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All sources NASA NTRS DOE OSTI

NASA NTRS1991

Effect of Compliant Walls on Secondary Instabilities in Boundary-Layer Transition

For aerodynamic and hydrodynamic vehicles, it is highly desirable to reduce drag and noise levels. A reduction in drag leads to fuel savings. In particular for submersible vehicles, a decrease in noise levels inhibits detection. A suggested means to obtain these reduction goals is by delaying the transition from laminar to turbulent flow in external boundary layers. For hydrodynamic applications, a passive device which shows promise for transition delays is the compliant coating. In previous studies with a simple mechanical model representing the compliant wall, coatings were found that provided transition delays as predicted from the semi-empirical e(sup n) method. Those studies were concerned with the linear stage of transition where the instability of concern is referred to as the primary instability. For the flat-plate boundary layer, the Tollmien-Schlichting (TS) wave is the primary instability. In one of those studies, it was shown that three-dimensional (3-D) primary instabilities, or oblique waves, could dominate transition over the coatings considered. From the primary instability, the stretching and tilting of vorticity in the shear flow leads to a secondary instability mechanism. This has been theoretical described by Herbert based on Floquet theory. In the present study, Herbert's theory is used to predict the development of secondary instabilities over isotropic and non-isotropic compliant walls. Since oblique waves may be dominant over compliant walls, a secondary theory extention is made to allow for these 3-D primary instabilities. The effect of variations in primary amplitude, spanwise wavenumber, and Reynolds number on the secondary instabilities are examined. As in the rigid wall case, over compliant walls the subharmonic mode of secondary instability dominates for low-amplitude primary disturbances. Both isotropic and non-isotropic compliant walls lead to reduced secondary growth rates compared to the rigid wall results. For high frequencies, the non-isotropic wall suppresses the amplification of the secondary instabilities, while instabilities over the isotropic wall may grow with an explosive rate similar to the rigid wall results. For the more important lower frequencies, both isotropic and non-isotropic compliant walls suppress the amplification of secondary instabilities compared to the rigid wall results. The twofold major discovery and demonstration of the present investigation are: (1) the use of passive devices, such as compliant walls, can lead to significant reductions in the secondary instability growth rates and amplification; (2) suppressing the primary growth rates and subsequent amplification enable delays in the growth of the explosive secondary instability mechanism.

Joslin, Ronald D.↗

NASA NTRS1990

Elastic/plastic analyses of advanced composites investigating the use of the compliant layer concept in reducing residual stresses resulting from processing

High residual stresses within intermetallic and metal matrix composite systems can develop upon cooling from the processing temperature to room temperature due to the coefficient of thermal expansion (CTE) mismatch between the fiber and matrix. As a result, within certain composite systems, radial, circumferential, and/or longitudinal cracks have been observed to form at the fiber-matrix interface. The compliant layer concept (insertion of a compensating interface material between the fiber and matrix) was proposed to reduce or eliminate the residual stress buildup during cooling and thus minimize cracking. The viability of the proposed compliant layer concept is investigated both elastically and elastoplastically. A detailed parametric study was conducted using a unit cell model consisting of three concentric cylinders to determine the required character (i.e., thickness and material properties) of the compliant layer as well as its applicability. The unknown compliant layer mechanical properties were expressed as ratios of the corresponding temperature dependent Ti-24Al-11Nb (a/o) matrix properties. The fiber properties taken were those corresponding to SCS-6 (SiC). Results indicate that the compliant layer can be used to reduce, if not eliminate, radial and circumferential residual stresses within the fiber and matrix and therefore also reduce or eliminate the radial cracking. However, with this decrease in in-plane stresses, one obtains an increase in longitudinal stress, thus potentially initiating longitudinal cracking. Guidelines are given for the selection of a specific compliant material, given a perfectly bonded system.

