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Fundamentals of Mold Free Casting: Experimental and Computational Studies

Researchers are developing the technology of 'Ballistic Particle Manufacturing' (BPM) in which individual drops are precisely layered onto a substrate, and the drops are deposited so as to prevent splatting. These individual drops will ultimately be combined to form a net-shape, three-dimensional object. Our understanding of controlled drop deposition as applied to BPM is far from complete. Process parameters include the size and temperature of the liquid metal drop, its impact velocity and trajectory, and the condition and temperature of the substrate. Quantitative knowledge of the fluid mechanics and heat transfer of drop deposition and solidification are necessary to fully optimize the manufacturing process and to control the material microstructure of the final part. The object of this study is to examine the dynamics of liquid metal drops as they impinge upon a solid surface and solidify under conditions consistent with BPM (i.e. conditions which produce non-splatting drops). A program of both numerical simulations and experiments will be conducted. Questions this study will address include the following: How do the deformation and solidification of the drop depend on the properties of the fluid drop and the solid substrate? How does the presence of previously deposited drops affect the impingement and solidification process? How does the impingement of the new drop affect already deposited material? How does the cooling rate and solidification of the drops influence the material microstructure?

Tryggvason, Gretar↗

Irreversible Entropy Production in Two-Phase Mixing Layers

This report presents a study of dissipation (irreversible production of entropy) in three-dimensional, temporal mixing layers laden with evaporating liquid drops. The purpose of the study is to examine the effects of evaporating drops on the development of turbulent features in flows. Direct numerical simulations were performed to analyze transitional states of three mixing layers: one without drops, and two that included drops at different initial mass loadings. Without drops, the dissipation is essentially due to viscous effects. It was found that in the presence of drops, the largest contribution to dissipation was made by heating and evaporation of the drops, and that at large length scales, this contribution is positive (signifying that the drops reduce turbulence), while at small scales, this contribution is negative (the drops increase turbulence). The second largest contribution to dissipation was found to be associated with the chemical potential, which leads to an increase in turbulence at large scales and a decrease in turbulence at small scales. The next smaller contribution was found to be that of viscosity. The fact that viscosity effects are only third in order of magnitude in the dissipation is in sharp contrast to the situation for the mixing layer without the drops. The next smaller contribution - that of the drag and momentum of the vapor from the drops - was found to be negative at lower mass loading but to become positive at higher mass loading.

Okongo, Nora↗

Comparison of Raindrop Size Distribution Measurements by Collocated Disdrometers

An impact-type Joss-Waldvogel disdrometer (JWD), a two-dimensional video disdrometer (2DVD), and a laser optical OTT Particle Size and Velocity (PARSIVEL) disdrometer (PD) were used to measure the raindrop size distribution (DSD) over a 6-month period in Huntsville, Alabama. Comparisons indicate event rain totals for all three disdrometers that were in reasonable agreement with a reference rain gauge. In a relative sense, hourly composite DSDs revealed that the JWD was more sensitive to small drops (,1 mm), while the PD appeared to severely underestimate small drops less than 0.76mm in diameter. The JWD and 2DVD measured comparable number concentrations of midsize drops (1-3mm) and large drops (3-5 mm), while the PD tended to measure relatively higher drop concentrations at sizes larger than 2.44mm in diameter. This concentration disparity tended to occur when hourly rain rates and drop counts exceeded 2.5mm/h and 400/min, respectively. Based on interactions with the PD manufacturer, the partially inhomogeneous laser beam is considered the cause of the PD drop count overestimation. PD drop fall speeds followed the expected terminal fall speed relationship quite well, while the 2DVD occasionally measured slower drops for diameters larger than 2.4mm, coinciding with events where wind speeds were greater than 4m/s. The underestimation of small drops by the PD had a pronounced effect on the intercept and shape of parameters of gamma-fitted DSDs, while the overestimation of midsize and larger drops resulted in higher mean values for PD integral rain parameters

disdrometers↗

Flame-Vortex Interactions Imaged in Microgravity - To Assess the Theory Flame Stretch

