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At least 109 records · Page 6

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DOE OSTI2025

Surface roughness and dimensional evaluation of laser powder bed fusion additively manufactured shell and tube heat exchangers

The growing interest in additively manufactured (AM) heat exchangers drove the need to understand how this construction technique impacts heat exchanger performance. Two primary factors driven by AM that influence heat exchanger performance are surface roughness and geometry. To better understand these parameters, a range of shell and tube heat exchangers constructed using laser powder bed fusion were evaluated. Of those evaluated, the surface roughness throughout a fourteen-tube, zero-baffle heat exchanger was measured using computed tomography. Between the inner and outer tubes, the inner tube surfaces had a greater surface roughness than the outer by 8.07 μm, while the surfaces at the top of the build volume had higher surface roughness values than the bottom. Dimensionally, the inner tube diameters of this heat exchanger were 0.15% different from the design value, while the outer diameters were within a 0.84 % difference. Manual measurements across seven other heat exchangers yielded a maximum 1.15% difference between the design and measured diameters. Across the build volume for all heat exchangers studied, the tube diameters at the top were larger than at the bottom by a maximum of 1.24% difference. Inconsistent melting throughout the individual parts and the build volume, as well as particle splatter and thermal gradient variation were attributed to the surface roughness and dimensional changes seen. These results strengthen the knowledge of dimensional and surface roughness considerations when designing AM heat exchangers.

36 MATERIALS SCIENCE↗

NASA NTRS1974

Kaumana lava tube

The entrance to Kaumana Lava Tube is in a picnic ground next to Highway 20 (Kaumana Drive) about 6.5 km southwest of Hilo. The area is passed on the way to the Kona Coast via the Saddle Road and is identified by a Hawaii Visitors Bureau sign. Although it is not the largest lava tube in the islands, Kaumana Lava Tube is an interesting geological formation, displaying many of the features typical of lava tube interiors. It is accessible, relatively easy to walk through, and is in an excellent state of preservation. The tube developed in a historic lava flow (1881, from Mauna Loa), and many aspects of lava tube activity are observed.

Greeley, R.↗

NASA NTRS1980

Tube-shape verifier

Inexpensive apparatus checks accuracy of bent tubes. Assortment of slotted angles and clamps is bolted down to flat aluminum plate outlining shape of standard tube bent to desired configuration. Newly bent tubes are then checked against this outline. Because parts are bolted down, tubes can be checked very rapidly without disturbing outline. One verifier per tube-bending machine can really speed up production in tube-bending shop.

Anderson, A. N.↗

NASA NTRS1979

Sunspots and the physics of magnetic flux tubes. I - The general nature of the sunspot. II - Aerodynamic drag

Analysis of the dynamical stability of a large flux tube suggests that the field of a sunspot must divide into many separate tubes within the first 1000 km below the surface. Buoyancy of the Wilson depression at the visible surface and probably also a downdraft beneath the sunspot hold the separate tubes in a loose cluster. Convective generation of Alfven waves, which are emitted preferentially downward, cools the tubes. Aerodynamic drag on a slender flux tube stretched vertically across a convective cell is also studied. Since the drag is approximately proportional to the local kinetic energy density, the density stratification weights the drag in favor of the upper layers. Horizontal motions concentrated in the bottom of the convective cell may reverse this density effect. A downdraft of about two km/sec through the flux tubes beneath the sunspot is hypothesized.

Parker, E. N.↗

NASA NTRS1981

Radiation losses in resonant tubes

The role of radiation losses in a resonant tube - the transfer of sound energy from the test gas through the confines of the tube to the ambient atmosphere - is investigated both theoretically and experimentally. It is concluded that losses of this sort make no noticeable contribution to the background losses, even at high gas pressures. Nevertheless, if an axial resonant frequency of the test gas closely matches a longitudinal resonant frequency of the tube wall, the internal sound pressure can excite tube displacements of disproportionate magnitude and thus cause excessive losses, not due to radiation but rather to frictional dissipation related to the motion of the tube structure. This mechanism is effective when the mode numbers of the gas and tube have opposite parity, and makes sound absorption measurements at the fundamental gas frequency particularly problematical. An experimental investigation confirms the existence of such additional losses when the parity condition is fulfilled.

