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At least 1,009 records · Page 56
All sourcesNASA NTRSDOE OSTI
NASA NTRS1996

Experimental Investigation of the Effects of Acceleration on Heat Transfer in the Turbulent Boundary Layer

The objective of this research was to experimentally investigate the combined effects of freestream acceleration and surface roughness on heat transfer and fluid flow in the turbulent boundary layer. The experiments included a variety of flow conditions ranging from aerodynamically smooth to transitionally rough to fully rough boundary layers with accelerations ranging from moderate to moderately strong. The test surfaces used were a smooth-wall test surface and two rough-wall surfaces which were roughened with 1.27 mm diameter hemispheres spaced 2 and 4 base diameters apart in a staggered array. The measurements consisted of Stanton number distributions, mean temperature profiles, skin friction distributions, mean velocity profiles, turbulence intensity profiles, and Reynolds stress profiles. The Stanton numbers for the rough-wall experiments increased with acceleration. For aerodynamically smooth and transitionally rough boundary layers, the effect of roughness is not seen immediately at the beginning of the accelerated region as it is for fully rough boundary layers; however, as the boundery layer thins under acceleration, the surface becomes relatively rougher resulting in a sharp increase in Stanton number.

Chakroun, Walid M.↗
NASA NTRS2023

Influences of Varied Electrical Discharge Machining Operations on Surface Conditions of Several Nickel-Based Superalloys

Nickel-based superalloys designed for use in gas turbine engines blades are difficult and expensive to properly machine without undue surface damage, due in part to their superior mechanical properties at high temperatures. Numerically controlled electrical discharge machining (EDM) has progressed to commonly be used as a machining process for initial sectioning, detailed roughing, and even some finishing operations. The objective of this study was to examine the effect of EDM on resulting surface conditions of superalloy 718 after slicing using typical rough, semi-finish, and finish condition sets with a typical wire EDM machine. Surface roughness, residual stress, and microstructures were compared for these conditions. The varied EDM conditions influenced surface roughness as intended. The residual stresses and surface roughness directly corresponding to the EDM steps were determined. While roughness decreased when progressing from rough to finish EDM conditions, tensile residual stresses unexpectedly increased. Brief assessments after EDM of two higher performance powder metallurgy disk superalloys ME209 and LSHR indicated this inverse relationship of roughness versus tensile residual stress was also present for these superalloys, where tensile residual stresses were significantly enhanced.

superalloys↗
NASA NTRS1984

Real Surface Effects in Elastohydrodynamic Lubrication

Following a general discussion of real effects in EHL, consideration is given in detail to the role played by stochastic roughness superimposed on the nominal solid boundaries. Particular attention is given to the full-film EHL regime where incipient asperity contact bears a negligible fraction of the load. Flow, from which an averaged Reynolds equation can be formed, is nonetheless modified by the amplitude and texture of the roughness patterns. In describing these effects by means of certain well-defined flow factors, it is found that only two extra parameters are needed - the rms surface height and the ratio of the correlation lengths in the two principal roughness directions. In a lowest order perturbation expansion of these flow factors in powers of the ratio of rms roughness to nominal film thickness, no other properties of the roughness appear. In most cases of practical interest, the factors describing Poiseuille flow are separable into the sum of two single-surface flow factors which means that a combination of a single equivalent rough surface versus an ideal smooth surface can always be found. For flow entrained by slip velocity the factors separate instead into a difference of single-surface factors and it becomes significant which of the two surfaces carries the equivalent roughness. Results are discussed of some applications of the averaged Reynolds equation based on the flow factor method to the EHL line contact problem. Finally, the partial EHL regime is considered where comparable load fractions are carried by the hydrodynamic film and by incipient mechanical contact. An extension of the method into this regime by combining it with asperity contact models appears most encouraging.

