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NASA NTRS2008

Probing a Spray Using Frequency-Analyzed Light Scattering

Frequency-analyzed laser-light scattering (FALLS) is a relatively simple technique that can be used to measure principal characteristics of a sheet of sprayed liquid as it breaks up into ligaments and then the ligaments break up into droplets. In particular, through frequency analysis of laser light scattered from a spray, it is possible to determine whether the laser-illuminated portion of the spray is in the intact-sheet region, the ligament region, or the droplet region. By logical extension, it is possible to determine the intact length from the location of the laser beam at the transition between the intact-sheet and ligament regions and to determine a breakup frequency from the results of the frequency analysis. Hence, FALLS could likely be useful both as a means of performing research on sprays in general and as a means of diagnostic sensing in diverse applications in which liquid fuels are sprayed. Sprays are also used for drying and to deposit paints and other coating materials.

Eskridge, Richard↗

NASA NTRS2011

Gas Dynamic Spray Technology Demonstration Project Management

The standard practice for protecting metallic substrates in atmospheric environments is the use of an applied coating system. Current coating systems used across AFSPC and NASA contain volatile organic compounds (VOCs) and hazardous air pollutants (HAPs). These coatings are sUbject to environmental regulations at the Federal and State levels that limit their usage. In addition, these coatings often cannot withstand the high temperatures and exhaust that may be experienced by Air Force Space Command (AFSPC) and NASA structures. In response to these concerns, AFSPC and NASA have approved the use of thermal spray coatings (TSCs). Thermal spray coatings are extremely durable and environmentally friendly coating alternatives, but utilize large cumbersome equipment for application that make the coatings difficult and time consuming to repair. Other concerns include difficulties coating complex geometries and the cost of equipment, training, and materials. Gas Dynamic Spray (GOS) technology (also known as Cold Spray) was evaluated as a smaller, more maneuverable repair method as well as for areas where thermal spray techniques are not as effective. The technology can result in reduced maintenance and thus reduced hazardous materials/wastes associated with current processes. Thermal spray and GOS coatings also have no VOCs and are environmentally preferable coatings. The primary objective of this effort was to demonstrate GDS technology as a repair method for TSCs. The aim was that successful completion of this project would result in approval of GDS technology as a repair method for TSCs at AFSPC and NASA installations to improve corrosion protection at critical systems, facilitate easier maintenance activity, extend maintenance cycles, eliminate flight hardware contamination, and reduce the amount of hazardous waste generated.

Lewis, Pattie↗

NASA NTRS2008

Joint Test Plan for Gas Dynamic Spray Technology Demonstration

Air Force Space Command (AFSPC) and NASA have similar missions, facilities, and structures located in similar harsh environments. Both are responsible for a number of facilities/structures with metallic structural and non-structural components in highly and moderately corrosive environments. Regardless of the corrosivity of the environment, all metals require periodic maintenance activity to guard against the insidious effects of corrosion and thus ensure that structures meet or exceed design or performance life. The standard practice for protecting metallic substrates in atmospheric environments is the use of an applied coating system. Current coating systems used across AFSPC and NASA contain volatile organic compounds (VOCs) and hazardous air pollutants (HAPs). These coatings are subject to environmental regulations at the Federal and State levels that limit their usage. In addition, these coatings often cannot withstand the high temperatures and exhaust that may be experienced by AFSPC and NASA structures. In response to these concerns, AFSPC and NASA have approved the use of thermal spray coatings (TSCs). Thermal spray coatings are extremely durable and environmentally friendly coating alternatives, but utilize large cumbersome equipment for application that make the coatings difficult and time consuming to repair. Other concerns include difficulties coating complex geometries and the cost of equipment, training, and materials. Gas Dynamic Spray (GDS) technology (also known as Cold Spray) will be evaluated as a smaller, more maneuverable repair method as well as for areas where thermal spray techniques are not as effective. The technology can result in reduced maintenance and thus reduced hazardous materials/wastes associated with current processes. Thermal spray and GDS coatings also have no VOCs and are environmentally preferable coatings. To achieve a condition suitable for the application of a coating system, including GDS coatings, the substrate must undergo some type of surface preparation and/or depainting operation to ensure adhesion of the new coating system. The GDS unit selected for demonstration has a powder feeding system that can be used for surface preparation or coating application. The surface preparation feature will also be examined. The primary objective of this effort is to demonstrate GDS technology as a repair method for TSCs. The project will also determine the optimal GDS coating thickness for acceptable performance. Successful completion of this project will result in approval of GDS technology as a repair method for TSCs at AFSPC and NASA installations and will improve corrosion protection at critical systems, facilitate easier maintenance activity, extend maintenance cycles, eliminate flight hardware contamination, and reduce the amount of hazardous waste generated.

