Engineering Papers⌕ Search

SEARCH · Engineering Papers

Results for “Flow Visualization”

Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 1,171 records · Page 65
All sourcesNASA NTRSDOE OSTI
NASA NTRS2018

Measurements to Understand the Flow Mechanisms Contributing to Tandem-Rotor Outwash

Downwash and outwash characteristics of a model-scale tandem-rotor system in the presence of the ground were analyzed by identifying and understanding the physical mechanisms contributing to the observed flow field behavior. A building block approach was followed in simplifying the problem, separating the effects of the fuselage, effects of one rotor on the other, etc. Flow field velocities were acquired in a vertical plane at four aircraft azimuths of a small-scale tandem rotor system using the particle image velocimetry (PIV) technique for radial distances up to 4 times the rotor diameter. Results were compared against full-scale CH-47D measurements. Excellent correlation was found between the small- and full-scale mean flow fields (after appropriate normalization using rotor and wall jet parameters). Following the scalability analysis, the effect of rotor height on the outwash was also studied. Close to the aircraft, an increase in rotor height above ground decreased the outwash velocity at all aircraft azimuths. However, farther away, the longitudinal and lateral axes of the aircraft showed increasing and decreasing outwash velocities, respectively, with increasing rotor height. Measurements also indicated the presence of large-scale (of the size of the rotor height) shear-layer vortical structures along the ground that could be the source of low-frequency (approximately 1 Hz) flow variation observed in the full-scale measurements. Flow visualization studies and PIV measurements were also made on jets of different sizes to complement the observations made on rotors wherever possible. Baseline rotor measurements were made out-of-ground effect to understand the nature of inflow distribution for realistic rotor configurations and their modified characteristics in the presence of ground. Lastly, a feasibility study on applying high-fidelity CFD simulations for outwash study was conducted using Helios to model an isolated rotor configuration IGE at full scale Reynolds number. The results were encouraging and demonstrated the practical challenges associated with predicting rotor outwash.

Measurements↗
NASA NTRS2005

DEVELOPMENT OF AN INFLIGHT COUNTERMEASURE TO MITIGATE POSTFLIGHT GAIT DYSFUNCTION

Following spaceflight crewmembers experience gait and postural instabilities due to inflight adaptive alterations in sensorimotor function. These changes can pose a risk to crew safety if nominal or emergency vehicle egress is required immediately following long-duration spaceflight. At present, no operational countermeasure is available to mitigate postflight locomotor disturbances. Therefore, the goal of this study is to develop an inflight training regimen that facilitates the recovery of locomotor function after long-duration spaceflight. The countermeasure we are developing is based on the concept of variable practice. During this type of training the subject gains experience producing the appropriate adaptive motor behavior under a variety of sensory conditions and response constraints. This countermeasure is built around current ISS treadmill exercise activities. Crewmembers will conduct their nominal inflight treadmill exercise while being exposed to variations in visual flow patterns. These variations will challenge the postural and locomotor systems repeatedly, thereby promoting adaptive reorganization in locomotor behavior. As a result of this training a subject learns to solve a class of motor problems, rather than a specific motor solution to one problem, Le., the subject learns response generalizability or the ability to "learn to learn" under a variety of environmental constraints. We anticipate that this training will accelerate recovery of postural and locomotor function during readaptation to gravitational environments following spaceflight facilitating neural adaptation to unit (Earth) and partial (Mars) gravity after long-duration spaceflight. The study calls for one group of subjects to perform the inflight treadmill training regimen while a control group of subjects performs only the nominal exercise procedures. Locomotor function in both groups is assessed before and after spaceflight using two tests of gait function: The Integrated Treadmill Locomotion Test (ITLT) and the Functional Mobility Test (FMT). The ITLT characterizes alterations in the integrated function of multiple sensorimotor subsystems responsible for the control of locomotion. This test calls for subjects to walk on a motorized treadmill while we assess changes in dynamic postural stability, head-trunk coordination, short-latency head stabilization responses, dynamic visual acuity, lower limb coordination strategies and gait cycle timing. To make these assessments we measure the following parameters while subjects walk on the treadmill: 1) full body 3-dimensional kinematics using a motion capture system (Motion Analysis Corp., Santa Rosa, CA); 2) the shock-wave transmitted from heel-strike to the head using triaxial accelerometers placed on the tibia and head (Entran, Fairfield, NJ); 3) vertical forces using an instrumented treadmill (Kistler Instrument Corp., Amherst, NY); 4) Dynamic visual acuity using Landolt Cs presented on a laptop computer located 4m from the eyes and 5) Gait cycle timing using foot-switches (Motion Lab Systems, Inc., Baton Rouge, LA) attached to the plantar surface of each shoe at the heel and toe. The FMT evaluates a subject's ability to perform challenging locomotor maneuvers similar to those encountered during an egress from a space vehicle. Subjects step over and duck under obstacles along with negotiating a series of pylons set up on a base of 10 cm thick medium density foam. The dependent measures for the FMT are time to complete the course and the number of obstacles touched. To date, we have collected pre and postflight locomotion data from Expeditions 5-9 who will serve as part of the control group for this study. Preliminary results comparing the recovery rates in gait control sub-systems obtained from the ITLT and FMT performance showed two recovery patterns: 1) a concordant recovery trend between gait control parameters and FMT performance indicating a restitution pattern of recovery and 2) gait controecovery that lagged recovery in FMT performance suggesting that improvement in locomotor function was attained through a pattern of substitution. These data suggest that recovery of postflight locomotor function may occur through adaptive mechanisms that lead to either restitution or substitution of function. Understanding the modes of postflight readaptation has implications for countermeasure development and testing and in astronaut postflight rehabilitation.

