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At least 1,495 records · Page 83

Direct Numerical Simulation of Acoustic Noise Generation from the Nozzle Wall of a Hypersonic Wind Tunnel

The acoustic radiation from the turbulent boundary layer on the nozzle wall of a Mach 6 Ludwieg Tube is simulated using Direct Numerical Simulations (DNS), with the flow conditions falling within the operational range of the Mach 6 Hypersonic Ludwieg Tube, Braunschweig (HLB). The mean and turbulence statistics of the nozzle-wall boundary layer show good agreement with those predicted by Pate's correlation and Reynolds Averaged Navier-Stokes (RANS) computations. The rms pressure fluctuation P'(rms)/T(w) plateaus in the freestream core of the nozzle. The intensity of the freestream noise within the nozzle is approximately 20% higher than that radiated from a single at pate with a similar freestream Mach number, potentially because of the contributions to the acoustic radiation from multiple azimuthal segments of the nozzle wall.

Huang, Junji↗

Metallic Wall Hall Thrusters

A Hall thruster apparatus having walls constructed from a conductive material, such as graphite, and having magnetic shielding of the walls from the ionized plasma has been demonstrated to operate with nearly the same efficiency as a conventional nonmagnetically shielded design using insulators as wall components. The new design is believed to provide the potential of higher power and uniform operation over the operating life of a thruster device.

Goebel, Dan Michael↗

Channel Wall Nozzle Manufacturing and Hot-Fire Testing using a Laser Wire Deposition Closeout Technique for Liquid Rocket Engines

A regeneratively-cooled nozzle for liquid rocket engine applications is a significant cost of the overall engine due to the complexities of manufacturing a large thin-walled structure that must operate in extreme temperature and pressure environments. NASA has been investigating and advancing methods for fabrication of liquid rocket engine channel wall nozzles to realize further cost and schedule improvements. The methods being evaluated are targeting increased scale required for current NASA and commercial space programs. Several advanced rapid fabrication methods are being investigated for forming of the inner liner, producing the coolant channels, closeout of the coolant channels, and fabrication of the manifolds. NASA Marshall Space Flight Center (MSFC) completed process development and subscale hot-fire testing of a series of these advanced fabrication channel wall nozzle technologies to gather performance data in a relevant environment. The primary fabrication technique being discussed in this paper is Laser Wire Deposition Closeout (LWDC). This process has been developed to significantly reduce time required for closeouts of regeneratively-cooled slotted liners. It allows for channel closeout to be formed in place in addition to the structural jacket without the need for channel fillers or complex tooling. Additional technologies were also tested as part of this program including water jet milling and arc-based additive manufacturing deposition. Each nozzle included different fabrication features, materials, and methods to demonstrate durability in a hot-fire environment. The results of design, fabrication and hot-fire testing performance is discussed in this paper.

Gradl, Paul R.↗

Channel Wall Nozzle Manufacturing and Hot-Fire Testing Using a Laser Wire Direct Closeout Technique for Liquid Rocket Engines

A regeneratively-cooled nozzle for liquid rocket engine applications is a significant cost of the overall engine due to the complexities of manufacturing a large thin-walled structure that must operate in extreme temperature and pressure environments. The National Aeronautics and Space Administration (NASA) has been investigating and advancing methods for fabrication of liquid rocket engine channel wall nozzles to realize further cost and schedule improvements over traditional techniques. The methods being evaluated are targeting increased scale required for current NASA and commercial space programs. Several advanced rapid fabrication methods are being investigated for forming of the inner liner, producing the coolant channels, closeout of the coolant channels, and fabrication of the manifolds. NASA's Marshall Space Flight Center (MSFC) has completed process development and subscale hot-fire testing of a series of these advanced fabrication channel wall nozzle technologies to gather performance data in a relevant environment. The primary fabrication technique being discussed in this paper is Laser Wire Direct Closeout (LWDC). This process has been developed to significantly reduce the time required for closeouts of regeneratively-cooled slotted liners. It allows for channel closeout to be formed in place in addition to the structural jacket without the need for channel fillers or complex tooling. Additional technologies were also tested as part of this program including water jet milling and arc-based additive manufacturing deposition. Each nozzle included different fabrication features, materials, and methods to demonstrate durability in a hot-fire environment. The results of design, fabrication, and hot-fire testing are discussed in this paper.