John H Tripp↗
NASA NTRS2019

Preliminary Scale-Resolving Simulations of Laminar-To-Turbulent Transition in Swept-Wing Flow

Swept wings and control surfaces are common elements of modern aircraft, and it has been shown both experimentally and theoretically that laminar-to-turbulent transition of the three-dimensional boundary layer that develops over them is highly sensitive to surface roughness. Numerous studies have been conducted on the effect of discrete roughness elements or distributed roughness elements on swept flow transition, however so far limited computational effort has been dedicated to the study of transition over swept wings with randomly distributed micron-sized roughness. In the present work, we set up to reproduce the extensive experimental data base generated by Dagenhart et al for the infinite swept wing NLF(2)-0415. To this purpose, we perform scale-resolving simulations of flow transition over smooth and rough surfaces using a high-order space-time spectral-element Discontinuous-Galerkin solver. Different types of surface roughnesses are implemented by elastically deforming the original mesh. The study shows that the experimental results cannot be accounted for by a perfectly smooth wing and reveals a strong sensitivity of the transition process to the representation of the surface roughness. The crossflow patterns and transition location approach those measured for some of the surface profiles, however a correlation between the wavenumber spectrum of the surface, grid resolution and boundary layer stability is yet to be established.

Denison, Marie↗
DOE OSTI2024

Experimental and numerical investigation of fracture conductivity between non-smooth rock surfaces with and without proppant

The enhancement of fracture conductivity is vital for the efficient recovery of subsurface resources, such as geothermal energy and petroleum hydrocarbons. Proppants, granular materials injected into hydraulic fractures to maintain their conductivity, have been studied primarily in the context of smooth fractures (i.e., fractures between smooth rock surfaces). However, non-smooth fractures (i.e., fractures between rough rock surfaces) are common in geoenergy reservoirs and thus require further investigations. In this study, we conducted laboratory measurements of fracture conductivity on shale slabs with non-smooth surfaces and carried out numerical simulation using the lattice Boltzmann (LB) method, which aimed to investigate the conductivity of non-smooth fractures with and without proppants placement. When ceramic proppant with an areal concentration of 2 lb/ft 2 was placed in the fracture, the conductivity was enhanced by roughly 3-8 times compared to fractures without proppant. In fractures with proppant, gas-measured conductivity was higher than that measured with water due to proppant embedment caused by water. The experiments demonstrate the advantages of using proppant in fractures, even if the rock surface roughness can provide certain fracture conductivity via the self-propping mechanism. For fractures without proppants, high rock surface roughness is not necessarily favorable for enhancing fracture conductivity because the self-propping mechanism requires shear slip along the fracture surface. If there is no shear slip, high rock surface roughness can cause a detrimental effect on the fracture conductivity due to the interlocking effect. Utilizing advanced experimental equipment and LB modeling, this research explores the interplays between proppant placement, fracture geometry, and stress conditions to develop a comprehensive understanding of the productivity in non-smooth fractures. Further, the outcomes of this investigation indicate the importance of creating fractures with surface roughness during hydraulic fracturing and will contribute to the development of more efficient stimulation techniques for subsurface energy extraction.

15 GEOTHERMAL ENERGY↗
DOE OSTI2024

Simulation of Microcapsule Transport in Fractured Media Using Coupled CFD‐DEM

Geothermal energy is sustainable and gaining momentum as a solution to energy crises and environmental issues. However, challenges like production temperature and thermal breakthrough can impact geothermal project efficiency. One innovative solution to alleviate the thermal breakthrough is to inject polymer-based materials that are encapsulated in microcapsules into fractures to modify fracture permeability and prevent preferential flow. In our study, we utilized a coupled computational fluid dynamics and discrete element method to simulate the transport of microcapsules under various scenarios controlled by microcapsule size, microcapsule concentration, and fracture roughness. For a smooth fracture, the results indicate that small microcapsules can travel through a smooth fracture regardless of their concentrations. Large microcapsules can transport through a smooth fracture when present in lower concentrations. However, medium and mixed-size microcapsules tend to cause the sealing of a smooth fracture, irrespective of their concentrations. For a rough fracture, the transport of microcapsules is complicated by their interactions with the rough fracture walls. The presence of two sealing positions in a rough fracture adds further complexity to this transport phenomenon. The size and concentration of microcapsules control one sealing location, while the rough fracture walls determine the other sealing location. The rough walls substantially affect microcapsule transport, rendering the role of microcapsule size and concentration less significant. The simulation results suggest that complex fracture surfaces significantly elevate the occurrence of sealing behavior. To mitigate sealing behavior within more complex fractures, it would be beneficial to use smaller and lower concentrations of microcapsules.