Bloomberg, J. J.↗
NASA NTRS2005

Development of an Inflight Countermeasure to Mitigate Postflight Gait Dysfunction

Following spaceflight crewmembers experience gait and postural instabilities due to inflight adaptive alterations in sensorimotor function. These changes can pose a risk to crew safety if nominal or emergency vehicle egress is required immediately following long-duration spaceflight. At present, no operational countermeasure is available to mitigate postflight locomotor disturbances. Therefore, the goal of this study is to develop an inflight training regimen that facilitates the recovery of locomotor function after long-duration spaceflight. The countermeasure we are developing is based on the concept of variable practice. During this type of training the subject gains experience producing the appropriate adaptive motor behavior under a variety of sensory conditions and response constraints. This countermeasure is built around current ISS treadmill exercise activities. Crewmembers will conduct their nominal inflight treadmill exercise while being exposed to variations in visual flow patterns. These variations will challenge the postural and locomotor systems repeatedly, thereby promoting adaptive reorganization in locomotor behavior. As a result of this training a subject learns to solve a class of motor problems, rather than a specific motor solution to one problem, Le., the subject learns response generalizability or the ability to "learn to learn" under a variety of environmental constraints. We anticipate that this training will accelerate recovery of postural and locomotor function during readaptation to gravitational environments following spaceflight facilitating neural adaptation to unit (Earth) and partial (Mars) gravity after long-duration spaceflight. The study calls for one group of subjects to perform the inflight treadmill training regimen while a control group of subjects performs only the nominal exercise procedures. Locomotor function in both groups is assessed before and after spaceflight using two tests of gait function: The Integrated Treadmill Locomotion Test (ITLT) and the Functional Mobility Test (FMT). The ITLT characterizes alterations in the integrated function of multiple sensorimotor subsystems responsible for the control of locomotion. This test calls for subjects to walk on a motorized treadmill while we assess changes in dynamic postural stability, head-trunk coordination, short-latency head stabilization responses, dynamic visual acuity, lower limb coordination strategies and gait cycle timing. To make these assessments we measure the following parameters while subjects walk on the treadmill: 1) full body 3-dimensional kinematics using a motion capture system (Motion Analysis Corp., Santa Rosa, CA); 2) the shock-wave transmitted from heel-strike to the head using triaxial accelerometers placed on the tibia and head (Entran, Fairfield, NJ); 3) vertical forces using an instumented treadmill (Kistler Instrument Corp., Amherst, NY); 4) Dynamic visual acuity using Landolt Cs presented on a laptop computer located 4m from the eyes and 5) Gait cycle timing using foot-switches (Motion Lab Systems, Inc., Baton Rouge, LA) attached to the plantar surface of each shoe at the heel and toe. The FMT evaluates s. subject's ability to perform challenging locomotor maneuvers similar to those encountered during an egress from a space vehicle. Subjects step over and duck under obstacles along with negotiating a series of pylons set up on a base of 10 cm thick medium density foam. The dependent measures for the FMT are time to complete the course and the number of obstacles touched. To date, we have collected pre and postflight locomotion data from Expeditions 5-9 who will serve as part of the control group for this study. Preliminary results comparing the recovery rates in gait control sub-systems obtained from the ITLT and FMT performance showed two recovery patterns: 1) a concordant recovery trend between gait control parameters and FMT performance indicating a restitution pattern of recovery and 2) gait controecovery that lagged recovery in FMT performance suggesting that improvement in locomotor function was attained through a pattern of substitution. These data suggest that recovery of postflight locomotor function may occur through adaptive mechanisms that lead to either restitution or substitution of function. Understanding the modes of postflight readaptation has implications for countermeasure development and testing and in astronaut postflight rehabilitation.