Arnold, Steven M.↗

DOE OSTI2024

Compliant Intramedullary Stems for Joint Reconstruction

The longevity of current joint replacements is limited by aseptic loosening, which is the primary cause of non-infectious failure for hip, knee, and ankle arthroplasty. Aseptic loosening is typically caused either by osteolysis from particulate wear, or by high shear stresses at the bone-implant interface from over-constraint. Our objective was to demonstrate feasibility of a compliant intramedullary stem that eliminates over-constraint without generating particulate wear. The compliant stem is built around a compliant mechanism that permits rotation about a single axis. We first established several models to understand the relationship between mechanism geometry and implant performance under a given angular displacement and compressive load. We then used a neural network to identify a design space of geometries that would support an expected 100-year fatigue life inside the body. We additively manufactured one representative mechanism for each of three anatomic locations, and evaluated these prototypes on a KR-210 robot. The neural network predicts maximum stress and torsional stiffness with 2.69% and 4.08% error respectively, relative to finite element analysis data. We identified feasible design spaces for all three of the anatomic locations. Simulated peak stresses for the three stem prototypes were below the fatigue limit. Benchtop performance of all three prototypes was within design specifications. Our results demonstrate the feasibility of designing patient- and joint-specific compliant stems that address the root causes of aseptic loosening. Guided by these results, we expect the use of compliant intramedullary stems in joint reconstruction technology to increase implant lifetime.

60 APPLIED LIFE SCIENCES↗

NASA NTRS1977

Compliant wall surface motion and its effect on the structure of a turbulent boundary layer

The status of the continuing compliant wall drag reduction research at NASA-Langley Research Center is discussed. Preliminary surface motion calculations are reported along with compliant surface design concepts and their numerical models. A compliant drag reduction theory based on stabilizing the turbulent substructure is proposed and previous experiments have been examined relative to that theory. Results of recent low speed compliant surface experiments have been reported which include initial attempts to measure local compliant surface motion.

Ash, R. L.↗

NASA NTRS1990

Parametric studies to determine the effect of compliant layers on metal matrix composite systems

Computational simulation studies are conducted to identify compliant layers to reduce matrix stresses which result from the coefficient of thermal expansion mismatch and the large temperature range over which the current metal matrix composites will be used. The present study includes variations of compliant layers and their properties to determine their influence on unidirectional composite and constituent response. Two simulation methods are used for these studies. The first approach is based on a three-dimensional linear finite element analysis of a 9 fiber unidirectional composite system. The second approach is a micromechanics based nonlinear computer code developed to determine the behavior of metal matrix composite system for thermal and mechanical loads. The results show that an effective compliant layer for the SCS 6 (SiC)/Ti-24Al-11Nb (Ti3Al + Nb) and SCS 6 (SiC)/Ti-15V-3Cr-3Sn-3Al (Ti-15-3) composite systems should have modulus 15 percent that of the matrix and a coefficient of thermal expansion of the compliant layer roughly equal to that of the composite system without the CL. The matrix stress in the longitudinal and the transverse tangent (loop) direction are tensile for the Ti3Al + Nb and Ti-15-3 composite systems upon cool down from fabrication. The fiber longitudinal stress is compressive from fabrication cool down. Addition of a recommended compliant layer will result in a reduction in the composite modulus.

Caruso, J. J.↗

NASA NTRS1990

Parametric studies to determine the effect of compliant layers on metal matrix composite systems

Caruso, J. J.↗

DOE OSTI2026

Reduction of baseplate distortion during directed energy deposition using compliant features