The goals of this research are to: 1) Assess the Theory of Flame Stretch by operating a unique flame-vortex experiment under microgravity conditions in the NASA Glenn 2.2 Second Drop Tower (drops to identify operating conditions have been completed); 2) Obtain high speed shadowgraph images (500-1000 frames/s) using the drop rig (images were obtained at one-g, and the NASA Kodak RO camera is being mounted on the drop rig); 3) Obtain shadowgraph and PIV images at 1-g while varying the effects of buoyancy by controlling the Froude number (completed); 4) Numerically model the inwardly-propagating spherical flame that is observed in the experiment using full chemistry and the RUN 1DL code (completed); 5) Send images of the flame shape to Dr. G. Patniak at NRL who is numerically simulating the entire flame-vortex interaction of the present experiment (data transfer completed); and 6) Assess the feasibility of obtaining PIV velocity field images in the drop rig, which would be useful (but not required) for our assessment of the Theory of Flame Stretch (PIV images were obtained at one-g using same low laser power that is available from fiber optic cable in drop tower). The motivation for the work is to obtain novel measurement needed to develop a physically accurate model of turbulent combustion that can help in the control of engine pollutants. The unique experiment allows, for the first time, the detailed study of a negatively-curved (negatively stretched) flame, which is one of the five fundamental types of premixed flames. While there have been studies of flat flames, positively-curved (outwardly-propagating) cases and positively-strained (counterflow) cases, this is the first detailed study of a negatively-curved (inwardly-propagating) flame. The first set of drops in the 2.2 Second Drop Tower showed that microgravity provides more favorable conditions for achieving inwardly-propagating flames (IPFs) than 1-g. A vortex interacts with a flame and creates a spherical pocket, which burns inwardly. Shadowgraphs at 1000 frames/sec quantify the Markstein number and flame speed. A Low-Laser Power PIV System was developed and is being added to the drop package. Numerical computations were required to explain why the Markstein numbers measured for the inwardly-propagating flames differ from those of outward propagating flames; this is an important research issue in the assessment of the Theory of Flame Stretch. The RUN-1DL code (developed by Prof. B. Rogg) was run for IPF and OPFs with complex methane and propane chemistry. Results confirmed that Ma for the IPFs are larger than for OPFs as was observed experimentally. Physical reasons for these new findings about the Theory of Flame Stretch are being determined from the experiments and the computations. Several journal papers have been published; the drop package is described in the AIAA Journal, while the one-g results appear in three other journal papers.

Driscoll, James F.↗

Improved Control of Charging Voltage for Li-Ion Battery

The protocol for charging a lithium-ion battery would be modified, according to a proposal, to compensate for the internal voltage drop (charging current internal resistance of the battery). The essence of the modification is to provide for measurement of the internal voltage drop and to increase the terminal-voltage setting by the amount of the internal voltage drop. Ordinarily, a lithium-ion battery is charged at constant current until its terminal voltage attains a set value equal to the nominal full-charge potential. The set value is chosen carefully so as not to exceed the lithium-plating potential, because plated lithium in metallic form constitutes a hazard. When the battery is charged at low temperature, the internal voltage drop is considerable because the electrical conductivity of the battery electrolyte is low at low temperature. Charging the battery at high current at any temperature also gives rise to a high internal voltage drop. In some cases, the internal voltage drop can be as high as 1 volt per cell. Because the voltage available for charging is less than the terminal voltage by the amount of the internal voltage drop, the battery is not fully charged (see figure), even when the terminal voltage reaches the set value. In the modified protocol, the charging current would be periodically interrupted so that the zero-current battery-terminal voltage indicative of the state of charge could be measured. The terminal voltage would also be measured at full charging current. The difference between the full-current and zero-current voltages would equal the internal voltage drop. The set value of terminal voltage would then be increased beyond the nominal full-charge potential by the amount of the internal voltage drop. This adjustment would be performed repeatedly, in real time, so that the voltage setting would track variations in the internal voltage drop to afford full charge without risk of lithium plating. If the charging current and voltage settings were controlled by a computer, then this method of charge control could readily be implemented in software.