Bloomberg, J. J.↗
NASA NTRS1994

Effect of delta tabs on mixing and axis switching in jets from asymmetric nozzles

The effect of delta tabs on mixing and the phenomenon of axis switching in free air jets from various asymmetric nozzles was studied experimentally. Flow visualization and Pitot probe surveys were carried out with a set of small nozzles (D = 1.47 cm) at a jet Mach number, Mj = 1.63. Hot wire measurements for streamwise vorticity were carried out with larger nozzles (D = 6.35 cm) at Mj = 0.31. Jet mixing with the asymmetric nozzles, as indicated by the mass fluxes downstream, was found to be higher than that produced by a circular nozzle. The circular nozzle with four delta tabs, however, produced fluxes much higher than that produced by a asymmetric nozzles themselves or by most of the tab configurations tried with them. Even higher fluxes could be obtained with only a few cases, e.g., with 3:1 rectangular nozzle with two large delta tabs placed on the narrow edges. In this case, the jet 'fanned out' at a large angle after going through one axis switch. The axis switching could be either stopped or augmented with suitable choice of the tab configurations. Two mechanisms are identified governing the phenomenon. One, as described in Ref. 12 and referred to here as the omega(sub Theta)-induced dynamics, is due to differential induced velocities of different segments of a rolled up azimuthal vortical structure. The other is the omega(sub x)-induced dynamics due to the induced velocities of streamwise vortex pairs in the flow. While the former dynamics are responsible for rapid axis switching in periodically forced jets, the effect of the tabs is governed mainly by the latter. It is inferred that both dynamics are active in a natural asymmetric jet issuing from a nozzle having an upstream contraction. The tendency for axis switching caused by the omega(sub Theta)-induced dynamics is resisted by the omega(sub x)-induced dynamics, leading to a delayed or no switch over in that case. In jets from orifices and in screeching jets, the omega(sub Theta)-induced dynamics dominate causing a faster switch over.

Zaman, K. B. M. Q.↗
NASA NTRS2024

Flow, Noise and Thrust of Supersonic Plug Nozzles

A model-scale experimental study is conducted with a plug nozzle exploring the performance of various plug geometries for supersonic aircraft concepts. All data are acquired with a given outer nozzle that is convergent and has an exit diameter of 2 inches. The shape of the centrally placed plug is varied from conic with various half-angles (lengths), to method of characteristics (MoC) designs, as well as truncated and porous geometries. Noise and schlieren flow visualization data, presented in an earlier paper, are briefly reviewed first. The focus in this paper is on the thrust performance. A newly constructed thrust stand is used to acquire data covering a nozzle pressure ratio (NPR) range from transonic (‘landing and takeoff’, LTO) to supersonic (‘cruise’) conditions. Back-to-back measurements allowed assessment of relative performance. A plug with its ‘crown’ located somewhat inside the nozzle, rather than near the exit, is found to perform better. A longer 10° plug performs better than a shorter 22° plug. A porous plug, that significantly suppresses broadband shock associated noise, is found to incur a modest thrust loss that might be an acceptable tradeoff near LTO conditions. A companion numerical simulation for some of the plug geometries yields data trends bearing reasonable agreement with the experimental results.