Zuckerwar, A. J.↗

NASA NTRS1982

Evaluation of candidate stirling engine heater tube alloys at 820 deg and 860 deg C

Seven commercial alloys were evaluated in Stirling simulator materials rigs. Five iron base alloys (N-155, A-286, Incoloy 800, 19-9DL, and 316 stainless steel), one nickel base alloy (Inconel 718), and one cobalt base alloy (HS-188) were tested in the form of thin wall tubing in a diesel fuel fired test rig. Tubes filled with hydrogen or helium at gas pressure of 21.6 MPa and temperatures of 820 and 860 C were endurance tested for 1000 and 535 hours, respectively. Results showed that under these conditions hydrogen permeated rapidly through the tube walls, thus requiring refilling during each five hour cycle. Helium was readily contained, exhibiting no measurable loss by permeation. Helium filled tubes tested at 860 C all exhibited creep-rupture failures within the 535 hour endurance test. Subsequent tensile test evaluation after removal from the rig indicated reduced room temperature ductility for some hydrogen-filled tubes compared to helium-filled tubes, suggesting possible hydrogen embrittlement in these alloys.

Misencik, J. A.↗

NASA NTRS1982

The Apollo 15 regolith - Comparative petrology of drive tube 15010/15011 and drill core section 15003

Two Apollo 15 regolith cores - double drive-tube 15010/15011 and deep drill core section 15003 - were compared. The drive tube was taken from near the edge of Hadley Rille within the mare region and the drill core was taken from the landing site, approximately the same distance as the drive tube from the Apennine Front. Optical modes were done on the two cores, each of which was divided into three stratigraphic units defined by minor differences in grain size and modal abundances. Electron microprobe data were collected on the mineral and glass fragments within each unit. Fused-soil-free bulk chemistries were calculated for each unit by modal recombination, using our modal data and average compositional and density data for soil components. It is found that the drive tube and drill core section are fairly homogeneous units both chemically and modally. Both soils are submature to immature. There are, however, significant differences between the cores. The drill core shows significant enrichments of highland lithic-fragments and highland-derived minerals and glasses relative to the drive tube. These differences are attributed to the fresh nature of the drive tube soil whose major source material is mare basalt ejecta from the shallow bedrock.

Walker, R. J.↗

NASA NTRS1984

Liquid-Nitrogen Test for Blocked Tubes

Nondestructive test identifies obstructed tube in array of parallel tubes. Trickle of liquid nitrogen allowed to flow through tube array until array accumulates substantial formation of frost from moisture in air. Flow stopped and warm air introduced into inlet manifold to heat tubes in array. Tubes still frosted after others defrosted identified as obstructed tubes. Applications include inspection of flow systems having parallel legs.

Wagner, W. R.↗

NASA NTRS1982

Evaluation of dopants in hydrogen to reduce hydrogen permeation in candidate Stirling engine heater head tube alloys at 760 deg and 820 deg

Alloy tubes filled with hydrogen doped with various amounts of carbon monoxide, carbon dioxide, ethane, ethylene, methane, ammonia, or water were heated in a diesel fuel-fired Stirling engine simulator materials test rig for 100 hours at 21 MPa and 760 or 820 C to determine the effectiveness of the dopants in reducing hydrogen permeation through the hot tube walls. Ultra high purity (UHP) hydrogen was used for comparison. The tube alloys were N-155, A-286, Incoloy 800, Nitronic 40, 19-9DL, 316 stainless steel, Inconel 718, and HS-188. Carbon dioxide and carbon monoxide in the concentration range 0.2 to 5 vol % were most effective in reducing hydrogen permeation through the hot tube walls for all alloys. Ethane, ethylene, methane, ammonia, and water at the concentrations investigated were not effective in reducing the permeation below that achieved with UHP hydrogen. One series of tests were conducted with UHP hydrogen in carburized tubes. Carburization of the tubes prior to exposure reduced permeation to values similar to those for carbon monoxide; however, carbon dioxide was the most effective dopant.

Misencik, J. A.↗

NASA NTRS1983

Reynolds number effects on pressure loss and turbulence characteristics of four tube-bundle heat exchangers

The aerodynamic characteristics of pressure loss and turbulence on four tube-bundle configurations representing heat-exchanger geometries with nominally the same heat capacity were measured as a function of Reynolds numbers from about 4000 to 400,000 based on tube hydraulic diameter. Two configurations had elliptical tubes, the other two had round tubes, and all four had plate fins. The elliptical-tube configurations had lower pressure loss and turbulence characteristics than the round-tube configurations over the entire Reynolds number range.