Timmerman, Paul↗

Estimating the Concentration of Large Raindrops from Polarimetric Radar and Disdrometer Observations

Estimation of rainfall integral parameters, including radar observables, and empirical relations between them are sensitive to the truncation of the drop size distribution (DSD), particularly at the large drop end. The sensitivity of rainfall integral parameters to the maximum drop diameter (D(sub max)) is exacerbated at C‐band since resonance effects are pronounced for large drops in excess of 5 mm diameter (D). Due to sampling limitations, it is often difficult to reliably estimate D(sub max) with disdrometers. The resulting uncertainties in D(sub max0 potentially increase errors in radar retrieval methods, particularly at C‐band, that rely on disdrometer observations for DSD input to radar models. In fact, D(sub max) is typically an assumed DSD parameter in the development of radar retrieval methods. Because of these very uncertainties, it is difficult to independently confirm disdrometer estimates of D(sub max) with polarimetric radar observations. A couple of approaches can be taken to reduce uncertainty in large drop measurement. Longer integration times can be used for the collection of larger disdrometer samples. However, integration periods must be consistent with a radar resolution volume (RRV) and the temporal and spatial scales of the physical processes affecting the DSD therein. Multiple co‐located disdrometers can be combined into a network to increase the sample size within a RRV. However, over a reasonable integration period, a single disdrometer sample volume is many orders of magnitudes less than a RRV so it is not practical to devise a network of disdrometers that has an equivalent volume to a typical RRV. Since knowledge of DSD heterogeneity and large drop occurrence in time and space is lacking, the specific accuracy or even general representativeness of disdrometer based D(sub max) and large drop concentration estimates within a RRV are currently unknown. To address this complex issue, we begin with a simpler question. Is the frequency of occurrence of large rain drops (D > 5 mm) in disdrometer observations, either stand alone or networked, generally representative and consistent with polarimetric radar observations? We first show from simulations that the concentration of large (D > 5 mm) rain drops (N(sub T5)) can be estimated from polarimetric observations of specific differential phase (K(sub dp)) and differential reflectivity (Z(sub dr)), N(sub T5)=F(K(sub dp),Z(sub dr)), or horizontal reflectivity (Z(sub h)) and Z(sub dr), N(sub T5)=(Z(sub h),Z(sub dr)). We assess the error associated with polarimetric retrieval of N(sub T5), including sensitivity to D(sub max) parameterization assumptions and measurement error in the radar simulations. Polarimetric measurements at S‐band and C‐band will then be used to retrieve estimates of N(sub T5) and compared to disdrometer estimates of N(sub T5). After careful consideration of retrieval error, we will check consistency between disdrometer and polarimetric radar estimates of N(sub T5) and the frequency of occurrence of large rain drops in a variety of precipitating regimes using data from NASA's Global Precipitation Measurement (GPM) Ground Validation (GV) program, including field campaigns such as MC3E (Oklahoma) and IFloodS (Iowa) and extended measurements over Huntsville, Alabama and NASA Wallops Flight Facility in coastal Virginia.