Gradl, Paul R.↗

Rough-Wall Turbulent Heat Transfer Experiments in Hypersonic Free Flight

Experiments are being conducted in the NASA Ames Hypervelocity Free Flight Aerodynamic Facility to quantify the effects on turbulent convective heat transfer of surface roughness representative of a new class of 3D woven thermal protection system mRough-wall turbulent heat transfer measurements were obtained on ballistic-range models in hypersonic flight in the NASA Ames Hypervelocity Free Flight Aerodynamic Facility. Each model had three different surface textures on segments of the conic frustum: smooth wall, sand roughness, and a pattern roughness, thus providing smooth-wall and sand-roughness reference data for each test. The pattern roughness was representative of a woven thermal protection system material developed by NASA's Heatshield for Extreme Entry Environment Technology project. The tests were conducted at launch speeds of 3.2 km/s in air at 0.15 atm. Roughness Reynolds numbers, k+, ranged for 12 to 70 for the sand roughness, and as high as 200 for the pattern roughness. Boundary-layer parameters required for calculating k+ were evaluated using computational fluid dynamics simulations. The effects of pattern roughness are generally characterized by an equivalent sand roughness determined with a correlation developed from experimental data obtained on specifically-designed roughness patterns that do not necessarily resemble real TPS materials. Two sand roughness correlations were examined: Dirling and van Rij, et al. Both gave good agreement with the measured heat-flux augmentation for the two larger pattern roughness heights tested, but not for the smallest height tested. It has yet to be determined whether this difference is due to limitations in the experimental approach, or due to limits in the correlations used. Future experiments are planned that will include roughness patterns more like those used in developing the equivalent sand roughness correlations.aterials being developed by NASA's Heatshield for Extreme Entry Environment Technology (HEEET) project. Data were simultaneously obtained on sand-grain roughened surfaces and smooth surfaces, which can be compared with previously obtained data. Results are presented in this extended abstract for one roughness pattern. The full paper will include results from three roughness patterns representing virgin HEEET, nominal turbulent ablated HEEET, and twice the roughness of nominal turbulent ablated HEEET. Results will be used to compare with commonly used equivalent sand grain roughness correlations.

pattern roughness↗

Bimetallic Channel Wall Nozzle Development and Hot-Fire Testing Using Additively Manufactured Laser Wire Direct Closeout Technology

NASA has been developing and advancing regeneratively-cooled channel wall nozzle technology for liquid rocket engines to reduce cost and schedules associated with fabrication. One of the primary methods being advanced is Laser Wire Direct Closeout (LWDC). LWDC was developed to provide an additively manufactured laser deposited closeout of the coolant channels that also forms the structural jacket in-situ. This technique has been previously demonstrated through process development and hot-fire testing on a series of subscale nozzles at NASA Marshall Space Flight Center. The hot-fire test articles were fabricated using monolithic alloys to simplify the fabrication process. Ongoing research is being conducted to further expand use of this process for increased scale and bimetallic or multi-alloy options. The use of multi-alloys is desired to fully optimize the combination of materials in the radial and axial directions to reduce overall weight of the nozzle and allow for higher thermal and structural margins on the channel wall nozzle. NASA recently completed process development and hot-fire testing of a series of channel wall nozzles that incorporate a copper-alloy as the hotwall liner material and a superalloy and combination thereof for the structural jacket using the LWDC technique. The fabrication process was further advanced by using a multi-alloy axial joint using explosive bonding integrating a copper-alloy at the forward end of the nozzle hotwall and a stainless-alloy for the remaining length. A third alloy was then used for the channel closeout using the LWDC process. This paper will describe the process development using the LWDC process for channel closeout utilizing the multi-alloys, hardware design and results from hot-fire testing on subscale multi-alloy LWDC channel cooled nozzles.