15 GEOTHERMAL ENERGY↗
DOE OSTI2024

Exploring the effects of molecular beam epitaxy growth characteristics on the temperature performance of state-of-the-art terahertz quantum cascade lasers

This study conducts a comparative analysis, using non-equilibrium Green’s functions (NEGF), of two state-of-the-art two-well (TW) Terahertz Quantum Cascade Lasers (THz QCLs) supporting clean 3-level systems. The devices have nearly identical parameters and the NEGF calculations with an abrupt-interface roughness height of 0.12 nm predict a maximum operating temperature (T max ) of ~ 250 K for both devices. However, experimentally, one device reaches a T max of ~ 250 K and the other a T max of only ~ 134 K. Both devices were fabricated and measured under identical conditions in the same laboratory, with high quality processes as verified by reference devices. The main difference between the two devices is that they were grown in different MBE reactors. Our NEGF-based analysis considered all parameters related to MBE growth, including the maximum estimated variation in aluminum content, growth rate, doping density, background doping, and abrupt-interface roughness height. From our NEGF calculations it is evident that the sole parameter to which a drastic drop in T max could be attributed is the abrupt-interface roughness height. We can also learn from the simulations that both devices exhibit high-quality interfaces, with one having an abrupt-interface roughness height of approximately an atomic layer and the other approximately a monolayer. However, these small differences in interface sharpness are the cause of the large performance discrepancy. This underscores the sensitivity of device performance to interface roughness and emphasizes its strategic role in achieving higher operating temperatures for THz QCLs. We suggest Atom Probe Tomography (APT) as a path to analyze and measure the (graded)-interfaces roughness (IFR) parameters for THz QCLs, and subsequently as a design tool for higher performance THz QCLs, as was done for mid-IR QCLs. Our study not only addresses challenges faced by other groups in reproducing the record T max of ~ 250 K and ~ 261 K but also proposes a systematic pathway for further improving the temperature performance of THz QCLs beyond the state-of-the-art.

77 NANOSCIENCE AND NANOTECHNOLOGY↗
DOE OSTI2021

SURFACE FINISHING AND ELECTROLESS NICKEL PLATING OF ADDITIVELY MANUFACTURED (AM) METAL COMPONENTS

This study investigates the application of electroless nickel deposition on additively manufactured stainless steel samples. Current additive manufacturing (AM) technologies produce metal components with a rough surface. Rough surfaces generally exhibit fatigue characteristics, increasing the probability of initiating a crack or fracture to the printed part. For this reason, the direct use of as-produced parts in a finished product cannot be actualized, which presents a challenge. Post-processing of the AM parts is therefore required to smoothen the surface. This study analyzes chempolish (CP) and electropolish (EP) surface finishing techniques for post-processing AM stainless steel components CP has a great advantage in creating uniform, smooth surfaces regardless of size or part geometry EP creates an extremely smooth surface, which reduces the surface roughness to the sub-micrometer level. In this study, we also investigate nickel deposition on EP, CP, and as-built AM components using electroless nickel solutions. Electroless nickel plating is a method of alloy treatment designed to increase manufactured component's hardness and surface resistance to the unrelenting environment. The electroless nickel plating process is more straightforward than its counterpart electroplating.. We use low-phosphorus (2-5% P), medium-phosphorus (6-9% P), and high-phosphorus (10-13% P). These Ni deposition experiments were optimized using the L9 Taguchi design of experiments (TDOE), which compromises the prosperous content in the solution, surface finish, plane of the geometry, and bath temperature. The pre-and post-processed surface of the AM parts was characterized by KEYENCE Digital MicroscopeVHX-7000 and Phenom XL Desktop SEM. The experimental results show that electroless nickel deposition produces uniform Ni coating on the additively manufactured components up to 20 μm per hour. Mechanical properties of as-built and Ni coated AM samples were analyzed by applying a standard 10 N scratch test. Nickel coated AM samples were up to two times scratch resistant compared to the as-built samples. This study suggests electroless nickel plating is a robust viable option for surface hardening and finishing AM components for various applications and operating conditions.

