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NASA NTRS1993

Current Status in Cavitation Modeling

Cavitation is a common problem for many engineering devices in which the main working fluid is in liquid state. In turbomachinery applications, cavitation generally occurs on the inlet side of pumps. The deleterious effects of cavitation include: lowered performance, load asymmetry, erosion and pitting of blade surfaces, vibration and noise, and reduction of the overall machine life. Cavitation models in use today range from rather crude approximations to sophisticated bubble dynamics models. Details about bubble inception, growth and collapse are relevant to the prediction of blade erosion, but are not necessary to predict the performance of pumps. An engineering model of cavitation is proposed to predict the extent of cavitation and performance. The vapor volume fraction is used as an indicator variable to quantify cavitation. A two-phase flow approach is employed with the assumption of the thermal equilibrium between liquid and vapor. At present velocity slip between the two phases is selected. Preliminary analyses of 2D flows shows qualitatively correct results.

Singhal, Ashok K.↗

NASA NTRS1991

Definition of two-phase flow behaviors for spacecraft design

Two-phase flow, thermal management systems are currently being considered as an alternative to conventional, single phase systems for future space missions because of their potential to reduce overall system mass, size, and pumping power requirements. Knowledge of flow regime transitions, heat transfer characteristics, and pressure drop correlations is necessary to design and develop two-phase systems. A boiling and condensing experiment was built in which R-12 was used as the working fluid. A two-phase pump was used to circulate a freon mixture and allow separate measurements of the vapor and liquid flow streams. The experimental package was flown five times aboard the NASA KC-135 aircraft which simulates zero-g conditions by its parabolic flight trajectory. Test conditions included stratified and annual flow regimes in 1-g which became bubbly, slug, or annular flow regimes on 0-g. A portion of this work is the analysis of adiabatic flow regimes. The superficial velocities of liquid and vapor have been obtained from the measured flow rates and are presented along with the observed flow regimes.

Reinarts, Thomas R.↗

NASA NTRS2004

Gas-Liquid Two-Phase Flow Through Packed Beds in Microgravity

Experimental data on flow pattern transitions, pressure drop, and flow characteristics for cocurrent gas–liquid flow through packed columns in microgravity is analyzed. The pulse flow regime exists over a wider range of gas and liquid flow rates under microgravity conditions. Furthermore, maps used to predict transition boundaries in normal gravity do not apply in microgravity. The flow regime data are compared to the widely used Talmor map and a new transition criterion between bubble and pulse flow in microgravity is proposed. The pressure-drop data clearly show that interfacial effects can increase the pressure drop by as much as 300% compared to those predicted by the single-phase Ergun equation. A two-phase friction factor is correlated to the superficial gas and liquid Reynolds numbers and the Suratman number. New data are also presented on the influence of gravity on the pulse amplitude and frequency.

Brian J. Motil↗

NASA NTRS2019

Rewet Temperature Correlations for Liquid-Nitrogen Boiling Pipe Flows Across Varying Flow Conditions and Orientations

In many convective liquid-vapor phase change heat transfer engineering applications, cryogenic fluids are widely used in industrial processes, spacecraft and cryosurgery systems, and so on. For example, cryogens are usually used as liquid fuels such as liquid hydrogen and oxygen in the rocket industry, liquid nitrogen (LN2) and helium are frequently used to cool superconducting magnetic device for medical applications. In these systems, proper transport, handling, and storage of cryogenic fluids are of extreme importance. Among all the cryogenic transport processes performed in room temperatures, quenching, also termed chilldown, is a unavoidable initial, transient phase-change heat transfer process that brings the system down to the cryogenic condition. The Leidenfrost temperature or rewet temperature that signals the end of film boiling is practically considered the completion point of a quenching process. Therefore, rewet temperature has been considered the most important parameter for the engineering design of cryogenic thermal management systems. As most of the previous correlations for predicting the Leidenfrost temperature and the rewet temperature have been basically developed for water, they are shown to disagree with recent liquid nitrogen pipe chilldown experiments in upward and downward flow directions over a wide range of flow rates, pressures, and degrees of inlet subcooling. In addition to a complete review of the literature, two new correlations are presented in this work, one based on bubble growth and another based on the theoretical maximum limit of superheat. Each correlation performs well over the entire data set.