Gradl, Paul↗

Characterization and Modeling of Cell Wall Imperfections in Aluminum Honeycomb Cores using X-ray CT Imaging

Honeycomb cell imperfections may significantly affect the failure of sandwich composites in core crushing and shear modes. Identification and quantification of the different types of imperfections and evaluation of their effects on the mechanical response of honeycomb cores in flatwise compression is presented. X-Ray computed tomography (CT) scans of honeycomb cores in co-cured composite sandwich panels were performed. Image analysis methods are applied to characterize and quantify core cell geometry and cell wall waviness. An approach is developed for extracting cell wall mid surface planes and waviness for constructing finite element models using shell elements. Analysis results from models with the as-manufactured imperfections are compared to results from models with idealized geometries to evaluate the effect of the as-manufactured imperfections on the initiation of cell wall buckling and subsequent core crushing.

aluminum honeycomb↗

Experimental Characterization of Surface Roughness and Geometric Evaluations of Thin-Wall Laser Powder Directed Energy Deposition

Additive Manufacturing (AM) has offered many new design and manufacturing opportunities for components across various industries. As AM evolves there is a need to better understand outputs of the process including geometric limitations and surface roughness based on specific application requirements. One possible application area of AM are components using thin-wall (<2 mm) microchannel heat exchangers for subsystems across aerospace, and industrial applications. AM offers the opportunity to significantly reduce the cost and lead time associated with fabricating these complex parts with internal features such as an array of cooling channels. Laser Powder Bed Fusion (L-PBF) has been continuously demonstrated as a technique to fabricate heat exchangers with internal geometric complexities. However, L-PBF is limited in the scale at which parts can be fabricated. Laser Powder Directed Energy Deposition (LP-DED) has been demonstrated as an AM technology to significantly increase the scale of which thin-wall microchannel heat exchangers could be manufactured. Successful deployment of the LP-DED technology requires critical understanding of the resulting features from the build process. Surface roughness is one of the critical areas that effects the friction factor and pressure drop within a heat exchanger and must be well understood. This presentation will provide an overview of the characterization work completed to understand the LP-DED process for thin-walls representative of hydrogen resistant alloy NASA HR-1 that would be used in a Hydrogen-environment application. An overview of the experiments conducted with varying LP-DED parameters, evaluation of various geometric channel and geometric build features and resulting surface finish will be provided along with a summary of conclusions from these experiments. Results indicate that powder size is a major contributor and surface roughness varies between closed channel shapes and external surfaces.

Directed Energy Deposition↗

Wall-modeled LES of Turbulent Flow Over a Two-dimensional Gaussian Bump

We perform wall-modeled large eddy simulations (WMLES) of turbulent flow over a nominally two-dimensional Gaussian-shaped bump geometry to assess its performance in the accelerating and separation regions of the flow. The flow conditions are based on high-fidelity numerical simulation of Uzun & Malik (AIAA Journal 2022). The oncoming flow Mach number is 0.2, with the bump length-based Reynolds number (ReL) of 2 million. In our previous study, while WMLES with the constant coefficient Vreman subgrid scale model and equilibrium wall model performed satisfactorily at lower ReL = 1 million, it failed to predict flow separation at the higher Re, contrary to the experimental observations. We investigate the sensitivity of WMLES to different subgrid scale models, wall models, and grid resolution and topology on flow separation by comparing with available data.

Computational Fluid Dynamics↗

Analysis of Cryogenic Propellant Liquefaction Rates in Cooled Constant-Wall-Temperature Tanks

NASA has been focused on developing technology that would allow the production of cryogenic propellants on the Lunar and Martian surfaces. Utilizing Lunar/Martian resources, the produced gaseous propellants must first be liquefied and stored prior to use on the Moon or Mars ascent vehicle. Liquefaction of cryogenic propellants is a necessary technical development to enable NASA’s future spaceflight goals. This paper presents an overview of a proposed model for a propellant liquefaction system, and the effect of tank wall temperatures on cryogenic propellant liquefaction rates. The propellant system was assumed to be a receiver of a gas from an In-Situ Resource Utilization (ISRU) harvester and condensed the gas by cooling the tank walls. First, the heat transfer principles pertinent to condensation are summarized, followed by an overview of the model which performed the analysis, including a summary of the Fortran algorithm implementation. The sensitivity of the condensation rate relative to varying tank wall temperatures is also discussed.