jets↗
DOE OSTI2013

Investigation of Gas Solid Fluidized Bed Dynamics with Non-Spherical Particles

One of the largest challenges for 21st century is to fulfill global energy demand while also reducing detrimental impacts of energy generation and use on the environment. Gasification is a promising technology to meet the requirement of reduced emissions without compromising performance. Coal gasification is not an incinerating process; rather than burning coal completely a partial combustion takes place in the presence of steam and limited amounts of oxygen. In this controlled environment, a chemical reaction takes place to produce a mixture of clean synthetic gas. Gas-solid fluidized bed is one such type of gasification technology. During gasification, the mixing behavior of solid (coal) and gas and their flow patterns can be very complicated to understand. Many attempts have taken place in laboratory scale to understand bed hydrodynamics with spherical particles though in actual applications with coal, the particles are non-spherical. This issue drove the documented attempt presented here to investigate fluidized bed behavior using different ranges of non-spherical particles, as well as spherical. For this investigation, various parameters are controlled that included particle size, bed height, bed diameter and particle shape. Particles ranged from 355 µm to 1180 µm, bed diameter varied from 2 cm to 7 cm, two fluidized beds with diameters of 3.4 cm and 12.4 cm, for the spherical and non-spherical shaped particles that were taken into consideration. Pressure drop was measured with increasing superficial gas velocity. The velocity required in order to start to fluidize the particle is called the minimum fluidization velocity, which is one of the most important parameters to design and optimize within a gas-solid fluidized bed. This minimum fluidization velocity was monitored during investigation while observing variables factors and their effect on this velocity. From our investigation, it has been found that minimum fluidization velocity is independent of bed height for both spherical and non-spherical particles. Further, it decrease with decreasing particle size and decreases with decreasing bed diameter. Shadow sizing, a non-intrusive imaging and diagnostic technology, was also used to visualize flow fields inside fluidized beds for both spherical and non- spherical particles and to detect the particle sizes.

09 BIOMASS FUELS↗
NASA NTRSDate not supplied

Flow and noise from supersonic plug nozzles

Nozzles with external plugs are candidates for propulsion of future supersonic aircraft. A model-scale experimental study is conducted exploring the flow and noise characteristics of various plug nozzles. For a given outer nozzle, the plug geometry is varied from conic with various half-angles (lengths) to plugs designed by the method of characteristics (MoC) as well as truncated and porous plugs. So far, noise characteristics and schlieren flow visualization data have been acquired. Limited numerical simulations have also been done addressing thrust performance. The simulations show that the MoC plugs out-perform the conic cases, especially around high Mach number cruise conditions. The experimental data, however, show that the MoC plugs are noisy relative to the conic cases at low Mach number landing and takeoff (LTO) conditions. The increased noise (with MoC at LTO) is accompanied by unsteady turbulent structures and increased jet spreading, as seen in schlieren pictures. At LTO, the longest conic plug is found to be the least noisy. Furthermore, a porous surface on the long conic plug effectively suppresses broadband shock associated noise (BBSN) at higher Mach numbers. Thus, a dilemma remains. MoC design gives best thrust performance at cruise but it is noisy at LTO. A long conic plug, on the other hand, is quieter at LTO but may have unacceptable thrust at cruise.

jets↗
NASA NTRSDate not supplied

Flow and Noise from Supersonic Plug Nozzles

Nozzles with external plugs are candidates for propulsion of future supersonic aircraft. A model-scale experimental study is conducted exploring the flow and noise characteristics of various plug nozzles. For a given outer nozzle, the plug geometry is varied from conic with various half-angles (lengths) to plugs designed by the method of characteristics (MoC) as well as truncated and porous plugs. So far, noise characteristics and schlieren flow visualization data have been acquired. Limited numerical simulations have also been done addressing thrust performance. The simulations show that the MoC plugs out-perform the conic cases, especially around high Mach number cruise conditions. The experimental data, however, show that the MoC plugs are noisy relative to the conic cases at low Mach number landing and takeoff (LTO) conditions. The increased noise (with MoC at LTO) is accompanied by unsteady turbulent structures and increased jet spreading, as seen in schlieren pictures. At LTO, the longest conic plug is found to be the least noisy. Furthermore, a porous surface on the long conic plug effectively suppresses broadband shock associated noise (BBSN) at higher Mach numbers. Thus, a dilemma remains. MoC design gives best thrust performance at cruise but it is noisy at LTO. A long conic plug, on the other hand, is quieter at LTO but may have unacceptable thrust at cruise.

