 55 degrees and HH polarization the effect of vertical surface height changes on the observed radar response are limited because the microwaves travel parallel to the incident plane and as a result will not interact directly with vertically oriented soil structures.

Joseph, A.T.↗