Carey, Lawrence D.↗

Powering OSCAR

Recycling waste has been an issue on Earth for decades. The OSCAR project seeks to find ways to make sure that it does not become an issue in space. The main focus of OSCAR is the combustion of waste and reclamation of gaseous products in microgravity. The first phase of testing relies on a ground rig that operates both under normal (Earth) gravity and in drop tower tests that briefly simulate a microgravity environment. In the second phase, a test will be performed during a suborbital flight were the experiment will be carried out in microgravity. Throughout the spring term, interns have played an integral part in continuing the progress made by the project. They performed work in upgrading the electrical and mechanical systems that make up OSCAR. They made multiple improvements to the test rig's operating software to improve readability and usability. They prepared and edited documents that were vital to the engineering process. And, they were responsible for performing lab tests and refining the lab operations document and procedure. The interns were a big help in maintaining the rigorous test schedule. OSCAR, which stands for Orbital Syngas Commodity Augmentation Reactor, is to find a way to turn astronaut waste into chemical energy. The two parts of this are important: finding a way to dispose of waste generated in space, and seeing if there is a way to recycle that waste into chemical energy. The importance of the disposal aspect is that there is currently no way to dispose of, or recycle, waste that is created in space other than jettisoning it (which is what the ISS does via empty supply capsules). As manned missions go deeper into space, that method will no longer be viable, as a craft would essentially be littering the space and planets that they visit. Energy reclamation is also important because of the high monetary and spatial costs of sending supplies on space missions. Every little bit extra that can be reused out of what is sent can save room and funds for other supplies. The facet of this problem that the OSCAR project is focusing on is how to combust waste in zero gravity. Combustion in the presence of gravity is one of those things that is taken for granted. When something burns on Earth, the flames rise above the fuel as oxygen flows from underneath. In microgravity, the flames surround the object completely, which restricts the amount of oxygen that can reach the fuel, and retards the combustion. OSCAR uses a vortex reaction chamber to counter this phenomenon. The OSCAR test rig will eventually be tested on a suborbital flight to see if it is an effective solution to the issue in real-world conditions. Currently, there is a prototype test rig that is fully functional. This rig has been previously tested in a 2 second drop test at Glenn Research Center’s (GRC) Zero Gravity Facility (ZGF). (The free-fall conditions of the drop mimic microgravity, if only for a brief period of time). This session’s focus was on upgrading the test rig and software, updating the paperwork, performing additional lab tests, and readying the rig for the five second drop test, again at GRC. II. Upgrades The state of the testing rig at the start of the session was in between its configurations for the two second drop tower and the five second drop tower. The rig needed upgrades to address various insufficiencies that either were discovered during the two second campaign or were a direct result of the differences between the two drop tower setups. The main differences that had to be handled were the increase in shock loads from 30g to 65g, a difference in drop indicating signal (on the falling edge of a pulse instead of a change from high to low), and the ambient pressure of the test apparatus (the two second tower dropped the rig in atmosphere, while the five second tower drops in vacuum).

Cauvel, Thomas↗

The structure of dilute combusting sprays

An experimental and theoretical study of drop processes in a turbulent flame is described. The experiments involved a monodisperse (105 and 180 micro m initial diameter) stream of methanol drops injected at the base of a turbulent methane-fueled diffusion flame burning in still air. The following measurements were made: mean and fluctuating phase velocities, mean drop number flux, drop-size distributions and mean gas-phase temperatures. Measurements were compared with predictions of two separated flow models: (1) deterministic separated flow, where drop-turbulence interactions are ignored; and (2) stochastic separated flow, where drop-turbulence interactions are considered using random-walk computations. The stochastic separated flow analysis yielded best agreement with measurements, since it provides for turbulent dispersion of drops which was important for present test conditions (and probably for most combusting sprays as well). Distinguishing the presence or absence of envelope flames around the drops, however, was relatively unimportant for present test conditions, since the drops spent most of their lifetime in fuel-rich regions of the flow where this distinction is irrelevant.

Shuen, J. S.↗

The structure and characterization of air-assisted swirl atomizer sprays

The detailed aerodynamic structure of air-assisted swirl atomizer sprays is investigated in this paper. In contrast to previously published papers on spray characterization, special emphasis is placed on the region near the atomizer exit where significant variation of the mean drop size and drop velocity occurs. Simple correlations are found for the spray mean drop size and some initial input parameters. Measurements of drop acceleration and deceleration can be well related to the line-of-sight variations in mean drop size and number density. It is found that the initial drop acceleration and spray dispersion cause the initial decrease of axial mean drop diameters and subsequent drop deceleration causes the increase of mean drop diameters.