Anson Koch↗

Analysis of Cryogenic Propellant Liquefaction Rates in Cooled Constant-Wall-TemperatureTanks

NASA has been focused on developing technology that would allow the production of cryogenic propellants on the Lunar and Martian surfaces. Utilizing Lunar/Martian resources, the produced gaseous propellants must first be liquefied and stored prior to use on the Moon or Mars ascent vehicle. Liquefaction of cryogenic propellants is a necessary technical development to enable NASA’s future spaceflight goals. This paper presents an overview of a proposed model for a propellant liquefaction system, and the effect of tank wall temperature and the ullage pressure control band on cryogenic propellant liquefaction rates. The propellant system was assumed to be a receiver of a gas from an In-Situ Resource Utilization (ISRU) harvester and condensed the gas by cooling the tank walls. First, the heat transfer principles pertinent to condensation are summarized, followed by an overview of the model which performed the analysis, including a summary of the Fortran algorithm implementation. The sensitivity of the condensation rate relative to varying tank wall temperatures is also discussed.

cryogenics↗

Wall-Jet Evolution During Plume-Surface Interaction Using PLIF Imaging

Planar laser-induced fluorescence (PLIF) flow visualization was used to examine the spatial evolution for the wall-jet formed by an impinging supersonic jet in a large-scale vacuum environment. This canonical configuration is representative of the plume-surface interaction induced by a rocket exhaust plume impinging on the planetary surface at lunar-relevant and Martian-relevant environments. PLIF flow visualization of the very low-density environment (as low as ~0.006% of standard atmospheric density) was performed using seeded nitric oxide in a nitrogen flow at three test conditions. Two conditions are representative of the lunar environment, and one is representative of the Martian environment. The combined images from two simultaneous PLIF views were used to construct a 2D slice of the flowfield spanning approximately 150 mm in height (determined by the laser sheet) and 500 mm in width (determined by the camera views). The three test conditions showed different behavior for the wall-jet, largely due to the different levels of lifting above the surface and the appearance of a physical process similar to a Kelvin–Helmholtz instability for the Martian-relevant case, which appeared to create a dramatic expansion of the wall-jet height with increased radial distance.

PSI↗

Wall-Jet Evolution During Plume-Surface Interaction Using PLIF Imaging

Planar laser-induced fluorescence (PLIF) flow visualization was used to examine the spatial evolution for the wall-jet formed by an impinging supersonic jet in a large-scale vacuum environment. This canonical configuration is representative of the plume-surface interaction induced by a rocket exhaust plume impinging on the planetary surface at lunar-relevant and Martian-relevant environments. PLIF flow visualization of the very low-density environment (as low as ~0.006% of standard atmospheric density) was performed using seeded nitric oxide in a nitrogen flow at three test conditions. Two conditions are representative of the lunar environment, and one is representative of the Martian environment. The combined images from two simultaneous PLIF views were used to construct a 2D slice of the flowfield spanning approximately 150 mm in height (determined by the laser sheet) and 500 mm in width (determined by the camera views). The three test conditions showed different behavior for the wall-jet, largely due to the different levels of lifting above the surface and the appearance of a physical process similar to a Kelvin–Helmholtz instability for the Martian-relevant case, which appeared to create a dramatic expansion of the wall-jet height with increased radial distance.

PSI↗

Unsteady CFD Simulations of a Compression Corner Geometry Using Wall-Modeled LES Methods in Loci/CHEM

As computing technology continues to improve, simulating unsteady aerodynamic environments on launch vehicle geometries becomes more viable. For NASA’s Space Launch System, the flowfield is characterized by large regions of unsteady turbulent wall-bounded flow. Simulating these unsteady wall-bounded environments is of interest to the SLS Aerodynamics team. Wall-modeled LES methods are currently the best approach for simulating these environments in engineering applications. Less-expensive computationally than fully-resolved methods while maintaining many of the benefits in simulating unsteady environments. Before applying these methods blindly to large geometries, best practices can first be applied and understood on smaller canonical problems.