liquid nitrogen↗

NASA NTRS2001

Growth and Morphology of Supercritical Fluids, a Fluid Physics Experiment Conducted on Mir, Complete

The Growth and Morphology of Supercritical Fluids (GMSF) is an international experiment facilitated by the NASA Glenn Research Center and under the guidance of U.S. principal investor Professor Hegseth of the University of New Orleans and three French coinvestigators: Daniel Beysens, Yves Garrabos, and Carole Chabot. The GMSF experiments were concluded in early 1999 on the Russian space station Mir. The experiments spanned the three science themes of near-critical phase separation rates, interface dynamics in near-critical boiling, and measurement of the spectrum of density fluctuation length scales very close to the critical point. The fluids used were pure CO2 or SF6. Three of the five thermostats used could adjust the sample volume with the scheduled crew time. Such a volume adjustment enabled variable sample densities around the critical density as well as pressure steps (as distinct from the usual temperature steps) applied to the sample. The French-built ALICE II facility was used for these experiments. It allows tightly thermostated (left photograph) samples (right photograph) to be controlled and viewed/measured. Its diagnostics include interferometry, shadowgraph, high-speed pressure measurements, and microscopy. Data were logged on DAT tapes, and PCMCIA cards and were returned to Earth only after the mission was over. The ground-breaking near critical boiling experiment has yielded the most results with a paper published in Physical Review Letters (ref. 1). The boiling work also received press in Science Magazine (ref. 2). This work showed that, in very compressible near-critical two-phase pure fluids, a vapor bubble was induced to temporarily overheat during a rapid heating of the sample wall. The temperature rise in the vapor was 23-percent higher than the rise in the driving container wall. The effect is due to adiabatic compression of the vapor bubble by the rapid expansion of fluid near the boundary during heatup. Thermal diffusivity is low near the critical point, so getting heat out of the compressed bubble is observably slow. This gives the appearance of a backward heat flow, or heat flow from a cold surface to a warm fluid.

Wilkinson, R. Allen↗

NASA NTRS2001

Effects of Gravity on Cocurrent Two-Phase Gas-Liquid Flows Through Packed Columns

This work presents the experimental results of research on the influence of gravity on flow pattern transitions, pressure drop and flow characteristics for cocurrent gas-liquid two-phase flow through packed columns. The flow pattern transition data indicates that the pulse flow regime exists over a wider range of gas and liquid flow rates under reduced gravity conditions compared to normal gravity cocurrent down-flow. This is illustrated by comparing the flow regime transitions found in reduced gravity with the transitions predicted by Talmor. Next, the effect of gravity on the total pressure drop in a packed column is shown to depend on the flow regime. The difference is roughly equivalent to the liquid static head for bubbly flow but begins to decrease at the onset of pulse flow. As the spray flow regime is approached by increasing the gas to liquid ratio, the effect of gravity on pressure drop becomes negligible. Finally, gravity tends to suppress the amplitude of each pressure pulse. An example of this phenomenon is presented.

Motil, Brian J.↗

NASA NTRS1999

Microgravity Two-Phase Flow Transition

Two-phase flows under microgravity condition find a large number of important applications in fluid handling and storage, and spacecraft thermal management. Specifically, under microgravity condition heat transfer between heat exchanger surfaces and fluids depend critically on the distribution and interaction between different fluid phases which are often qualitatively different from the gravity-based systems. Heat transfer and flow analysis in two-phase flows under these conditions require a clear understanding of the flow pattern transition and development of appropriate dimensionless scales for its modeling and prediction. The physics of this flow is however very complex and remains poorly understood. This has led to various inadequacies in flow and heat transfer modeling and has made prediction of flow transition difficult in engineering design of efficient thermal and flow systems. In the present study the available published data for flow transition under microgravity condition are considered for mapping. The transition from slug to annular flow and from bubbly to slug flow are mapped using dimensionless variable combination developed in a previous study by the authors. The result indicate that the new maps describe the flow transitions reasonably well over the range of the data available. The transition maps are examined and the results are discussed in relation to the presumed balance of forces and flow dynamics. It is suggested that further evaluation of the proposed flow and transition mapping will require a wider range of microgravity data expected to be made available in future studies.