Mao, C.-P.↗

An Assessment of Molten Metal Detachment Hazards During Electron Beam Welding in the Space Shuttle Bay at LEO for the International Space Welding Experiment

In 1997, the United States [NASA] and the Paton Electric Welding Institute are scheduled to cooperate in a flight demonstration on the U.S. Space Shuttle to demonstrate the feasibility of welding in space for a possible repair option for the International Space Station Alpha. This endeavor, known as the International Space Welding Experiment (ISWE), will involve astronauts performing various welding exercises such as brazing, cutting, welding, and coating using an electron beam space welding system that was developed by the E.O. Paton Electric Welding Institute (PWI), Kiev Ukraine. This electron beam welding system known as the "Universal Weld System" consists of hand tools capable of brazing, cutting, autogeneous welding, and coating using an 8 kV (8000 volts) electron beam. The electron beam hand tools have also been developed by the Paton Welding Institute with greater capabilities than the original hand tool, including filler wire feeding, to be used with the Universal Weld System on the U.S. Space Shuttle Bay as part of ISWE. The hand tool(s) known as the Ukrainian Universal Hand [Electron Beam Welding] Tool (UHT) will be utilized for the ISWE Space Shuttle flight welding exercises to perform welding on various metal alloy samples. A total of 61 metal alloy samples, which include 304 stainless steel, Ti-6AI-4V, 2219 aluminum, and 5456 aluminum alloys, have been provided by NASA for the ISWE electron beam welding exercises using the UHT. These samples were chosen to replicate both the U.S. and Russian module materials. The ISWE requires extravehicular activity (EVA) of two astronauts to perform the space shuttle electron beam welding operations of the 61 alloy samples. This study was undertaken to determine if a hazard could exist with ISWE during the electron beam welding exercises in the Space Shuttle Bay using the Ukrainian Universal Weld System with the UHT. The safety issue has been raised with regard to molten metal detachments as a result of several possible causes such as welder procedural error, externally applied impulsive forces(s), filler wire entrainment and snap-out, cutting expulsion, and puddle expulsion. Molten metal detachment from either the weld/cut substrate or weld wire could present harm to a astronaut in the space environment it the detachment was ti burn through the fabric of the astronaut Extravehicular Mobility Unit (EMC). In this paper an experimental test was performed in a 4 ft. x 4 ft. vacuum chamber at MSFC enabling protective garment to be exposed to the molten metal drop detachments to over 12 inches. The chamber was evacuated to vacuum levels of at least 1 x 10(exp -5) torr (50 micro-torr) during operation of the 1.0 kW Universal Hand Tool (UHT). The UHT was manually operated at the power mode appropriate for each material and thickness. The space suit protective welding garment, made of Teflon fabric (10 oz. per yard) with a plain weave, was placed on the floor of the vacuum chamber to catch the molten metal drop detachments. A pendulum release mechanism consisting of four hammers, each weighing approximately 3.65 lbs, was used to apply an impact forces to the weld sample/plate during both the electron beam welding and cutting exercises. Measurements were made of the horizontal fling distances of the detached molten metal drops. The volume of a molten metal drop can also be estimated from the size of the cut. Utilizing equations, calculations were made to determine chande in surafec area (Delat a(surface)) for 304 stainless steel for cutting based on measurements of metal drop sizes at the cut edges. For the cut sample of 304 stainless steel based on measurement of the drop size at the edge, Delta-a(surface) was determined to be 0.0054 2 in . Calculations have indicated only a small amount of energy is required to detach a liquid metal drop. For example, approximately only 0.000005 ft-lb of energy is necessary to detach a liquid metal steel drop based on the above theoretical analysis. However, some of the energy will be absorbed by the plate before it reaches the metal drop. Based on the theoretical calculations, it was determined that during a weld cutting exercise, the titanium alloy would be the most difficult to detach molten metal droplets followed by stainless steel and then by aluminum. The results of the experimental effort have shown that molten metal will detach if large enough of a hammer blow is applied to the weld sample plate during the full penetration welding and cutting exercises. However, no molten metal detachments occurred as a result of the filler wire snap-out tests from the weld puddle since it was too difficult to cause the metal to flick-out from the pool. Molten metal detachments, though not large in size, did result from the direct application of the electron beam on the end of the filler weld wire.