jets↗
DOE OSTI2021

Direct numerical simulation of supercritical oxy-methane mixing layers with CO 2 substituted counterparts

Direct numerical simulations (DNS) of temporally developing, three dimensional, CH 4 /CO 2 , CH 4 /O 2 and CO 2 /O 2 mixing layers, are conducted at a supercritical pressure of 300 atm. To effectively model the supercritical regime, the employed formulation includes the compressible form of the governing equations, the cubic Peng-Robinson equation of state and a generalized formulation for heat and mass flux vectors derived from non-equilibrium thermodynamics and fluctuation theory. A linear inviscid stability analysis is also performed for each case, to determine its most unstable wavelength. Flow visualizations reveal the presence of high density gradient magnitude regions for all three mixing layers, with conditional averages indicating increased presence of heavier fluid species within these regions. No significant departures are observed from perfect gas behavior, with compressibility factors very close to unity for all three mixing cases. Applicability of presumed probability density function methods (PDF) is examined for the three supercritical mixing layers. An a priori analysis is also conducted to investigate various simplifying assumptions employed in modeling various subgrid scale (SGS) flux models. Two additional terms are identified in the large eddy simulations (LES) equations, the gradient of SGS contribution of pressure in the momentum equation and the gradient of SGS contribution of heat flux in energy equation, whose magnitudes are similar and comparable with their respective resolved terms. The performance of the scale similarity model to represent these additional terms is investigated. Lastly, the performance of Smagorinsky, gradient and scale similarity models are also investigated.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
DOE OSTI2020

Diabatic visualization shows effects of micro-fins on evaporation of R410A: Smooth, axial micro-fin, and helical micro-fin tubes

A novel approach to visualize the flow boiling inside a clear micro-fin tube under diabatic conditions is presented. Transparent smooth, axial micro-fin, and helical micro-fin tubes are made by 3D printing. The 3D printed tube is placed inside a glass tube and heated by the transparent secondary fluid flowing between the two tubes for providing the evaporation conditions and transparency. R410A flow boiling and the flow patterns in the three geometries captured with a high speed camera are compared. The experimental results show that micro-fin geometry influences flow behavior. Bubbles are mainly generated in the groove region due to a higher superheat than the fin region. Some of the liquid refrigerant is trapped in the grooves of the upper part of the micro-fin tube when the slug flow is present, and bubbles are generated in this thin liquid layer. In addition, the bubbles in the helical micro-fin tube are easier to merge because of the obstacle of the fin geometry for the bubble flowing path. As the two bubble merge, the conversion of surface free energy causes the bubble to travel with a higher velocity.

3D printed↗
DOE OSTI2022

Effect of coaxial nozzle wear on catchment efficiency in direct energy deposition built components

Laser based Direct Energy Deposition (DED) systems using metallic powder feedstock are recognized as a promising manufacturing method for their ability to shorten production cycles and create complex part geometries. Components are built by generating a melt pool with a high-power laser beam while material is coaxially injected and left to solidify. An impediment to large scale use of DED lies in poor powder catchment efficiency, the condition in which a portion of injected powder escapes the melt pool resulting in a ratio of decreased printed material mass to mass of supplied feedstock. The wear state of a coaxial nozzle on a DED system within a hybrid manufacturing machine tool has been observed to decrease catchment efficiency over time. Herein this study investigates this effect by adapting flow visualization techniques to an in-situ process monitoring format, the implementation of a Computational Fluid Dynamics (CFD) simulation, and deposition testing. Nozzle geometric defects due to wear are identified and categorized, and the impact of nozzle tip wear, resulting in axial tip reduction, on powder catchment efficiency is proven by multiple calculation methods. A linear correlation between catchment efficiency and powder stream diameter is identified, causing a 15–20% loss in efficiency sustained over incremental nozzle tip reduction up to − 1 mm. These results provide a foundation for further study of wear effects and Zero defect manufacturing solutions for powder fed DED systems.