Keywords: additive manufacturing, fatigue, chempol↗
DOE OSTI2021

A Novel Laser-Aided Machining and Polishing Process for Additive Manufacturing Materials with Multiple Endmill Emulating Scan Patterns

In additive manufacturing (AM), the surface roughness of the deposited parts remains significantly higher than the admissible range for most applications. Additionally, the surface topography of AM parts exhibits waviness profiles between tracks and layers. Therefore, post-processing is indispensable to improve surface quality. Laser-aided machining and polishing can be effective surface improvement processes that can be used due to their availability as the primary energy sources in many metal AM processes. While the initial roughness and waviness of the surface of most AM parts are very high, to achieve dimensional accuracy and minimize roughness, a high input energy density is required during machining and polishing processes although such high energy density may induce process defects and escalate the phenomenon of wavelength asperities. In this paper, we propose a systematic approach to eliminate waviness and reduce surface roughness with the combination of laser-aided machining, macro-polishing, and micro-polishing processes. While machining reduces the initial waviness, low energy density during polishing can minimize this further. The average roughness (Ra=1.11μm) achieved in this study with optimized process parameters for both machining and polishing demonstrates a greater than 97% reduction in roughness when compared to the as-built part.

42 ENGINEERING↗
NASA NTRS1982

Frictional heating due to asperity interaction of elastohydrodynamic line-contact surfaces

A numerical solution of an elastohydrodynamically lubricated (EHL) line contact between two long, rough-surface cylinders that considers the frictional heating of asperities was obtained. Pressure distribution, temperature distribution, film thickness and EHL load for given speeds, lubricant properties, material properties of surfaces, and surface roughness parameters were theoretically solved by simultaneous solution of the elasticity equation and the Reynolds equation for two partially lubricated rough surfaces. The pressure due to asperity contact was calculated by assuming a Gaussian distribution of surface irregularities. The elastic deformation used for film thickness computation was found from the two kinds of pressure by plane strain analysis. The temperature rise in the contact zone was calculated by using the Blok-Jaeger flash temperature model. The effects of surface roughness on EHL load for various slide-role ratios, surface roughness parameters, surface patterns, and temperature parameters was studied. It was found that the maximum temperature rise in most cases occurred in the inlet zone, and that the minimum film thickness decreased and the maximum temperature increased as the surface roughness was increased.

Majumdar, B. C.↗
NASA NTRS1984

Viking bistatic radar experiment - Summary of results in near-equatorial regions

Viking bistatic radar have been processed using Hagfors' scattering function to obtain estimates of rms surface roughness from ground tracks primarily in the equatorial region of Mars. Roughness varies from as little as 0.75 deg rms east of Solis and Sinai Plana to at least 8 deg on the western slope of Arsia Mons. Estimated roughness in cratered terrain is generally about 5 deg or less, implying the existence of smoothing processes on scales less than 100 m. There is good agreement between bistatic roughness estimates and earth-based results at ground track intersections near the equator in both cratered terrain and plains. Surface tilt probability density functions derived from these observations are usually more sharply peaked than the Hagfors function for similar values of rms surface roughness. Earlier results using the Gaussian model appear to have overestimated the surface roughness by 30-40 percent.

Simpson, R. A.↗
NASA NTRS1993

Friction and wear of plasma-deposited diamond films

Reciprocating sliding friction experiments in humid air and in dry nitrogen and unidirectional sliding friction experiments in ultrahigh vacuum were conducted with a natural diamond pin in contact with microwave-plasma-deposited diamond films. Diamond films with a surface roughness (R rms) ranging from 15 to 160 nm were produced by microwave-plasma-assisted chemical vapor deposition. In humid air and in dry nitrogen, abrasion occurred when the diamond pin made grooves in the surfaces of diamond films, and thus the initial coefficients of friction increased with increasing initial surface roughness. The equilibrium coefficients of friction were independent of the initial surface roughness of the diamond films. In vacuum the friction for diamond films contacting a diamond pin arose primarily from adhesion between the sliding surfaces. In these cases, the initial and equilibrium coefficients of friction were independent of the initial surface roughness of the diamond films. The equilibrium coefficients of friction were 0.02 to 0.04 in humid air and in dry nitrogen, but 1.5 to 1.8 in vacuum. The wear factor of the diamond films depended on the initial surface roughness, regardless of environment; it increased with increasing initial surface roughness. The wear factors were considerably higher in vacuum than in humid air and in dry nitrogen.