Distortion in additive manufacturing (AM) remains a barrier to its adoption in precision industries. Baseplate warpage is one such issue which compromises the feasibility of post-process precision machining. The restriction to thermal contraction of the deposited part, imposed by the baseplate, generates bending moments, that in turn causes warpage. A novel distortion mitigation strategy using baseplates with integrated compliant features, which enables thermal contraction of the build is presented. Six unique design concepts are evaluated, including a solid reference, using two deposition geometries. A laser, hot-wire, directed energy deposition (DED) process is used to deposit a symmetric cylindrical part (C-part) and a T-shaped asymmetric part (T-part). Flatness deviation of baseplates is measured using structured light 3D scanning. Measurements reveal a reduction in net flatness deviation of 58.8% for the C-part and 40.9% for the T-part, compared to the solid reference. While most designs yielded reductions exceeding 30% and 20% for the C- and T-parts, respectively, one configuration resulted in increased deviation. Finite element (FE) simulations are performed to elucidate the underlying mechanisms affecting distortion of compliant baseplates during DED. Despite variations between predictions and measurements, agreement in the general trend is observed. It also revealed that initial flatness errors in baseplates significantly affect its deviation during deposition. Predictions indicate that compliant features significantly affect the thermal distribution as well as the evolution of flatness deviation in the baseplate during deposition. Notably, one design exhibited a reduction in distortion during cooling, following its initial increase during deposition. FE predictions show a maximum reduction of 60.9% and 38.8% in net flatness deviation for the C- and T-parts, respectively. The performance of compliant baseplates is found to be governed by both its the thermal and mechanical characteristics, which are crucial factors to be considered during design.

Mathews, Ritin [ORNL] (ORCID:0000000301440828)↗

NASA NTRS1975

Compliant wall-turbulent skin-friction reduction research

Previous compliant-wall experiments successful in reducing skin-friction drag probably have had a (unplanned) membrane resonance at a favorable frequency, amplitude, wave shape, length, and speed. The most probable drag reduction mechanism involves a direct coupling between the fluid and the moving wall when the wall natural resonance frequencies are near the fundamental turbulent burst frequency. Local skin-friction reductions of 61% were measured with mylar/PVC plastisol compliant surfaces. These reductions were observed only at certain flow conditions, indicating that changing tunnel total temperature may have altered the substrate dynamic modulus, damping, and coupled mylar tension. Apparently, the coupled membrane/substrate must be excited in compatible narrow-band natural frequency modes. An accelerated effort is required to develop practical durable compliant surfaces optimized for maximum drag reduction. Application of compliant walls to other transportation modes appears feasible with liquid flows offering the greatest skin-friction drag reduction potential.

Fischer, M. C.↗

NASA NTRS1977

Analytical and numerical investigation of structural response of compliant wall materials

Surface motion of compliant walls in drag reduction experiments was analyzed. The spectrum of surface motion indicates that membranes over deep cavities respond at low frequencies and large wavelengths. The membrane over a deep cavity is therefore found not to yield the desired reponse predicted by the postulated mechanism. The membrane over a thin air gap is found to act as a wavelength chopper, and analysis of the nonlinear response of the compliant surface indicates its possible suitability for compliant wall experiments. Periodic structures are found to lock in the desired wavelengths of motion. Laminated structures are found to be very ineffective as compliant models, except when there is no bonding between the membrane and the backing. Computer programs developed for these analyses are documented.

Goglia, G. L.↗

NASA NTRS1978

Analytical and numerical investigation of structural response of compliant wall materials, part 1

Surface motion of compliant walls in drag reduction experiments was analyzed. Critical comparison was made between the dynamic motion of the structure and the postulated mechanism of drag reduction. The spectrum of surface motion indicated that membranes over deep cavities respond at low frequencies and large wavelengths. The membrane over a deep cavity is therefore found not to yield the desired response predicted by the postulated mechanism. The membrane over a thin air gap is found to act as a wavelength chopper, and analysis of the nonlinear response of that compliant surface indicated its possible suitability for compliant wall experiments. Periodic structures are found to lock in the desired wavelengths of motion, and it was shown that at least in Kramer's initial experiments they produced high frequency surface motions. Laminated structures are found to be very ineffective as compliant models, except when there is no bonding between the membrane and the backing. Computer programs developed for these analyses are documented.