42 ENGINEERING↗
DOE OSTI2024

Bifurcation of equilibrium positions for ellipsoidal particles in inertial shear flows between two walls

We conducted a systematic numerical investigation of spherical, prolate and oblate particles in an inertial shear flow between two parallel walls, using smoothed particle hydrodynamics (SPH). It was previously shown that above a critical Reynolds number, spherical particles experience a supercritical pitchfork bifurcation of the equilibrium position in shear flow between two parallel walls, namely that the central equilibrium position becomes unstable, leading to the emergence of two new off-centre stable positions (Foxet al.,J. Fluid Mech., vol. 915, 2021). This phenomenon was unexpected given the symmetry of the system. In addition to confirming this finding, we found, surprisingly, that ellipsoidal particles can also return to the centre position from the off-centre positions when the particle Reynolds number is further increased, while spherical particles become unstable under this increased Reynolds number. By utilizing both SPH and the finite element method for flow visualization, we explained the underlining mechanism of this reverse of bifurcation by altered streamwise vorticity and symmetry breaking of pressure. Furthermore, we expanded our investigation to include asymmetric particles, a novel aspect that had not been previously modelled, and we observed similar trends in particle dynamics for both symmetric and asymmetric ellipsoidal particles. While further validation through laboratory experiments is necessary, our research paves the road for development of new focusing and separation methods for shaped particles.

Mechanics↗
DOE OSTI2021

2D-to-3D image translation of complex nanoporous volumes using generative networks

Image-based characterization offers a powerful approach to studying geological porous media at the nanoscale and images are critical to understanding reactive transport mechanisms in reservoirs relevant to energy and sustainability technologies such as carbon sequestration, subsurface hydrogen storage, and natural gas recovery. Nanoimaging presents a trade off, however, between higher-contrast sample-destructive and lower-contrast sample-preserving imaging modalities. Furthermore, high-contrast imaging modalities often acquire only 2D images, while 3D volumes are needed to characterize fully a source rock sample. In this work, we present deep learning image translation models to predict high-contrast focused ion beam-scanning electron microscopy (FIB-SEM) image volumes from transmission X-ray microscopy (TXM) images when only 2D paired training data is available. We introduce a regularization method for improving 3D volume generation from 2D-to-2D deep learning image models and apply this approach to translate 3D TXM volumes to FIB-SEM fidelity. We then segment a predicted FIB-SEM volume into a flow simulation domain and calculate the sample apparent permeability using a lattice Boltzmann method (LBM) technique. Results show that our image translation approach produces simulation domains suitable for flow visualization and allows for accurate characterization of petrophysical properties from non-destructive imaging data.

58 GEOSCIENCES↗
DOE OSTI2018

Qualification of a multi-diagnostic detonator-output characterization procedure utilizing PMMA witness blocks

In this study, experiments were conducted to qualify a multi-diagnostic characterization procedure for the performance output of a detonator when fired into a poly(methyl methacrylate) (PMMA) witness block. A suite of optical diagnostics were utilized in combination to both bound the shock wave interaction state at the detonator/PMMA interface and characterize the nature of the shock wave decay in PMMA. The diagnostics included the Shock Wave Image Framing Technique (SWIFT), a photocathode tube streak camera, and photonic Doppler velocimetry (PDV). High-precision, optically clear witness blocks permitted dynamic flow visualization of the shock wave in PMMA via focused shadowgraphy. SWIFT-and streak-imaging diagnostics captured the spatiotemporally evolving shock wave, providing a two-dimensional temporally discrete image set and a one-dimensional temporally continuous image, respectively. PDV provided the temporal velocity history of the detonator output along the detonator axis. Lastly, through combination of the results obtained, a bound was able to be placed on the interface condition and a more-physical profile representing the shock wave decay in PMMA for an exploding-bridgewire detonator was achieved.