Fragomeni, James M.↗

Spatial Characteristics of Water Spray Formed by Two Impinging Jets at Several Jet Velocities in Quiescent Air

The spatial characteristics of a spray formed by two impinging water jets in quiescent air were studied over a range of nominal jet velocities of 30 to 74 feet per second. The total included angle between the 0.089-inch jets was 90 deg. The jet velocity, spray velocity, disappearance of the ligaments just before drop formation, mass distribution, and size and position of the largest drops were measured in a circumferential survey around the point of jet impingement. Photographic techniques were used in the evaluations. The distance from the point of jet impingement to ligament breakup into drops was about 4 inches on the spray axis and about 1.3 inches in the radial position +/-90 deg from the axis. The distance tended to increase slightly with increase in jet velocity. The spray velocity varied from about 99 to about 72 percent of the jet velocity for a change in circumferential position from the spray axis to the +/-80 deg positions. The percentages tended to increase slightly with an increase in jet velocity. Fifty percent of the mass was distributed about the spray axis in an included angle of slightly less than 40 deg. The effect of jet velocity was small. The largest observed drops (2260-micron or 0.090-in. diam.) were found on and about the spray axis. The size of the largest drops decreased for an increase in radial angular position, being about 1860 microns (0.074 in.) at the +/-90 deg positions. The largest drop sizes tended to decrease for an increase in jet velocity, although the velocity effect was small. A drop-size distribution analysis indicated a mass mean drop size equal to 54 percent of an extrapolated maximum drop size.

Foster, Hampton H.↗

Residual Gas Effects on Detached Solidification in Microgravity

Many microgravity directional solidification experiments yielded ingots with portions that grew without contacting the ampoule wall, leading to greatly improved crystallographic perfection. Our long-term goal is to make such detached solidification reproducible, which requires a full understanding of the mechanisms underlying it. Our Moving Meniscus Model of steady-state detachment predicts that it depends strongly on the surface tension of the melt and the advancing contact angle with the ampoule wall. Detached solidification is more likely when the contact angle for the melt on the ampoule wall is high, i.e. non-wetting. It has been claimed that impurities increase the contact angle. The objective of the current project is to determine the influence of residual gases on the surface tension and contact angle of molten semiconductors on typical ampoule materials. We are focusing on determining the influence of oxygen on the contact angle of molten InSb on clean silica ('quartz'), including the advancing and retreating contact angles in addition to the usual equilibrium contact angle. We have created a gas flow system that allows us to control the oxygen partial pressure over a sessile drop of InSb on a horizontal quartz surface. The cell is slowly tilted while videotaping to reveal the contact angles on the two sides of the drop just prior to it rolling down the surface. Thus far, we have learned the following: (1) Molten InSb readily forms an oxide layer in the presence of the trace amounts of oxygen found in high purity argon; (2) This oxide contains a substantial amount of Ga, which presumably is a trace contaminant that is not detectable in the starting material; (3) The addition of 10% hydrogen to the argon gas is sufficient to reduce the oxide and produce a clean drop; (4) An infrared filter must precede the video camera in order to produce a sharp image of the drop for later image analysis; (5) Tilting the surface on which the drop rests causes the two sides of the drop to display different contact angles, reflecting contact line sticking; (6) Vibration strongly accelerates the approach of the drop to its final shape on a horizontal surface by helping to overcome sticking of the contact line; (7) Oscillation of the drop surface due to vibration appears to increase as the surface is inclined from horizontal. Presumably, the angle at which the drop rolls down the surface is also reduced by vibration. This observation is particularly significant, as the meniscus must move along the ampoule wall during detached solidification.