Balasubramanian, R.↗

NASA NTRS1985

The effects of compliant walls on transition and turbulence

Two theoretical approaches to the phenomenon of drag reduction by a compliant wall are proposed. One is to study the limit cycle oscillations of the Navier-Stokes equations for a boundary layer flow over a compliant wall or a Poiseuille flow in a channel with a compliant wall. The other is a complementary study of a simpler, sequential model, which partially decouples the fluid and wall motions. In this approach, a 'Total Model' is constructed from suitable component models. While the first study is more rigorously based, it will be initially limited, by computational constraints, to relatively low Reynolds numbers. The second, more approximate approach, will allow consideration of a fully developed turbulent flow. The Total Model will predict the compliant wall motion accurately, but will not per se be sufficient to predict the skin friction drag. However, once the wall motion is known, the skin friction drag and the pressure drag can be computed separately, using one of the existing models.

Dowell, E. H.↗

NASA NTRS1991

The effect of compliant walls on secondary instabilities in boundary layer transition

The effect of compliant walls on the stage of transition where three-dimensional secondary instabilities (SIs) are excited is studied. A theory developed by Herbert (1983) to represent SIs for two-dimensional primary instabilities is extended to allow for oblique waves. The effects of the variations in primary amplitude, spanwise, wavenumber, and Reynolds number on the SIs are examined. As in the rigid-wall case, the subharmonic mode of SI dominates for low-amplitude disturbances over compliant walls. Both isotropic and nonisotropic compliant walls lead to reduced SI growth rates as compared to the rigid-wall results. Calculations show that, for high frequencies, the nonisotropic wall suppresses the amplification of the SIs, while for the isotropic wall SIs grow with an explosive rate similar to the rigid-wall results. For lower frequencies, both types of compliant wall suppress the amplification of SIs.

Joslin, Ronald D.↗

NASA NTRS1990

Dry compliant seal for phosphoric acid fuel cell

A dry compliant overlapping seal for a phosphoric acid fuel cell preformed f non-compliant Teflon to make an anode seal frame that encircles an anode assembly, a cathode seal frame that encircles a cathode assembly and a compliant seal frame made of expanded Teflon, generally encircling a matrix assembly. Each frame has a thickness selected to accommodate various tolerances of the fuel cell elements and are either bonded to one of the other frames or to a bipolar or end plate. One of the non-compliant frames is wider than the other frames forming an overlap of the matrix over the wider seal frame, which cooperates with electrolyte permeating the matrix to form a wet seal within the fuel cell that prevents process gases from intermixing at the periphery of the fuel cell and a dry seal surrounding the cell to keep electrolyte from the periphery thereof. The frames may be made in one piece, in L-shaped portions or in strips and have an outer perimeter which registers with the outer perimeter of bipolar or end plates to form surfaces upon which flanges of pan shaped, gas manifolds can be sealed.

Granata, Jr., Samuel J.↗

NASA NTRS2013

Nickel-Graphite Composite Compliant Interface and/or Hot Shoe Material

Next-generation high-temperature thermoelectric-power-generating devices will employ segmented architectures and will have to reliably withstand thermally induced mechanical stresses produced during component fabrication, device assembly, and operation. Thermoelectric materials have typically poor mechanical strength, exhibit brittle behavior, and possess a wide range of coefficient of thermal expansion (CTE) values. As a result, the direct bonding at elevated temperatures of these materials to each other to produce segmented leg components is difficult, and often results in localized microcracking at interfaces and mec hanical failure due to the stresses that arise from the CTE mismatch between the various materials. Even in the absence of full mechanical failure, degraded interfaces can lead to increased electrical and thermal resistances, which adversely impact conversion efficiency and power output. The proposed solution is the insertion of a mechanically compliant layer, with high electrical and thermal conductivity, between the low- and high-temperature segments to relieve thermomechanical stresses during device fabrication and operation. This composite material can be used as a stress-relieving layer between the thermoelectric segments and/or between a thermoelectric segment and a hot- or cold-side interconnect material. The material also can be used as a compliant hot shoe. Nickel-coated graphite powders were hot-pressed to form a nickel-graphite composite material. A freestanding thermoelectric segmented leg was fabricated by brazing the compliant pad layer between the high-temperature p- Zintl and low-temperature p-SKD TE segments using Cu-Ag braze foils. The segmented leg stack was heated in vacuum under a compressive load to achieve bonding. The novelty of the innovation is the use of composite material that re duces the thermomechanical stresses en - countered in the construction of high-efficiency, high-temperature therm - o-electric devices. The compliant pad enables the bonding of dissimilar thermoelectric materials while maintaining the desired electrical and thermal properties essential for efficient device operation. The modulus, CTE, electrical, and thermal conductances of the composite can be controlled by varying the ratio of nickel to graphite.