47 OTHER INSTRUMENTATION↗
DOE OSTI2022

Novel Tube Design for Superheater Heat Exchanger Enabled Via Additive Manufacturing

Superheater tubes are critical boiler components that operate at relatively higher temperatures and pressure. Amongst the primary concerns for these tubes is the deposition of ash particles on the tube surface, leading to the reduced thickness of the tube due to material corrosion, consequently causing early creep failure of the component. In this research, a novel tube design has been proposed which resembles a teardrop or ogive shape to reduce the drag and concurrently improve the creep life of the superheater tubes. To administer the practicality of novel tubes, metal additive manufacturing (AM), for instance, laser-powder bed fusion (L-PBF), has been proposed. These unconventional designs were assessed and compared with the baseline circular tube design for mechanical design requirements (hoop stress and creep life) and the particle and flue gas flow characteristics around the differently shaped tubes. A thermomechanical finite element (FE) analysis was performed for hoop stress calculations. This study also emphasizes on effect of circumferential thermal variation on hoop stress distribution in tubes. Therefore, a detailed two-dimensional (2D) thermal simulation has been performed to report the circumferential thermal variation on the tube. A computational fluid dynamics (CFD) analysis coupled with particle tracing was performed for gas flow visualization and particle tracing around the proposed shapes and baseline circular-shaped tube design. The Schlieren optic setup was built and leveraged for qualitative validation of the proposed design. The complete design methodology established in the paper shows teardrop-shaped tubes better in terms of drag and creep life in contrast to the circular-shaped tube.

42 ENGINEERING↗
DOE OSTI2018

Dynamic stabilization of the Rayleigh-Bénard instability by acceleration modulation

This paper presents the results of an experimental investigation of the parametric stabilization of Rayleigh-Bénard convection through the imposition of sinusoidal vibration. The ability to dynamically stabilize Rayleigh-Bénard convection using acceleration modulation is of interest to groups who design and study thermoacoustic machines as the introduction of parasitic convection can have deleterious effects on the desired operation and thermodynamic efficiency of the device. These performance issues caused by suspected convective instability have been seen both in traveling wave thermoacoustic refrigerators and cryogenic pulse tube chillers. This paper reports the results of an experiment intended to determine the vibratory, fluidic, and geometric conditions under which a small, rectangular container of statically unstable fluid may be stabilized by vertical vibration with comparison to the computational methods of R. M. Carbo [J. Acoust. Soc. Am. 135, 654–668 (2014)]. Measurements are obtained using a large-displacement kinematic shaker of an original design with the convecting gas characterized using both thermal transport measurements and flow visualization employing tracer particles illuminated by a diode laser light sheet phase-locked to the shaker. These experiments are believed to be the first demonstrating the suppression of convection through vibration in rectangular containers.

Swaminathan, Anand↗
DOE OSTI2015

A Kinetic Approach to Modeling the Manufacture of High Density Polyurethane Structural Foam: Foaming and Polymerization

This report details the study of PMDI structural foam and the development of a computational model to represent it. This polyurethane has a fast catalyst, such that foaming and polymerization occur simultaneously. The foam is over-packed to twice or more of its free rise density to reach the density of interest. Our approach is to combine model development closely with experiments to discover underlying physical phenomena, to parameterize models, and to validate the models once they have been developed. The model must be able to represent the expansion, filling of molds, curing, and final foam properties. PMDI is a chemically blown foam, where carbon dioxide is produced via the reaction of water and isocyanate. The isocyanate also reacts with polyol in a competing reaction, which produces the polymer. A new kinetic model is developed and implemented, which follows a simplified mathematical formalism that decouples these two reactions. The model predicts the polymerization reaction via condensation chemistry, where vitrification and glass transition temperature evolution must be included to correctly predict the temperature dependence of the kinetics. The foam gas generation kinetics are determined by tracking the molar concentration of both water and carbon dioxide. Understanding the thermal history and loads on the foam due to exothermicity and oven curing is very important to the results, since the kinetics and material properties are all sensitive to temperature. The conservation equations, including the equations of motion, an energy balance, and three rate equations are solved via a stabilized finite element method. We assume generalized-Newtonian rheology that is dependent on the extent of cure, gas fraction, and temperature. The conservation equations are combined with a level set method to determine the location of the free surface over time. Results from the model are compared to experimental flow visualization data and post-test X-ray computed tomography (CT) data for the density. Several geometries are investigated including a mock encapsulation part, two configurations of a mock structural part, and a bar geometry to specifically test the density model. We have found that the model predicts both average density and filling profiles well. However, it under predicts density gradients, especially in the gravity direction. Further model improvements are also discussed.

36 MATERIALS SCIENCE↗