Regel, Liya L.↗

Raindrop Size Distribution Measurements in Tropical Cyclones

Characteristics of the raindrop size distribution in seven tropical cyclones have been studied through impact-type disdrometer measurements at three different sites during the 2004-06 Atlantic hurricane seasons. One of the cyclones has been observed at two different sites. High concentrations of small and/or midsize drops were observed in the presence or absence of large drops. Even in the presence of large drops, the maximum drop diameter rarely exceeded 4 mm. These characteristics of raindrop size distribution were observed in all stages of tropical cyclones, unless the storm was in the extratropical stage where the tropical cyclone and a midlatitude frontal system had merged. The presence of relatively high concentrations of large drops in extratropical cyclones resembled the size distribution in continental thunderstorms. The integral rain parameters of drop concentration, liquid water content, and rain rate at fixed reflectivity were therefore lower in extratropical cyclones than in tropical cyclones. In tropical cyclones, at a disdrometercalculated reflectivity of 40 dBZ, the number concentration was 700 plus or minus 100 drops m(sup -3), while the liquid water content and rain rate were 0.90 plus or minus 0.05 g m(sup -3) and 18.5 plus or minus 0.5 mm h(sup -1), respectively. The mean mass diameter, on the other hand, was 1.67 plus or minus 0.3 mm. The comparison of raindrop size distributions between Atlantic tropical cyclones and storms that occurred in the central tropical Pacific island of Roi-Namur revealed that the number density is slightly shifted toward smaller drops, resulting in higher-integral rain parameters and lower mean mass and maximum drop diameters at the latter site. Considering parameterization of the raindrop size distribution in tropical cyclones, characteristics of the normalized gamma distribution parameters were examined with respect to reflectivity. The mean mass diameter increased rapidly with reflectivity, while the normalized intercept parameter had an increasing trend with reflectivity. The shape parameter, on the other hand, decreased in a reflectivity range from 10 to 20 dBZ and remained steady at higher reflectivities. Considering the repeatability of the characteristics of the raindrop size distribution, a second impact disdrometer that was located 5.3 km away from the primary site in Wallops Island, Virginia, had similar size spectra in selected tropical cyclones.

Tokay, Ali↗

Integral Battery Power Limiting Circuit for Intrinsically Safe Applications

A circuit topology has been designed to guarantee the output of intrinsically safe power for the operation of electrical devices in a hazardous environment. This design uses a MOSFET (metal oxide semiconductor field-effect transistor) as a switch to connect and disconnect power to a load. A test current is provided through a separate path to the load for monitoring by a comparator against a preset threshold level. The circuit is configured so that the test current will detect a fault in the load and open the switch before the main current can respond. The main current passes through the switch and then an inductor. When a fault occurs in the load, the current through the inductor cannot change immediately, but the voltage drops immediately to safe levels. The comparator detects this drop and opens the switch before the current in the inductor has a chance to respond. This circuit protects both the current and voltage from exceeding safe levels. Typically, this type of protection is accomplished by a fuse or a circuit breaker, but in order for a fuse or a circuit breaker to blow or trip, the current must exceed the safe levels momentarily, which may be just enough time to ignite anything in a hazardous environment. To prevent this from happening, a fuse is typically current-limited by the addition of the resistor to keep the current within safe levels while the fuse reacts. The use of a resistor is acceptable for non-battery applications where the wasted energy and voltage drop across the resistor can be tolerated. The use of the switch and inductor minimizes the wasted energy. For example, a circuit runs from a 3.6-V battery that must be current-limited to 200 mA. If the circuit normally draws 10 mA, then an 18-ohm resistor would drop 180 mV during normal operation, while a typical switch (0.02 ohm) and inductor (0.97 ohm) would only drop 9.9 mV. From a power standpoint, the current-limiting resistor protection circuit wastes about 18 times more power than the switch and the inductor configuration. In the fault condition, both the resistor and the inductor react immediately. The resistor reacts by allowing more current to flow and dropping the voltage. Initially, the inductor reacts by dropping the voltage, and then by not allowing the current to change. When the comparator detects the drop in voltage, it opens the switch, thus preventing any further current flow. The inductor alone is not sufficient protection, because after the voltage drop has settled, the inductor would then allow the current to change, in this example, the current would be 3.7 A. In the fault condition, the resistor is flowing 200 mA until the fuse blows (anywhere from 1 ms to 100 s), while the switch and inductor combination is flowing about 2 A test current while monitoring for the fault to be corrected. Finally, as an additional safety feature, the circuit can be configured to hold the switch opened until both the load and source are disconnected.