Parang, M.↗

NASA NTRSDate not supplied

CFD Modeling & Validation of Single Bubble Growth During Cavitation in Zero Gravity

Cryogenic Fluid Management (CFM) in zero gravity represents a vital area of research as NASA pursues future long-duration space missions. Success of these missions relies heavily on the ability to store and transfer the cryogenic liquid fuels efficiently and safely. In the Zero Boil-Off Tank (ZBOT-1) Experiment in 2018, unexpected and intense phase change occurred at the screened Liquid Acquisition Device (LAD) during tank pressure control that was later attributed to cavitation. The cavitation ultimately resulted in pump failure. Since cryogen cavitation during storage and transfer of propellants in microgravity has been a source of serious concern for the aerospace community, a series of drop tower experiments with liquid methane were also performed at the University of Bremen to carefully study cavitation from a single bubble nucleus in an engineered micron-sized wall cavity. As the test cell is depressurized during the 10-second drop, cavitation causes bubble growth from the nucleus. Here, in a collaboration between the Case Western Reserve University and University of Bremen, we present a two-phase Computational Fluid Dynamics (CFD) model of bubble growth from a single wall cavity during depressurization in microgravity. Both 2D axisymmetric and 3D parametric simulation case studies are performed to show the evolution of the bubble growth. The model uses a Volume of Fluid (VOF) approach with and without adaptive mesh refinement and adaptive time stepping to capture the growth dynamics using an explicit formulation with algebraic reconstruction of the interface. CFD results show good agreement with corresponding experiment. Based on the velocity, temperature, and volume fraction fields generated by the validation case studies, detailed discussion and analysis of fluid flow and heat transfer during bubble growth process are presented to delineate the intricacies of the cavitation process. Strengths and shortcomings of the present numerical approach in capturing this phenomenon are also highlighted.

Two Phase Flow↗

NASA NTRS2005

Gas-Tolerant Device Senses Electrical Conductivity of Liquid

The figure depicts a device for measuring the electrical conductivity of a flowing liquid. Unlike prior such devices, this one does not trap gas bubbles entrained in the liquid. Usually, the electrical conductivity of a liquid is measured by use of two electrodes immersed in the liquid. A typical prior device based on this concept contains large cavities that can trap gas. Any gas present between or near the electrodes causes a significant offset in the conductivity reading and, if the gas becomes trapped, then the offset persists. Extensive tests on two-phase (liquid/ gas) flow have shown that in the case of liquid flowing along a section of tubing, gas entrained in the liquid is not trapped in the section as long as the inner wall of the section is smooth and continuous, and the section is the narrowest tubing section along the flow path. The design of the device is based on the foregoing observation: The electrodes and the insulators separating the electrodes constitute adjacent parts of the walls of a tube. The bore of the tube is machined to make the wall smooth and to provide a straight flow path from the inlet to the outlet. The diameter of the electrode/insulator tube assembly is less than the diameter of the inlet or outlet tubing. An outer shell contains the electrodes and insulators and constitutes a leak and pressure barrier. Any gas bubble flowing through this device causes only a momentary conductivity offset that is filtered out by software used to process the conductivity readings.

O'Connor, Edward W.↗

NASA NTRS1997

Modeling of Water Injection into a Vacuum

A loosely coupled two-phase vacuum water plume model has been developed. This model consists of a source flow model to describe the expansion of water vapor, and the Lagrangian equations of motion for particle trajectories. Gas/Particle interaction is modeled through the drag force induced by the relative velocities. Particles are assumed traveling along streamlines. The equations of motion are integrated to obtain particle velocity along the streamline. This model has been used to predict the mass flux in a 5 meter radius hemispherical domain resulting from the burst of a water jet of 1.5 mm in diameter, mass flow rate of 24.2 g/s, and stagnation pressure of 21.0 psia, which is the nominal Orbiter water dump condition. The result is compared with an empirical water plume model deduced from a video image of the STS-29 water dump. To further improve the model, work has begun to numerically simulate the bubble formation and bursting present in a liquid stream injected into a vacuum. The technique of smoothed particle hydrodynamics was used to formulate this simulation. A status and results of the on-going effort are presented and compared to results from the literature.

