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DOE OSTI2021

Two Dimensional Topology Optimization of Heat Exchangers with the Density and Level-Set Methods

We design heat exchangers using two topology optimization approaches: the density, i.e. volume fraction and level set methods. Our goal is to maximize the heat exchange between two fluids in separate channels while constraining the pressure drop across each channel. The heat exchanger is modeled with a coupled thermal-flow formulation. The flow is governed by an isothermal and incompressible Stokes-Brinkman equation and the heat transfer is governed by a convection-diffusion equation with high Peclet number. We solve one set of Stokes-Brinkman equations per fluid. Each Brinkman term in the flow equation serves to model the other phase as a solid, thereby preventing mixing. We first represent the solid and fluid phases using a volume fraction variable and apply a SIMP-like penalization in the Brinkman term to drive the optimization to a discrete design. The cost and constraint function derivatives are automatically calculated with the library pyadjoint and the optimization is performed by the Method of Moving Asymptotes. In a second optimization formulation, we use the level set approach to define the interface that separates the two fluids. Pyadjoint calculates the shape derivatives of the cost and constraint functions and the Hamilton-Jacobi advects the interface, allowing for topological changes. We present results in two dimensions and discuss the advantages and disadvantages of each approach.

42 ENGINEERING↗

NASA NTRS2005

Benchmark Problems Used to Assess Computational Aeroacoustics Codes

The field of computational aeroacoustics (CAA) encompasses numerical techniques for calculating all aspects of sound generation and propagation in air directly from fundamental governing equations. Aeroacoustic problems typically involve flow-generated noise, with and without the presence of a solid surface, and the propagation of the sound to a receiver far away from the noise source. It is a challenge to obtain accurate numerical solutions to these problems. The NASA Glenn Research Center has been at the forefront in developing and promoting the development of CAA techniques and methodologies for computing the noise generated by aircraft propulsion systems. To assess the technological advancement of CAA, Glenn, in cooperation with the Ohio Aerospace Institute and the AeroAcoustics Research Consortium, organized and hosted the Fourth CAA Workshop on Benchmark Problems. Participants from industry and academia from both the United States and abroad joined to present and discuss solutions to benchmark problems. These demonstrated technical progress ranging from the basic challenges to accurate CAA calculations to the solution of CAA problems of increasing complexity and difficulty. The results are documented in the proceedings of the workshop. Problems were solved in five categories. In three of the five categories, exact solutions were available for comparison with CAA results. A fourth category of problems representing sound generation from either a single airfoil or a blade row interacting with a gust (i.e., problems relevant to fan noise) had approximate analytical or completely numerical solutions. The fifth category of problems involved sound generation in a viscous flow. In this case, the CAA results were compared with experimental data.

Dahl, Milo D.↗

NASA NTRS2010

NASA Ares I Launch Vehicle Upper Stage Reaction Control System (ReCS) Cold Flow Development Test Overview

NASA s Ares I launch vehicle, consisting of a five segment solid rocket booster first stage and a liquid bi-propellant J2-X engine Upper Stage, is the vehicle that s been chosen to launch the Orion Crew Module, which will return humans to the Moon, Mars, and beyond. After First Stage booster separation, the Reaction Control System (ReCS), a monopropellant hydrazine system, will provide the Upper Stage element with three degrees of freedom control as needed. This paper provides an overview of the system level development testing that has taken place on the Ares I launch vehicle Upper Stage ReCS. The ReCS System Development Test Article (SDTA) was built as a flight representative water flow test article whose primary test objective was to obtain fluid system performance data to evaluate the integrate system performance characteristics and verify analytical models. Water is the industry standard for cold flow testing of hydrazine systems, because the densities are very close and the speeds of sound are well characterized. The completion of this development level test program was considered necessary to support the ReCS Critical Design Review. This paper will address the design approach taken in building the test article, the objectives of the test program, types of testing completed, general results, the ability of the program to meet the test objectives, and lessons learned

Dervan, Melanie↗

DOE OSTI2020

Development and validation of the cavitation-induced erosion risk assessment tool