Gentry, L., Jr.↗

NASA NTRS1984

Evaluation of candidate Stirling engine heater tube alloys after 3500 hours exposure to high pressure doped hydrogen or helium

The heater head tubes of current prototype automotive Stirling engines are fabricated from alloy N-155, an alloy which contains 20 percent cobalt. Because the United States imports over 90 percent of the cobalt used in this country and resource supplies could not meet the demand imposed by automotive applications of cobalt in the heater head (tubes plus cylinders and regenerator housings), it is imperative that substitute alloys free of cobalt be identified. The research described herein focused on the heater head tubes. Sixteen alloys (15 potential substitutes plus the 20 percent Co N-155 alloy) were evaluated in the form of thin wall tubing in the NASA Lewis Research Center Stirling simulator materials diesel fuel fired test rigs. Tubes filled with either hydrogen doped with 1 percent CO2 or with helium at a gas pressure of 15 MPa and a temperature of 820 C were cyclic endurance tested for times up to 3500 hr. Results showed that two iron-nickel base superalloys, CG-27 and Pyromet 901 survived the 3500 hr endurance test. The remaining alloys failed by creep-rupture at times less than 3000 hr, however, several other alloys had superior lives to N-155. Results further showed that doping the hydrogen working fluid with 1 vol % CO2 is an effective means of reducing hydrogen permeability through all the alloy tubes investigated.

Misencik, J. A.↗

NASA NTRS1984

Correlation of transonic-cone preston-tube data and skin friction

Preston-tube measurements obtained on the Arnold Engineering Development Center (AEDC) Transition Cone have been correlated with theoretical skin friction coefficients in transitional and turbulent flow. This has been done for the NASA Ames 11-Ft Transonic Wind Tunnel (11 TWT) and flight tests. The developed semi-empirical correlations of Preston-tube data have been used to derive a calibration procedure for the 11 TWT flow quality. This procedure has been applied to the corrected laminar data, and an effective freestream unit Reynolds number is defined by requiring a matching of the average Preston-tube pressure in flight and in the tunnel. This study finds that the operating Reynolds number is below the effective value required for a match in laminar Preston-tube data. The distribution of this effective Reynolds number with Mach number correlates well with the freestream noise level in this tunnel. Analyses of transitional and turbulent data, however, did not result in effective Reynolds numbers that can be correlated with background noise. This is a result of the fact that vorticity fluctuations present in transitional and turbulent boundary layers dominate Preston-tube pressure fluctuations and, therefore, mask the tunnel noise eff ects. So, in order to calibrate the effects of noise on transonic wind tunnel tests only laminar data should be used, preferably at flow conditions similar to those in flight tests. To calibrate the effects of transonic wind-tunnel noise on drag measurements, however, the Preston-tube data must be supplemented with direct measurements of skin friction.

Abu-Mostafa, A. S.↗

NASA NTRS1986

Development of composite tube protective coatings

Protective coatings for graphite/epoxy (Gr/Ep) tubular structures proposed for the Space Station are evaluated. The program was divided into four parts; System Definition, Coating Concept Selection and Evaluation, Scale-up and Assembly, and Reporting. System Definition involved defining the structural and environmental properties required of the Gr/Ep tubes. The prepreg and ply sequence selected was a P75S/934 (O2, + or - 20, O2)sub s layup which meets the various structural requirements of the Space Station. Coating Concept and Selection comprised the main emphasis of the effort. Concepts for protectively coating the Gr/Ep tubes included the use of metal foil and electroplating. The program results demonstrated that both phosphoric and chromic acid anodized Al foil provided adequate adhesion to the Gr/Ep tubes and stability of optical properties when subjected to atomic oxygen and thermal cycling representative of the LEO environment. SiO2/Al coatings sputtered onto Al foils also resulted in an excellent protective coating. The electroplated Ni possessed unacceptable adhesion loss to the Gr/Ep tubes during atomic oxygen testing. Scale-Up and Assembly involved fabricating and wrapping 8-ft-long by 2-in-diameter Gr/EP tubes with chromic acid anodized foil and delivering these tubes, along with representative Space Station erectable end fittings, to NASA LaRC.

Dursch, H.↗

NASA NTRS1986

Propagation of sound waves in tubes of noncircular cross section

Plane-acoustic-wave propagation in small tubes with a cross section in the shape of a flattened oval is described. Theoretical descriptions of a plane wave propagating in a tube with circular cross section and between a pair of infinite parallel plates, including viscous and thermal damping, are expressed in similar form. For a wide range of useful duct sizes, the propagation constant (whose real and imaginary parts are the amplitude attenuation rate and the wave number, respectively) is very nearly the same function of frequency for both cases if the radius of the circular tube is the same as the distance between the parallel plates. This suggests that either a circular-cross-section model or a flat-plate model can be used to calculate wave propagation in flat-oval tubing, or any other shape tubing, if its size is expressed in terms of an equivalent radius, given by g = 2 x (cross-sectional area)/(length of perimeter). Measurements of the frequency response of two sections of flat-oval tubing agree with calculations based on this idea. Flat-plate formulas are derived, the use of transmission-line matrices for calculations of plane waves in compound systems of ducts is described, and examples of computer programs written to carry out the calculations are shown.