Alred, John W.↗

NASA NTRS2021

Experimental and Computational Investigation of Flow Boiling in Microgravity

This study explores use of Computational Fluid Dynamics (CFD) to predict near-saturated flow boiling of FC-72 in microgravity. The computational method employs transient analysis to predict detailed interfacial behavior and heat transfer characteristics along a rectangular channel heated along two opposite walls. Predicted results are validated against experimental temperature measurements and high-speed video images captured during a series of parabolic aircraft maneuvers for three sets of operating conditions which include variations of both mass velocity and wall heat flux. The computational method is based on the multi-phase volume of fluid (VOF) model, which is combined with appropriate phase change and turbulence models, and accounts for both shear-lift force on bubbles and conjugate heat transfer along the heating walls. A key advantage of the CFD method is ability to capture details that are very difficult to measure experimentally, including detailed spatial variations of bubble shape, void fraction, mixture fluid temperature, liquid velocity, and vapor velocity, results for which are presented for each of the three test cases. Different flow regimes predicted along the heated length exhibit a number of dominant mechanisms including bubble nucleation, bubble growth, coalescence, vapor blankets, interfacial waviness, and residual liquid sub-layer, all of which agree well with experiment. Vapor velocity is shown to increase appreciably along the heated length because of increased void fraction, while liquid velocity experiences large fluctuations. Non-equilibrium effects are accentuated with increasing mass velocity, contributing minor deviations of fluid temperature from simulations compared to those predicted by the analytical method. Predicted wall temperature is fairly uniform in the middle of the heated length but increases in the entrance region, due to sensible heat transfer in the subcooled liquid, and decreases toward the exit, mostly because of flow acceleration resulting from increased void fraction.

two-phase cooling; flow boiling; CFD; microgravity↗

NASA NTRSDate not supplied

Mini-Channel Flow Boiling in 1g and μg

Subcooled flow boiling combines complex processes governed by a strong coupling of heat and mass transfer, hydrodynamics, and liquid-vapor transitions. The gravitational body force plays an important role in these processes. By exploiting the latent heat of vaporization, subcooled flow boiling can transfer up to several orders-of-magnitude more heat compared to forced liquid flow. It is widely used in Earth-based thermal equipment to reduce the cost, size, and power required to move heat. Subcooled flow boiling is now considered a promising technology for space applications since it offers a means to control the motion of bubbles near the heated surface and thereby enhance nucleate boiling. However, a lack of data and predictive models on the role that gravity plays in these phenomena hinders the use of flow boiling in a microgravity environment. We will present results of experiments on transients in nucleate boiling that were carried out in the Flow Boiling Module (FBM) on the International Space Station (ISS). The unique ISS FBM ability is to couple large heat loads with flow visualization in testing flow boiling under strict control of experimental conditions in long-duration microgravity. Comparison of results of microgravity experiments with data obtained in a similar setup on the NASA GRC demonstrates the role of gravity in nucleate boiling. The work is supported by the NASA Flight Opportunities program (grant 80NSSC21K0501) and NSF/CASIS program (NSF CBET grants 1832260, 2126461, 2126462).