Burns, Bradley M.↗

The structure of evaporating and combusting sprays: Measurements and predictions

An apparatus developed, to allow observations of monodisperse sprays, consists of a methane-fueled turbulent jet diffusion flame with monodisperse methanol drops injected at the burner exit. Mean and fluctuating-phase velocities, drop sizes, drop-mass fluxes and mean-gas temperatures were measured. Initial drop diameters of 100 and 180 microns are being considered in order to vary drop penetration in the flow and effects of turbulent dispersion. Baseline tests of the burner flame with no drops present were also conducted. Calibration tests, needed to establish methods for predicting drop transport, involve drops supported in the post-flame region of a flat-flame burner operated at various mixture ratios. Spray models which are being evaluated include: (1) locally homogeneous flow (LFH) analysis, (2) deterministic separated flow (DSF) analysis and (3) stochastic separated flow (SSF) analysis.

Shuen, J. S.↗

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.↗

Comparison of High Aspect Ratio Cooling Channel Designs for a Rocket Combustion Chamber with Development of an Optimized Design

An analytical investigation on the effect of high aspect ratio (height/width) cooling channels, considering different coolant channel designs, on hot-gas-side wall temperature and coolant pressure drop for a liquid hydrogen cooled rocket combustion chamber, was performed. Coolant channel design elements considered were: length of combustion chamber in which high aspect ratio cooling was applied, number of coolant channels, and coolant channel shape. Seven coolant channel designs were investigated using a coupling of the Rocket Thermal Evaluation code and the Two-Dimensional Kinetics code. Initially, each coolant channel design was developed, without consideration for fabrication, to reduce the hot-gas-side wall temperature from a given conventional cooling channel baseline. These designs produced hot-gas-side wall temperature reductions up to 22 percent, with coolant pressure drop increases as low as 7.5 percent from the baseline. Fabrication constraints for milled channels were applied to the seven designs. These produced hot-gas-side wall temperature reductions of up to 20 percent, with coolant pressure drop increases as low as 2 percent. Using high aspect ratio cooling channels for the entire length of the combustion chamber had no additional benefit on hot-gas-side wall temperature over using high aspect ratio cooling channels only in the throat region, but increased coolant pressure drop 33 percent. Independent of coolant channel shape, high aspect ratio cooling was able to reduce the hot-gas-side wall temperature by at least 8 percent, with as low as a 2 percent increase in coolant pressure drop. ne design with the highest overall benefit to hot-gas-side wall temperature and minimal coolant pressure drop increase was the design which used bifurcated cooling channels and high aspect ratio cooling in the throat region. An optimized bifurcated high aspect ratio cooling channel design was developed which reduced the hot-gas-side wall temperature by 18 percent and reduced the coolant pressure drop by 4 percent. Reductions of coolant mass flow rate of up to 50 percent were possible before the hot-gas-side wall temperature reached that of the baseline. These mass flow rate reductions produced coolant pressure drops of up to 57 percent.

Wadel, Mary F.↗