Lewis, Pattie↗

NASA NTRS2016

An Overview of Spray Modeling With OpenNCC and its Application to Emissions Predictions of a LDI Combustor at High Pressure

The open national combustion code (Open- NCC) is developed with the aim of advancing the current multi-dimensional computational tools used in the design of advanced technology combustors. In this paper we provide an overview of the spray module, LSPRAY-V, developed as a part of this effort. The spray solver is mainly designed to predict the flow, thermal, and transport properties of a rapidly evaporating multi-component liquid spray. The modeling approach is applicable over a wide-range of evaporating conditions (normal, superheat, and supercritical). The modeling approach is based on several well-established atomization, vaporization, and wall/droplet impingement models. It facilitates large-scale combustor computations through the use of massively parallel computers with the ability to perform the computations on either structured & unstructured grids. The spray module has a multi-liquid and multi-injector capability, and can be used in the calculation of both steady and unsteady computations. We conclude the paper by providing the results for a reacting spray generated by a single injector element with 600 axially swept swirler vanes. It is a configuration based on the next-generation lean-direct injection (LDI) combustor concept. The results include comparisons for both combustor exit temperature and EINOX at three different fuel/air ratios.

spray modeling↗

NASA NTRS1977

Development of a plasma sprayed ceramic gas path seal for high pressure turbine applications

The plasma sprayed graded layered yittria stabilized zirconia (ZrO2)/metal(CoCrAlY) seal system for gas turbine blade tip applications up to 1589 K (2400 F) seal temperatures was studied. Abradability, erosion, and thermal fatigue characteristics of the graded layered system were evaluated by rig tests. Satisfactory abradability and erosion resistance was demonstrated. Encouraging thermal fatigue tolerance was shown. Initial properties for the plasma sprayed materials in the graded, layered seal system was obtained, and thermal stress analyses were performed. Sprayed residual stresses were determined. Thermal stability of the sprayed layer materials was evaluated at estimated maximum operating temperatures in each layer. Anisotropic behavior in the layer thickness direction was demonstrated by all layers. Residual stresses and thermal stability effects were not included in the analyses. Analytical results correlated reasonably well with results of the thermal fatigue tests. Analytical application of the seal system to a typical gas turbine engine application predicted performance similar to rig specimen thermal fatigue performance. A model for predicting crack propagation in the sprayed ZrO2/CoCrAlY seal system was proposed, and recommendations for improving thermal fatigue resistance were made. Seal system layer thicknesses were analytically optimized to minimize thermal stresses in the abradability specimen during thermal fatigue testing. Rig tests on the optimized seal configuration demonstrated some improvement in thermal fatigue characteristics.

Shiembob, L. T.↗

NASA NTRS1977

Combustion of liquid sprays at high pressures

The combustion of pressure atomized fuel sprays in high pressure stagnant air was studied. Measurements were made of flame and spray boundaries at pressures in the range 0.1-9 MPa for methanol and n-pentane. At the higher test pressure levels, critical phenomena are important. The experiments are compared with theoretical predictions based on a locally homogeneous two-phase flow model. The theory correctly predicted the trends of the data, but underestimates flame and spray boundaries by 30-50 percent, indicating that slip is still important for the present experiments (Sauter mean diameters of 30 microns at atmospheric pressure under cold flow conditions). Since the sprays are shorter at high pressures, slip effects are still important even though the density ratio of the phases approach one another as the droplets heat up. The model indicates the presence of a region where condensed water is present within the spray and provides a convenient means of treating supercritical phenomena.

Shearer, A. J.↗

NASA NTRS1978

The role of drop velocity in statistical spray description

The justification for describing a spray by treating drop velocity as a random variable on an equal statistical basis with drop size was studied experimentally. A double-exposure technique using fluorescent drop photography was used to make size and velocity measurements at selected locations in a steady ethanol spray formed by a swirl atomizer. The size-velocity data were categorized to construct bivariate spray density functions to describe the spray immediately after formation and during downstream propagation. It was found that a statistical treatment of drop velocity was supported by the data. Spray density function shapes and modal characteristics depended strongly on position and the amount of droplet-gas interaction that had occurred. Bimodal density functions were formed by environmental interaction during downstream propagation. Large differences were also found between spatial mass density and mass flux size distributions at the same location.