Two-phase flow and phase transition↗

NASA NTRSDate not supplied

Validation of CFD Model Prediction of Flow Boiling Regime Transitions during LN2 Line Chilldown

Propellant storage and transfer during future long-duration missions will involve fuel depot operations in which a donor depot tank is used to fill a receiver spacecraft tank with a cryogenic propellant. Prior to the on-Orbit filling operation both the receiver tank and the transfer line must be cooled. The line chilldown process involves transition between boiling regimes in microgravity that will be quite different from their 1g ground-based counterparts. Since the cryogenic propellant itself will be used to perform the chilldown process, the time constants to cool the wall and the amount of fuel that will be used become important design considerations. In this light, the focus of the present work is to understand the flow boiling characteristics of a cryogenic fluid, namely, liquid nitrogen, during the chill-down of a transfer line using CFD modelling and simulations. The cryogenic chill-down process involves different flow boiling regimes: film boiling, transition boiling and nucleate boiling. The prediction of transition between these regimes in a CFD framework is new and challenging. The present work addresses this challenge by employing a volume-of-fluid (VOF) based methodology with Lee phase change model to predict the film boiling regime of the chill-down process in ANSYS Fluent®. The transition and nucleate boiling regimes are predicted by incorporating a sub-grid model developed by Craft Tech that accounts for bubble nucleation, growth, shedding frequency, and departure diameter. The sub-grid model is implemented into Fluent via a user-defined function for wall-fluid heat flux calculations. The sub-grid model is similar in formulation to the well-known Rensselaer Polytechnic Institute (RPI) boiling model. The model constants are tested for different operating conditions and designated values are reported. The CFD model is validated against published experimental data for liquid nitrogen chill-down of a heated stainless-steel pipe in 1g. Predicted results showing good agreement of wall temperature, rewetting temperature, and transition between film and nucleate boiling with the experimental measurements are presented and discussed.

Boiling regimes↗

NASA NTRS1975

Non-equilibrium one-dimensional two-phase flow in variable area channels

A one-dimensional nonequilibrium flow analysis has been formulated for a one component two phase flow. The flow is considered homogeneous and essentially isothermal. Phase change is assumed to occur at heterogeneous nucleation sites and the growth of the vapor bubbles is governed by heat conduction from the liquid to the bubble. The analysis adjusted for friction is applied to liquid nitrogen flow in a venturi and comparison is made with the NASA experimental results of Simoneau. Good agreement with the experiments is obtained when one assumes the effective activation energy for nucleus formation to be small but nonzero. The computed pressure distributions deviate from the experimental results in the throat region of the venturi in a manner consistent with centrifugal effects not accounted for in the one-dimensional theory. The results are shown to depend not only on cavitation number but on additional dimensionless parameters governing the nonequilibrium production and subsequent growth of nuclei.

Rohatgi, U. S.↗

NASA NTRS1980

Conceptual design of two-phase fluid mechanics and heat transfer facility for spacelab

Five specific experiments were analyzed to provide definition of experiments designed to evaluate two phase fluid behavior in low gravity. The conceptual design represents a fluid mechanics and heat transfer facility for a double rack in Spacelab. The five experiments are two phase flow patterns and pressure drop, flow boiling, liquid reorientation, and interface bubble dynamics. Hardware was sized, instrumentation and data recording requirements defined, and the five experiments were installed as an integrated experimental package. Applicable available hardware was selected in the experiment design and total experiment program costs were defined.

North, B. F.↗

NASA NTRS1981

Depressurization and two-phase flow of water containing high levels of dissolved nitrogen gas

Depressurization of water containing various concentrations of dissolved nitrogen gas was studied. In a nonflow depressurization experiment, water with very high nitrogen content was depressurized at rates from 0.09 to 0.50 MPa per second and a metastable behavior which was a strong function of the depressurization rate was observed. Flow experiments were performed in an axisymmetric, converging diverging nozzle, a two dimensional, converging nozzle with glass sidewalls, and a sharp edge orifice. The converging diverging nozzle exhibited choked flow behavior even at nitrogen concentration levels as low as 4 percent of the saturation level. The flow rates were independent of concentration level. Flow in the two dimensional, converging, visual nozzle appeared to have a sufficient pressure drop at the throat to cause nitrogen to come out of solution, but choking occurred further downstream. The orifice flow motion pictures showed considerable oscillation downstream of the orifice and parallel to the flow. Nitrogen bubbles appeared in the flow at back pressures as high as 3.28 MPa, and the level at which bubbles were no longer visible was a function of nitrogen concentration.