Miyoshi, Kazuhisa↗
NASA NTRS1993

Effect of sound on boundary layer stability

Experiments are conducted in the Arizona State University Unsteady Wind Tunnel with a zero-pressure-gradient flat-plate model that has a 67:1 elliptical leading edge. Boundary-layer measurements are made of the streamwise fluctuating-velocity component in order to identify the amplified T-S waves that are forced by downstream-traveling sound waves. Measurements are taken with circular 3-D roughness elements placed at the Branch 1 neutral stability point for the frequency under consideration, and then with the roughness element downstream of Branch 1. These roughness elements have a principal chord dimension equal to 2 lambda(sub TS)/pi of the T-S waves under study and are 'stacked' in order to resemble a Gaussian height distribution. Measurements taken just downstream of the roughness (with leading-edge T-S waves, surface roughness T-S waves, instrumentation sting vibrations, and the Stokes wave subtracted) show the generation of 3-D T-S waves, but not in the characteristic heart-shaped disturbance field predicted by 3-D asymptotic theory. Maximum disturbance amplitudes are found on the roughness centerline. However, some near-field characteristics predicted by numerical modeling are observed.

Saric, William S.↗
NASA NTRS1992

Microtopographic evolution of lava flows at Cima volcanic field, Mojave Desert, California

Microtopographic profiles were measured and power spectra calculated for dated lava flow surfaces at Cima volcanic field in the eastern Mojave Desert of California in order to quantify changes in centimeter- to meter-scale roughness as a function of age. For lava flows younger than about 0.8 m.y., roughness over all spatial scales decreases with age, with meter-scale roughness decreasing slightly more than centimeter scales. Flows older than about 0.8 m.y. show a reversal of this trend, becoming as rough as young flows at these scales. Modeling indicates that eolian deposition can explain most of the change observed in the offset, or roughness amplitude, of power spectra of flow surface profiles up to 0.8 m.y. Other processes, such as rubbing and stone pavement development, appear to have a minor effect in this age range. Changes in power spectra of surfaces older than about 0.8 m.y. are consistent with roughening due to fluvial dissection. These results agree qualitatively with a process-response model that attributes systematic changes in flow surface morphology to cyclic changes in the rates of eolian, soil formation, and fluvial processes. Identification of active surficial processes and estimation of the extent of their effects, or stage of surficial evolution, through measurement of surface roughness will help put the correlation of surficial units on a quantitative basis. This may form the basis for the use of radar remote sensing data to help in regional correlations of surficial units.

Farr, Tom G.↗
NASA NTRS1993

Synergism of active and passive microwave data for estimating bare surface soil moisture

Active and passive microwave sensors were applied effectively to the problem of estimating the surface soil moisture in a variety of environmental conditions. Research to date has shown that both types of sensors are also sensitive to the surface roughness and the vegetation cover. In estimating the soil moisture, the effect of the vegetation and roughness are often corrected either by acquiring multi-configuration (frequency and polarization) data or by adjusting the surface parameters in order to match the model predictions to the measured data. Due to the limitations on multi-configuration spaceborne data and the lack of a priori knowledge of the surface characteristics for parameter adjustments, it was suggested that the synergistic use of the sensors may improve the estimation of the soil moisture over the extreme range of naturally occurring soil and vegetation conditions. To investigate this problem, the backscattering and emission from a bare soil surface using the classical rough surface scattering theory were modeled. The model combines the small perturbation and the Kirchhoff approximations in conjunction with the Peak formulation to cover a wide range of surface roughness parameters with respect to frequency for both active and passive measurements. In this approach, the same analytical method was used to calculate the backscattering and emissivity. Therefore, the active and passive simulations can be combined at various polarizations and frequencies in order to estimate the soil moisture more actively. As a result, it is shown that (1) the emissivity is less dependent on the surface correlation length, (2) the ratio of the backscattering coefficient (HH) over the surface reflectivity (H) is almost independent of the soil moisture for a wide range of surface roughness, and (3) this ratio can be approximated as a linear function of the surface rms height. The results were compared with the data obtained by a multi-frequency radiometer-scatterometer system working at frequencies between 3.0 GHz to 11.0 GHz. The data were acquired over bare soil surfaces with moisture variations due to freezing and thawing and roughness changes due to rain and erosion. The model predictions are shown to be in reasonable agreement with the data. In addition, it was shown that the same ratio when calculated from the data shows almost no dependence on the soil moisture. Finally, a simple technique which combines the backscattering coefficient at HH polarization (active sensing) with the emissivity at H polarization (passive sensing) is suggested for retrieving the soil moisture from bare soil surfaces.