Bryson Frank↗

Continuous growth of single-wall carbon nanotubes using chemical vapor deposition

The invention relates to a chemical vapor deposition process for the continuous growth of a carbon single-wall nanotube where a carbon-containing gas composition is contacted with a porous membrane and decomposed in the presence of a catalyst to grow single-wall carbon nanotube material. A pressure differential exists across the porous membrane such that the pressure on one side of the membrane is less than that on the other side of the membrane. The single-wall carbon nanotube growth may occur predominately on the low-pressure side of the membrane or, in a different embodiment of the invention, may occur predominately in between the catalyst and the membrane. The invention also relates to an apparatus used with the carbon vapor deposition process.

77 NANOSCIENCE AND NANOTECHNOLOGY↗

Understanding Free and Complexed Enzyme Mechanisms and Factors Contributing to Cell Wall Recalcitrance (Presentation)

Fungal free enzymes and bacterial complexed cellulosomes deconstruct biomass using different physical mechanisms. Free enzymes, which typically contain a large proportion of GH7 cellobiohydrolase, diffuse throughout the substrate and hydrolyze primarily from the cellulose reducing end, resulting in 'sharpened' macrofibrils. In contrast, complexed cellulosomes contain a diverse array of carbohydrate binding modules and multiple catalytic specificities leading to delamination and physical peeling of the cellulose macrofibril structures. To investigate how cellulose structure contributes to recalcitrance, we compared the deconstruction of cellulose I, II, and III; using free and complexed enzyme systems. We also evaluated both systems on Clean Fractionation and alkaline pretreated biomass, which remove much of the lignin, to determine the impact on enzyme loading reduction. Free fungal enzymes demonstrated a swelling of the outer surface of the plant cell walls while removing localized disruptions, resulting in a smooth surface appearance. Cellulosomes produced cell wall surfaces with localized areas of disruption and little surface layer swelling. These studies contribute to the overall understanding of biomass recalcitrance and how combining different enzymatic paradigms may lead to the formulation of new enzyme cocktails to reduce the cost of producing sugars from plant cell wall carbohydrates.

09 BIOMASS FUELS↗

Building America Case Study: Retrofit Measure for Embedded Wood Members in Insulated Mass Masonry Walls, Lawrence, Massachusetts

?There are many existing buildings with load-bearing mass masonry walls, whose energy performance could be improved with the retrofit of insulation. However, adding insulation to the interior side of walls of such masonry buildings in cold (and wet) climates may cause performance and durability problems. Some concerns, such as condensation and freeze-thaw have known solutions. But wood members embedded in the masonry structure will be colder (and potentially wetter) after an interior insulation retrofit. Moisture content and relative humidity were monitored at joist ends in historic mass brick masonry walls retrofitted with interior insulation in a cold climate (Zone 5A); data were collected from 2012-2015. Eleven joist ends were monitored in all four orientations. One limitation of these results is that the renovation is still ongoing, with limited wintertime construction heating and no permanent occupancy to date. Measurements show that many joists ends remain at high moisture contents, especially at north- and east-facing orientations, with constant 100 percent RH conditions at the worst cases. These high moisture levels are not conducive for wood durability, but no evidence for actual structural damage has been observed. Insulated vs. non-insulated joist pockets do not show large differences. South facing joists have safe (10-15 percent) moisture contents. Given the uncertainty pointed out by research, definitive guidance on the vulnerability of embedded wood members is difficult to formulate. In high-risk situations, or when a very conservative approach is warranted, the embedded wood member condition can be eliminated entirely, supporting the joist ends outside of the masonry pocket.

BSC↗

Thin-walled reinforcement lattice structure for hollow CMC buckets

A hollow ceramic matrix composite (CMC) turbine bucket with an internal reinforcement lattice structure has improved vibration properties and stiffness. The lattice structure is formed of thin-walled plies made of CMC. The wall structures are arranged and located according to high stress areas within the hollow bucket. After the melt infiltration process, the mandrels melt away, leaving the wall structure to become the internal lattice reinforcement structure of the bucket.

47 OTHER INSTRUMENTATION↗