This work presents the development of a cavitation-induced erosion risk assessment (CIERA) tool that links multiphase flow simulation predictions with the progress towards material erosion. To develop a robust erosion modeling tool, the cavitation and erosion predictions for pressurized diesel fuel flow within a channel geometry were validated over a range of Reynolds and cavitation number conditions in two different aluminum channel geometries, one featuring a rounded inlet corner and the other with a sharp inlet corner. The multiphase flow development within the channel was modeled using a compressible mixture model, where phase change was represented with the homogeneous relaxation model and the turbulent flow evolution was modeled using a dynamic structure approach for Large Eddy Simulations. To improve representation of the incubation period before material rupture over existing approaches, a physics-based metric was derived based on the cumulative energy absorbed by the solid material from repeated hydrodynamic impacts. When the average peak pressure was related to the incubation period, the incubation period and its sensitivity to changes in flow conditions were found to be overpredicted. In contrast, predictions from CIERA provided a more accurate means to qualitatively and quantitatively predict the influence of flow conditions on the incubation period before material erosion. When the predicted stored energy was related to the solid material properties to estimate the incubation period, multiphase flow simulations demonstrated accurate representation of the sensitivity of erosion severity to changes in flow conditions. The use of CIERA led to quantitative agreement of the predicted incubation period within 5% of the experimentally measured incubation period.

42 ENGINEERING↗

DOE OSTI2024

Evaporation from thin porous Coatings: Pore size effects and predictive equation for homogeneous coatings

Evaporation of small water droplets on solids is hindered because surface tension pulls the droplet into a spherical cap that has a small perimeter. Our solution is to coat a solid with a very thin, porous layer into which the droplet flows to create a large-area disk with concomitant high rate of evaporation. We investigate evaporation by varying factors that have not been previously considered: pore size and distribution, contact angle, temperature, and relative humidity (RH). A larger pore size resulted in faster evaporation, which we explain through faster transport within the coating. Even faster evaporation occurred for a bilayer structure with small particles on the air side and larger particles on the solid side. Further, the water advancing contact angle had an insignificant effect in the range from < 10° through to 60°. Our results for different pore sizes, temperature, humidity, and contact angle all collapse onto a single curve when appropriately normalized. This validates an equation that can be used for the evaporation from a homogeneous coating that depends only one empirical factor and the droplet volume. Since the volume is often user-controlled, we envisage that this equation can be used to predict evaporation and guide design of fast-drying coatings.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

NASA NTRS1994

Experimental Investigation of Plume-Induced Flow Separation on the National Launch System 1 1/2-Stage Launch Vehicle

An experimental investigation of plume-induced flow separation on the National Launch System (NLS) 1 1/2-stage launch vehicle was done. This investigation resulted from concerns raised about the flow separation that was encountered on the Saturn 5. A large similarity exists between configurations and nominal trajectories. The study involved the use of solid plume simulators to simulate the base pressure encountered by the vehicle due to engine exhaust plumes at predetermined critical Mach numbers based on Saturn 5 flight plume effects. The solid plume was varied in location, resulting in a parametric study of base pressure effects on flow separation. In addition to the parametric study of arbitrary plume locations, the base pressure resulting from the nominal trajectory was tested. This analysis was accomplished through two wind tunnel tests run at NASA Marshall Space Flight Center's 14 x 14-inch Trisonic Wind Tunnel during 1992. The two tests were a static stability and a pressure test each using a 0.004-scale NLS 1 1/2-stage model. This study verified that flow separation is present at Mach 2.74 and 3.48 for predicted flight base pressures at nominal or higher levels. The flow separation at the predicted base pressure is only minor and should not be of great concern. It is not of the magnitude of the flow separation that was experienced on the Saturn 5. If the base pressure exceeds these nominal conditions, the flow separation can drastically increase, and is of concern.

Springer, A.↗

DOE OSTI2022

Wedge-Shaped Hopper Design for Milled Woody Biomass Flow

The bioenergy industry has been challenged by unstable flow and transport of milled biomass in material handling operations. Handling issues such as hopper clogging and auger jamming are attributed to knowledge gaps between existing handling units designed for bulk solids and their suitability for milled biomass with high compressibility. This work investigates various flow behaviors of granular woody biomass in wedge-shaped hoppers. Herein, hopper flow physical experiments and numerical simulations are conducted to study the influence of the critical material attributes and critical processing parameters on the flow pattern, arching, and throughput. The results show that (1) the preferred flow pattern, mass flow, can be achieved by controlling the material’s internal friction angle, hopper inclination, and hopper wall friction; (2) hopper arching, governed by the competing gravity-driven force against flow resistance from material internal friction and material–wall friction, can be controlled by the hopper wall friction angle and the inclination angle; and (3) flow throughput can be accurately estimated from our empirical equation with inputs of hopper outlet geometry and particle-scale to bulk-scale material attributes. This study elucidates woody biomass flow physics and provides guidance for industrial equipment design.