Saatchi, Sasan S.↗
NASA NTRS1993

Effect of sound on boundary layer stability

Experiments are conducted in the Arizona State University Unsteady Wind Tunnel with a zero-pressure-gradient flat-plate model that has a 67:1 elliptical leading edge. Boundary-layer measurements are made of the streamwise fluctuating-velocity component in order to identify the amplified T-S waves that are forced by downstream-travelling, sound waves. Measurements are taken with circular 3-D roughness elements placed at the Branch 1 neutral stability point for the frequency under consideration, and then with the roughness element downstream of Branch 1. These roughness elements have a principal chord dimension equal to 2(lambda)(sub TS)/pi, of the T-S waves under study and are 'stacked' in order to resemble a Gaussian height distribution. Measurements taken just downstream of the roughness (with leading-edge T-S waves, surface roughness T-S waves, instrumentation sting vibrations and the Stokes wave subtracted) show the generation of 3-D-T-S waves, but not in the characteristic heart-shaped disturbance field predicted by 3-D asymptotic theory. Maximum disturbance amplitudes are found on the roughness centerline. However, some near-field characteristics predicted by numerical modelling are observed.

Saric, William S.↗
NASA NTRS1998

Effects of Ice Accretion on Aircraft Aerodynamics

The primary objective of this research was to support the development of a new ice accretion model by improving our physical understanding of the ice accretion process through experimental measurements. The focus was on the effect of the initial ice roughness (smooth/rough boundary) on the accretion process. This includes understanding the boundary-layer development over the roughness and especially its effect on the heat transfer which is fundamental to the ice accretion process. The research focused on acquiring the experimental data needed to formulate a new ice accretion physical model. Research was conducted to analyze boundary-layer data taken on a NACA 0012 airfoil with roughness to simulate the smooth/rough boundary. The effect of isolated roughness on boundary-layer transition was studied experimentally to determine if the classical critical roughness Reynolds number criteria could be applied to transition in the airfoil leading-edge area. The effect of simulated smooth/rough boundary roughness on convective heat transfer was studied to complete the study. During the course of this research the effect of free-stream wind tunnel turbulence on the boundary layer was measured. Since this quantity was not well known, research to accurately measure the wind tunnel turbulence in an icing cloud was undertaken. Preliminary results were attained and the final data were acquired, reduced and presented under a subsequent grant.

Bragg, Michael B.↗
NASA NTRS2004

Boundary Layer Control for Hypersonic Airbreathing Vehicles

Active and passive methods for tripping hypersonic boundary layers have been examined in NASA Langley Research Center wind tunnels using a Hyper-X model. This investigation assessed several concepts for forcing transition, including passive discrete roughness elements and active mass addition (or blowing), in the 20-Inch Mach 6 Air and the 31-Inch Mach 10 Air Tunnels. Heat transfer distributions obtained via phosphor thermography, shock system details, and surface streamline patterns were measured on a 0.333-scale model of the Hyper-X forebody. The comparisons between the active and passive methods for boundary layer control were conducted at test conditions that nearly match the Hyper-X nominal Mach 7 flight test-point of an angle-of-attack of 2-deg and length Reynolds number of 5.6 million. For passive roughness, the primary parametric variation was a range of trip heights within the calculated boundary layer thickness for several trip concepts. The passive roughness study resulted in a swept ramp configuration, scaled to be roughly 0.6 of the calculated boundary layer thickness, being selected for the Mach 7 flight vehicle. For the active blowing study, the manifold pressure was systematically varied (while monitoring the mass flow) for each configuration to determine the jet penetration height, with schlieren, and transition movement, with the phosphor system, for comparison to the passive results. All the blowing concepts tested, which included various rows of sonic orifices (holes), two- and three-dimensional slots, and random porosity, provided transition onset near the trip location with manifold stagnation pressures on the order of 40 times the model surface static pressure, which is adequate to ensure sonic jets. The present results indicate that the jet penetration height for blowing was roughly half the height required with passive roughness elements for an equivalent amount of transition movement.

Berry, Scott A.↗