Richards, W. B.↗

NASA NTRS1988

Shuttle crew escape tube study

An investigation was performed to examine the feasibility of an escape tube as an aid in crew bailout from the Shuttle Orbiter at subsonic speeds. The deployable escape tube extended from the main side hatch downwards. Wind-tunnel tests with scaled models demonstrated that successful bailout was possible when the tube exit was at least 1 foot below the wing leading edge. The aerodynamics of the Orbiter were only slightly degraded with the tube deployed. Several tube designs were investigated, the most promising of which was an inflatable elastic/fabric 'Airmat' configuration. Loads on the tube were within capability of current airmat technology.

Ware, George M.↗

NASA NTRS1990

A life comparison of tube and channel cooling passages for thrust chambers

The life analysis used to compare copper tubes and milled copper channels for rocket engine cooling passages is described. Copper tubes were chosen as a possible replacement for the existing milled copper channel configuration because (1) they offer increased surface area for additional enthalpy extraction; (2) they have ideal pressure vessel characteristics; and (3) the shape of the tube is believed to allow free expansion, thus accommodating the strain resulting from thermal expansion. The analysis was a two-dimensional elastic-plastic comparison, using a finite element method, to illustrate that, under the same thermal and pressure loading, the compliant shape of the tube increases the life of the chamber. The analysis indicates that for a hot-gas-side-wall temperature of 100 F the critical strain decreases from 1.25 percent in the channel to 0.94 percent in the tube. Since the life of rocket thrust chambers is most often limited by cyclic strain or strain range, this decrease corresponds to an expected tube life which is nearly twice the channel life.

Jankovsky, R. S.↗

NASA NTRS1992

Interfacial tension measurement of immiscible liq uids using a capillary tube

The interfacial tension of immiscible liquids is an important thermophysical property that is useful in the behavior of liquids both in microgravity (Martinez et al. (1987) and Karri and Mathur (1988)) and in enhanced oil recovery processes under normal gravity (Slattery (1974)). Many techniques are available for its measurement, such as the ring method, drop weight method, spinning drop method, and capillary height method (Adamson (1960) and Miller and Neogi (1985)). Karri and Mathur mention that many of the techniques use equations that contain a density difference term and are inappropriate for equal density liquids. They reported a new method that is suitable for both equal and unequal density liquids. In their method, a capillary tube forms one of the legs of a U-tube. The interfacial tension is related to the heights of the liquids in the cups of the U-tube above the interface in the capillary. Our interest in this area arose from a need to measure small interfacial tension (around 1 mN/m) for a vegetable oil/silicon oil system that was used in a thermocapillary drop migration experiment (Rashidnia and Balasubramaniam (1991)). In our attempts to duplicate the method proposed by Karri and Mathur, we found it quite difficult to anchor the interface inside the capillary tube; small differences of the liquid heights in the cups drove the interface out of the capillary. We present an alternative method using a capillary tube to measure the interfacial tensions of liquids of equal or unequal density. The method is based on the combined capillary rises of both liquids in the tube.

Rashidnia, N.↗

NASA NTRS1990

A small, single stage orifice pulse tube cryocooler demonstration

This final report summarizes and presents the analytical and experimental progress in the present effort. The principal objective of this effort was the demonstration of a 0.25 Watt, 80 Kelvin orifice pulse tube refrigerator. The experimental apparatus is described. The design of a partially optimized pulse tube refrigerator is included. The refrigerator demonstrates an ultimate temperature of 77 K, has a projected cooling power of 0.18 Watts at 80 K, and has a measured cooling power of 1 Watt at 97 K, with an electrical efficiency of 250 Watts/Watt, much better than previous pulse tube refrigerators. A model of the pulse tube refrigerator that provides estimates of pressure ratio and mass flow within the pulse tube refrigerator, based on component physical characteristics is included. A model of a pulse tube operation based on generalized analysis which is adequate to support local optimization of existing designs is included. A model of regenerator performance based on an analogy to counterflow heat exchangers is included.

Hendricks, John B.↗