09 BIOMASS FUELS↗

DOE OSTI2020

Laminar drag reduction in microchannels with liquid infused textured surfaces

Liquid infused surfaces (LIS) achieve non-wetting properties through asperity structures containing pockets of a lubricating liquid rather than air. Although studies have demonstrated several potential applications of LIS, the effect of liquid infused texture on the flow of liquid in microchannels has not been systematically addressed. The present work focuses on the effect of liquid-infused texture geometry and the infused liquid properties on the flow characteristics of a bulk fluid in rectangular and round microchannel geometries. Considering four different textured geometries of transverse ridges, longitudinal ridges, in-lined square posts and staggered squares, a detailed parametric study is presented to assess the resulting drag reduction and friction factor, expressed in terms of the Poiseuille number, on the flow in microchannels. The effect of geometrical parameters is investigated for different asperity solid fraction (Φ s ), asperity height (h s ) and channel thickness (H) or tube diameter (D), while the effect of the infused fluid is studied in terms of a ratio of its viscosity relative to the viscosity of the flowing bulk fluid. Based on the results of the parametric study an extension of the conventional Moody diagram for non-wetting surfaces is developed. Finally, a design of experiments study is conducted to relate the drag reduction and Poiseuille number to the various governing parameters, using which conditions that maximize drag reduction are identified.

42 ENGINEERING↗

NASA NTRS2000

Exploratory Investigation of Aerodynamic Characteristics of Helicopter Tail Boom Cross-Section Models with Passive Venting

Two large-scale, two-dimensional helicopter tail boom models were used to determine the effects of passive venting on boom down loads and side forces in hovering crosswind conditions. The models were oval shaped and trapezoidal shaped. Completely porous and solid configurations, partial venting in various symmetric and asymmetric configurations, and strakes were tested. Calculations were made to evaluate the trends of venting and strakes on power required when applied to a UH-60 class helicopter. Compared with the UH-60 baseline, passive venting reduced side force but increased down load at flow conditions representing right sideward flight. Selective asymmetric venting resulted in side force benefits close to the fully porous case. Calculated trends on the effects of venting on power required indicated that the high asymmetric oval configuration was the most effective venting configuration for side force reduction, and the high asymmetric with a single strake was the most effective for overall power reduction. Also, curves of side force versus flow angle were noticeable smoother for the vented configurations compared with the solid baseline configuration; this indicated a potential for smoother flight in low-speed crosswind conditions.

Banks, Daniel W.↗

NASA NTRS1972

Lunar ash flow with heat transfer.

The most important heat-transfer process in the ash flow under consideration is heat convection. Besides the four important nondimensional parameters of isothermal ash flow (Pai et al., 1972), we have three additional important nondimensional parameters: the ratio of the specific heat of the gas, the ratio of the specific heat of the solid particles to that of gas, and the Prandtl number. We reexamine the one dimensional steady ash flow discussed by Pai et al. (1972) by including the effects of heat transfer. Numerical results for the pressure, temperature, density of the gas, velocities of gas and solid particles, and volume fraction of solid particles as function of altitude for various values of the Jeffreys number, initial velocity ratio, and two different gas species (steam and hydrogen) are presented.

Pai, S. I.↗

NASA NTRS1959

Effects of Cross-Sectional Shape, Solidity, and Distribution of Heat-Transfer Coefficient on the Torsional Stiffness of Thin Wings Subjected to Aerodynamic Heating

A study has been made of the effects of varying the shape, solidity, and heat-transfer coefficient of thin wings with regard to their influence on the torsional-stiffness reduction induced by aerodynamic heating. The variations in airfoil shape include blunting, flattening, and combined blunting and flattening of a solid wing of symmetrical double-wedge cross section. Hollow double-wedge wings of constant skin thickness with and without internal webs also are considered. The effects of heat-transfer coefficients appropriate for laminar and turbulent flow are investigated in addition to a step transition along the chord from a lower to a higher constant value of heat-transfer coefficient. From the results given it is concluded that the flattening of a solid double wedge decreases the reduction in torsional stiffness while slight degrees of blunting increase the loss. The influence of chordwise variations in heat-transfer coefficient due to turbulent and laminar boundary-layer flow on the torsional stiffness of solid wings is negligible. The effect of a step transition in heat-transfer coefficient along the chord of a solid wing can, however, become appreciable. The torsional-stiffness reduction of multiweb and hollow double-wedge wings is substantially less than that calculated for a solid wing subjected to the same heating conditions.