Groeneweg, J. F.↗

NASA NTRS1980

Evaluation of a locally homogeneous flow model of spray combustion

A model of spray combustion which employs a second-order turbulence model was developed. The assumption of locally homogeneous flow is made, implying infinitely fast transport rates between the phase. Measurements to test the model were completed for a gaseous n-propane flame and an air atomized n-pentane spray flame, burning in stagnant air at atmospheric pressure. Profiles of mean velocity and temperature, as well as velocity fluctuations and Reynolds stress, were measured in the flames. The predictions for the gas flame were in excellent agreement with the measurements. The predictions for the spray were qualitatively correct, but effects of finite rate interphase transport were evident, resulting in a overstimation of the rate development of the flow. Predictions of spray penetration length at high pressures, including supercritical combustion conditions, were also completed for comparison with earlier measurements. Test conditions involved a pressure atomized n-pentane spray, burning in stagnant air at pressures of 3, 5, and 9 MPa. The comparison between predictions and measurements was fair. This is not a very sensitive test of the model, however, and further high pressure experimental and theoretical results are needed before a satisfactory assessment of the locally homogeneous flow approximation can be made.

Mao, C. P.↗

NASA NTRS1984

Measurement of spray combustion processes

A free jet configuration was chosen for measuring noncombusting spray fields and hydrocarbon-air spray flames in an effort to develop computational models of the dynamic interaction between droplets and the gas phase and to verify and refine numerical models of the entire spray combustion process. The development of a spray combustion facility is described including techniques for laser measurements in spray combustion environments and methods for data acquisition, processing, displaying, and interpretation.

Peters, C. E.↗

NASA NTRS1983

Evaporation and combustion of sprays

A description is provided of recent spray evaporation and combustion models, taking into account turbulent two- and three-dimensional spray processes found in furnaces, gas turbine combustors, and internal combustion engines. Within the class of spray models of interest, two major categories are distinguished, including locally homogeneous flow (LHF) models and separated flow (SF) models. SF models are of the greatest practical importance, but LHF models have distinct advantages in some cases. Attention is also given to recent progress on modeling interactions between drops and the flow in both dilute and dense sprays, involving sprays having low and high liquid volume fractions, respectively.

Faeth, G. M.↗

NASA NTRS1984

Analytic modeling of a spray diffusion flame

A detailed model for a spray diffusion flame is described. The model is based on the boundary layer form of the equations of motion, with droplet transport accounted for using a discretized droplet size distribution function. Interphase transport of mass and energy are accounted for, with a flame-sheet model used to describe the combustion process on a droplet scale. Near dynamic equilibrium is assumed for the description of droplet transport; droplets can diffuse relative to the gas phase. Gas-phase mixing is accounted for using a two-equation turbulence model; buoyancy effects are included, with a temperature fluctuation equation used to account for buoyancy effects on turbulence structure. Thermal radiation from gas-phase CO2 and H2O is included. Gas-phase chemical kinetics are modeled using a 20-reaction, 10-species version of the advanced quasi-global chemical kinetics formulation. Results are compared with data for a vaporizing Freon spray and a pentane spray flame. It is shown that the computational approach provides a reasonably valid picture of the overall development of a spray diffusion flame, and, furthermore, provides a useful tool for the parametric examination of the spray combustion process.

Harsha, P. T.↗

NASA NTRS1986

Spray atomization and combustion

New theoretical and experimental methods for studying sprays are reviewed. Common methods to analyze dilute sprays are described and used to interpret recent measurements of the structure of dilute sprays and related dispersed turbulent jets. Particle-laden jets, nonevaporating, evaporating, and combusting sprays, and noncondensing and condensing bubbly jets are examined and used to initially evaluate current analytical methods for a wide range of conditions. Dense sprays are briefly discussed.

Faeth, G. M.↗

NASA NTRS1987

Two-phase flow measurements of a spray in a turbulent flow

The dynamics of spray drop interaction with a turbulent coflowing air stream were investigated using a Phase Doppler Particle Analyzer that determines both drop size and velocity. Detailed measurements obtained included spray drop size, axial and radial velocity, angle of trajectory, drop Reynolds number, and size-velocity correlations. The gas-phase flow field was also ascertained via the behavior of the smallest drops. Also investigated were the drag coefficients of droplets in a turbulent air cross flow for both monodispersions and polydispersions. Most notable aspects of the coflow included the effect of air streams with velocities significantly different from the spray sheet. Local changes in number density were produced as a result of lateral convection and streamwise accelerations and decelerations of various drop size classes. The complexity of the spray field interaction illustrated by this data effectively describes the development of the spray due to the influence of the airflow. The droplet drag measurements showed similar behavior for monodispersed and polydispersed flows and similar trends to previously obtained data. The measurements also pointed out further studies which would assist in creating an improved drag law for polydispersed drops in a turbulent environment.