Simoneau, R. J.↗

NASA NTRS2000

Computations of Boiling in Microgravity

The absence (or reduction) of gravity, can lead to major changes in boiling heat transfer. On Earth, convection has a major effect on the heat distribution ahead of an evaporation front, and buoyancy determines the motion of the growing bubbles. In microgravity, convection and buoyancy are absent or greatly reduced and the dynamics of the growing vapor bubbles can change in a fundamental way. In particular, the lack of redistribution of heat can lead to a large superheat and explosive growth of bubbles once they form. While considerable efforts have been devoted to examining boiling experimentally, including the effect of microgravity, theoretical and computational work have been limited. Here, the growth of boiling bubbles is studied by direct numerical simulations where the flow field is fully resolved and the effects of inertia, viscosity, surface deformation, heat conduction and convection, as well as the phase change, are fully accounted for. Boiling involves both fluid flow and heat transfer and thus requires the solution of the Navier-Stokes and the energy equations. The numerical method is based on writing one set of governing transport equations which is valid in both the liquid and vapor phases. This local, single-field formulation incorporates the effect of the interface in the governing equations as source terms acting only at the interface. These sources account for surface tension and latent heat in the equations for conservation of momentum and energy as well as mass transfer across the interface due to phase change. The single-field formulation naturally incorporates the correct mass, momentum and energy balances across the interface. Integration of the conservation equations across the interface directly yields the jump conditions derived in the local instant formulation for two-phase systems. In the numerical implementation, the conservation equations for the whole computational domain (both vapor and liquid) are solved using a stationary grid and the phase boundary is followed by a moving unstructured two-dimensional grid. While two-dimensional simulations have been used for preliminary studies and to examine the resolution requirement, the focus is on fully three-dimensional simulations. The numerical methodology, including the parallelization and grid refinement strategy is discussed, and preliminary results shown. For buoyancy driven flow, the heat transfer is in good agreement with experimental correlations. The changes when gravity is turned off and/or fluid shear is added are discussed, as well as the difference between simulations of a layer freely releasing bubbles versus simulations using only one wavelength initial perturbation. Figure 1 shows the early stages of the formation of a three-dimensional bubble from a thin vapor layer. The boundary conditions are periodic in the x and y direction, the bottom is a hot and the top allows a free outflow. The jagged edge of the surface close to the bottom of the computational domain is due to some of the surface elements being on the other side of the domain and some elements not plotted by our plotting routine. In the second figure, we show the temperature distribution through two perpendicular planes.

Tryggvason, G.↗

NASA NTRS2001

Near-Horizontal, Two-Phase Flow Patterns of Nitrogen and Hydrogen at Low Mass Heat and Flux (on CD-ROM)

One reason for NASA's interest in cryogenic two-phase flow with low mass and heat flux is the need to design spacecraft heat exchangers used for vaporizing cryogenic propellants. The CD-ROM provides digitized movies of particular flow patterns observed in experimental work. The movies have been provided in (QuickTime9Trademark) format, encoded at 320w x 240h pixels, 15 fps, using the Sorenson(Trademark) Video Codec for compression. Experiments were conducted to obtain data on the two-phase (liquid and vapor) flow behavior of cryogenic nitrogen and hydrogen under low mass and heat flux conditions. Tests were performed in normal gravity with a 1.5 degree up flow configuration. View ports in the apparatus permitted visual observation of the two-phase flow patterns. Computer codes to predict flow patterns were developed from theoretical/empirical models reported in the literature. Predictions from the computer codes were compared with experimental flow pattern observations. Results are presented employing the traditional two-dimensional flow pattern map format using the liquid and gas superficial velocities as coordinates. In general, the agreement between the experimental results and the analytical predictive methods is reasonably good. Small regions of the flow pattern maps are identified where the models are deficient as a result of neglecting phase change phenomena. Certain regions of the maps were beyond the range of the experiments and could not be completely validated. Areas that could benefit from further work include modeling of the transition from separated flow, collection of additional data in the bubble and annular flow regimes, and collection of experimental data at other inclination angles, tube diameters and high heat flux.

TWO PHASE FLOW↗