Thomson, Robert G.↗

NASA NTRS2013

In Situ Solid Particle Generator

Particle seeding is a key diagnostic component of filter testing and flow imaging techniques. Typical particle generators rely on pressurized air or gas sources to propel the particles into the flow field. Other techniques involve liquid droplet atomizers. These conventional techniques have drawbacks that include challenging access to the flow field, flow and pressure disturbances to the investigated flow, and they are prohibitive in high-temperature, non-standard, extreme, and closed-system flow conditions and environments. In this concept, the particles are supplied directly within a flow environment. A particle sample cartridge containing the particles is positioned somewhere inside the flow field. The particles are ejected into the flow by mechanical brush/wiper feeding and sieving that takes place within the cartridge chamber. Some aspects of this concept are based on established material handling techniques, but they have not been used previously in the current configuration, in combination with flow seeding concepts, and in the current operational mode. Unlike other particle generation methods, this concept has control over the particle size range ejected, breaks up agglomerates, and is gravity-independent. This makes this device useful for testing in microgravity environments.

Agui, Juan H.↗

NASA NTRS1977

Calculations of the moon's thermal history at different concentrations of radioactive elements, taking into account differentiation on melting

Calculations of the thermal history of the moon were done by solving the thermal conductivity equation for the case in which the heat sources are the long lived radioactive elements Th, U, and K-40. The concentrations of these elements were adjusted to give 4 variations of heat flow. Calculations indicated that the moon's interior was heated to melting during the first 0.7 to 2.3 x 10 to the 9th power years. The maximum fusion involved practically the entire moon to a distance from 15 to 45 km beneath the surface, and started 3.5 to 4.0 x 10 to the 9th power years ago, or 2.5 x 3.0 x 10 to the 9th power years ago and continued for 1 to 2 x 10 to the 9th power years. The moon today is cooling. The current thickness of the solid crust is from 150 to 200 km and the heat flow exceeds the stationary value 1.5 fold.

Ornatskaya, O. I.↗

NASA NTRS2004

Fixed Packed Bed Reactors in Reduced Gravity

We present experimental data on flow pattern transitions, pressure drop and flow characteristics for cocurrent gas-liquid flow through packed columns in microgravity. The flow pattern transition data indicates that the pulse flow regime exists over a wider range of gas and liquid flow rates under microgravity conditions compared to 1-g and the widely used Talmor map in 1-g is not applicable for predicting the transition boundaries. A new transition criterion between bubble and pulse flow in microgravity is proposed and tested using the data. Since there is no static head in microgravity, the pressure drop measured is the true frictional pressure drop. The pressure drop data, which has much smaller scatter than most reported 1-g data clearly shows that capillary effects can enhance the pressure drop (especially in the bubble flow regime) as much as 200% compared to that predicted by the single phase Ergun equation. The pressure drop data are correlated in terms of a two-phase friction factor and its dependence on the gas and liquid Reynolds numbers and the Suratman number. The influence of gravity on the pulse amplitude and frequency is also discussed and compared to that under normal gravity conditions. Experimental work is planned to determine the gas-liquid and liquid-solid mass transfer coefficients. Because of enhanced interfacial effects, we expect the gas-liquid transfer coefficients kLa and kGa (where a is the gas-liquid interfacial area) to be higher in microgravity than in normal gravity at the same flow conditions. This will be verified by gas absorption experiments, with and without reaction in the liquid phase, using oxygen, carbon dioxide, water and dilute aqueous amine solutions. The liquid-solid mass transfer coefficient will also be determined in the bubble as well as the pulse flow regimes using solid benzoic acid particles in the packing and measuring their rate of dissolution. The mass transfer coefficients in microgravity will be compared to those in normal gravity cocurrent flow to determine the mass transfer enhancement and propose new mass transfer correlations for two-phase gas-liquid flows through packed beds in microgravity.