Rudoff, R. C.↗

NASA NTRS1986

Flow rate and trajectory of water spray produced by an aircraft tire

One of the risks associated with wet runway aircraft operation is the ingestion of water spray produced by an aircraft's tires into its engines. This problem can be especially dangerous at or near rotation speed on the takeoff roll. An experimental investigation was conducted in the NASA Langley Research Center Hydrodynamics Research Facility to measure the flow rate and trajectory of water spray produced by an aircraft nose tire operating on a flooded runway. The effects of various parameters on the spray patterns including distance aft of nosewheel, speed, load, and water depth were evaluated. Variations in the spray pattern caused by the airflow about primary structure such as the fuselage and wing are discussed. A discussion of events in and near the tire footprint concerning spray generation is included.

Daugherty, Robert H.↗

NASA NTRS1987

Two-phase measurements of a spray in the wake of a bluff body

The dynamics of spray drop interaction with the turbulent, recirculating wake of a flat disk bluff body were investigated using a phase Doppler particle analyzer to determine drop size and velocity and the gas-phase velocity. Detailed measurements obtained included spray drop size, axial and radial velocity, angle of trajectory, and size-velocity correlations. The gas-phase velocity was determined from seeding of the two-phase flow. Results showed dramatic differences in drop behavior for various size classes when interacting with the turbulent flow field. Small drops were quickly entrained and recirculated, while initially, the larger drops continued in the general direction of the spray cone. Further downstream, significant numbers of large drops recirculated, generating a bifurcated size-velocity correlation. These lateral convections and streamwise accelerations and decelerations strongly influenced the number density along with size and velocity distributions. The complex interaction of the spray with the turbulent air-flow points out the need for spatially-resolved measurements that determine drop behavior for individual size classes, rather than characterizing a spray only via simple integral quantities such as the Sauter mean diameter.

Rudoff, R. C.↗

NASA NTRS1988

Liquid sprays and flow studies in the direct-injection diesel engine under motored conditions

A two dimensional, implicit finite difference method of the control volume variety, a two equation model of turbulence, and a discrete droplet model were used to study the flow field, turbulence levels, fuel penetration, vaporization, and mixing in diesel engine environments. The model was also used to study the effects of engine speed, injection angle, spray cone angle, droplet distribution, and intake swirl angle on the flow field, spray penetration and vaporization, and turbulence in motored two-stroke diesel engines. It is shown that there are optimum conditions for injection, which depend on droplet distribution, swirl, spray cone angle, and injection angle. The optimum conditions result in good spray penetration and vaporization and in good fuel mixing. The calculation presented clearly indicates that internal combustion engine models can be used to assess, at least qualitatively, the effects of injection characteristics and engine operating conditions on the flow field and on the spray penetration and vaporization in diesel engines.

Nguyen, Hung Lee↗

NASA NTRS1987

Experiments on spray interactions in the wake of a bluff body

The dynamics of spray drop interaction within the turbulent wake of a bluff body were investigated using the Aerometrics Phase Doppler Particle Analyzer that determines both drop size and velocity. Detailed measurements obtained included spray drop size, axial and radial velocity, angle of trajectory, and size-velocity correlations. The gas-phase flow field was also ascertained via the behavior of the smallest drops. Results showed dramatic differences in drop behavior when interacting with turbulence for the various size classes. Small drops were recirculated in a pair of toroidal vortices located behind the bluff body, whereas the larger drops followed the general direction of the spray cone angle. The spray field interaction illustrated by these data casts some doubt on attempts to describe sprays via simple integral quantities such as the Sauter mean diameter.

Rudoff, R. C.↗

NASA NTRS1989

Computations of turbulent evaporating sprays

A computational study of turbulent evaporating sprays is reported. The major focus is to examine the sensitivity of the vaporization behavior of turbulent sprays to the transient liquid-phase processes. Three models considered to represent these processes are the thin skin, infinite diffusion, and diffusion limit models. Favre-averaged equations with k-epsilon-g turbulence model are employed for the gas phase. The Lagrangian approach with a stochastic separated flow method is used for the liquid phase where the effects of gas turbulence on droplet trajectories and interphase transport rates are considered using random-walk computations. Also the variable-property effects are considered in detail. Results indicate that, depending upon the boiling temperature and heat of vaporization of the fuel considered, the vaporization behavior of turbulent sprays may be quite sensitive to the modeling of transient liquid-phase processes. Thus, it is important that for most hydrocarbon fuels these processes be adequately represented in any comprehensive spray computations. The present results also provide further support to the conclusions of earlier studies which have been based on simplified spray configurations.

Aggarwal, S. K.↗