Motil, Brian J.↗

NASA NTRS2016

An Iron-Rain Model for Core Formation on Asteroid 4 Vesta

Asteroid 4 Vesta is differentiated into a crust, mantle, and core, as demonstrated by studies of the eucrite and diogenite meteorites and by data from NASA's Dawn spacecraft. Most models for the differentiation and thermal evolution of Vesta assume that the metal phase completely melts within 20 degrees of the eutectic temperature, well before the onset of silicate melting. In such a model, core formation initially happens by Darcy flow, but this is an inefficient process for liquid metal and solid silicate. However, the likely chemical composition of Vesta, similar to H chondrites with perhaps some CM or CV chondrite, has 13-16 weight percent S. For such compositions, metal-sulfide melting will not be complete until a temperature of at least 1350 degrees Centigrade. The silicate solidus for Vesta's composition is between 1100 and 1150 degrees Centigrade, and thus metal and silicate melting must have substantially overlapped in time on Vesta. In this chemically and physically more likely view of Vesta's evolution, metal sulfide drops will sink by Stokes flow through the partially molten silicate magma ocean in a process that can be envisioned as "iron rain". Measurements of eucrites show that moderately siderophile elements such as Ni, Mo, and W reached chemical equilibrium between the metal and silicate phases, which is an important test for any Vesta differentiation model. The equilibration time is a function of the initial metal grain size, which we take to be 25-45 microns based on recent measurements of H6 chondrites. For these sizes and reasonable silicate magma viscosities, equilibration occurs after a fall distance of just a few meters through the magma ocean. Although metal drops may grow in size by merger with other drops, which increases their settling velocities and decreases the total core formation time, the short equilibration distance ensures that the moderately siderophile elements will reach chemical equilibrium between metal and silicate before metal drop merger becomes important. In this model, there must be at least 30 percent melting of the silicate phase when metal melting is complete, corresponding to a crust thickness of at least 30 kilometers on Vesta, consistent with Dawn gravity observations. Greater degrees of silicate melting and a correspondingly thicker crust are possible if Vesta accreted sufficiently rapidly.

Kiefer, Walter S.↗

NASA NTRS2015

Scaled Rocket Testing in Hypersonic Flow

NASA's Space Launch System (SLS) uses four clustered liquid rocket engines along with two solid rocket boosters. The interaction between all six rocket exhaust plumes will produce a complex and severe thermal environment in the base of the vehicle. This work focuses on a recent 2% scale, hot-fire SLS base heating test. These base heating tests are short-duration tests executed with chamber pressures near the full-scale values with gaseous hydrogen/oxygen engines and RSRMV analogous solid propellant motors. The LENS II shock tunnel/Ludwieg tube tunnel was used at or near flight duplicated conditions up to Mach 5. Model development was strongly based on the Space Shuttle base heating tests with several improvements including doubling of the maximum chamber pressures and duplication of freestream conditions. Detailed base heating results are outside of the scope of the current work, rather test methodology and techniques are presented along with broader applicability toward scaled rocket testing in supersonic and hypersonic flow.

Dufrene, Aaron↗

DOE OSTI2022

Eddy Current Flow Meter Measurements and Modeling Validation

The goal of the eddy current flow meter (ECFM) is to monitor velocities and temperatures of conductive liquid metals. The ECFM can also detect voids in two-phase liquid metal flows. Measurement of these flows can greatly improve the accuracy of the empirical formulas used for fluid dynamics near the reactor core and aid in mapping any non-uniformities in fluid flow such as estimates of temperature and phase. While the eventual goal is to develop the ECFM for the liquid sodium surrounding the Versatile Test Reactor (VTR) core, this report focuses on modeling and experimental validation of ECFM for a moving solid test rod and for liquid mercury in the Target Test Facility (TTF) flow loop to better understand and further develop ECFM measurement capabilities by validating model predictions with benchmark experiments. Eventually the models could be used to design and optimize future ECFMs for specific applications such as monitoring flow within the VTR pool.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2020

Development of a Reference Model for Molten-Salt-Cooled Pebble-Bed Reactor Using SAM

To support the development and utilization of the SAM code for fluoride-salt-cooled high-temperature pebble-bed reactor (PB-FHR) safety analysis and licensing, an effort was devoted to developing reference models for PB-FHR primary loop and the reactor cavity cooling system (RCCS). A reference standard problem of a prototypical reactor design is foundational to NRC and industry to verify the adequacy of computer codes and evaluation models for a specific reactor type. The SAM code was enhanced for the reference PB-FHR model development, including a 1D-3D flow coupling scheme and conjugate heat transfer between porous media and solid structures. The reference FHR primary loop model was developed based on the UC Berkeley Mk1 FHR design with additional design features from the Kairos Power’s KP-FHR core. The PB-FHR core is modeled by a two-dimensional porous medium while the rest of the primary loop is represented by a SAM one-dimensional model. A SAM one-dimensional primary loop model was also developed for comparison using a single channel approach for the reactor core. Furthermore, the water-based NSTF cavity was modeled using SAM multi-dimensional flow module, to assist in evaluating SAM capabilities of modeling the emergency heat removal systems relying on RCCS concepts.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