Firdosy, Samad A.↗

NASA NTRS2014

Design of 3D-Printed Titanium Compliant Mechanisms

This paper describes 3D-printed titanium compliant mechanisms for aerospace applications. It is meant as a primer to help engineers design compliant, multi-axis, printed parts that exhibit high performance. Topics covered include brief introductions to both compliant mechanism design and 3D printing in titanium, material and geometry considerations for 3D printing, modeling techniques, and case studies of both successful and unsuccessful part geometries. Key findings include recommended flexure geometries, minimum thicknesses, and general design guidelines for compliant printed parts that may not be obvious to the first time designer.

Merriam, Ezekiel G.↗

DOE OSTI2025

Developing a Nuclear Quality Assurance Compliant Design Methodology for Neutronic Analysis of Xe-100 Design

The primary objective of this work is to develop a design methodology compliant with nuclear quality assurance standards for the Xe-100 neutronic design verification studies. To achieve this, a Monte Carlo model of the Xe-100 reactor was constructed using the exclusion principle, transformation technique, and universe-based level specification following Idaho National Laboratory (INL) NQA level-1 compliant standards and an NQA-1 compliant version of MCNP6. The model encompasses the entire reactor core structures, including the upper plenum, core region, and lower plenum sections, along with all sub-components. The active core section was represented using the spectral regions, each comprising a particular fuel composition and temperature averaged over the considered zone, calculated by X-energy using Very Superior Old Programs (VSOP). Additionally, a component-wise temperature map was implemented into the model, not only for the core region but also for the structural components. Temperature-dependent cross-section libraries, along with thermal scattering law libraries, generated using INL NQA-1 compliant version of NJOY21, were utilized for each isotope in the burnt fuel and the structural materials. Furthermore, the volume of each modeled component was estimated using a stochastic approach with the ray tracing method in MCNP and criticality calculations were performed.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

NASA NTRS1974

On the theory of compliant wall drag reduction in turbulent boundary layers

A theoretical model has been developed which can explain how the motion of a compliant wall reduces turbulent skin friction drag. Available experimental evidence at low speeds has been used to infer that a compliant surface selectively removes energy from the upper frequency range of the energy containing eddies and through resulting surface motions can produce locally negative Reynolds stresses at the wall. The theory establishes a preliminary amplitude and frequency criterion as the basis for designing effective drag reducing compliant surfaces.

Ash, R. L.↗

NASA NTRS1975

Experimental verification of turbulent skin friction reduction with compliant walls

Preliminary compliant wall skin friction test results obtained in a low-turbulence pressure tunnel are reported. Compliant surface skins consisted of 0.0025 cm thick mylar, stretched under tension and area-bonded or longitudinally strip-bonded with silicone rubber adhesive to polyurethane foam. Mean velocity and fluctuating survey data were obtained with a single slanted hot wire. Mean velocity profiles for the area-bonded mylar surface skins indicated up to a 20% reduction in boundary-layer thickness (and lower momentum thickness) over rigid surfaces. This reduction in boundary-layer thickness indicates that a drag reduction occurred. In addition, a 16% reduction in wall shear was evident for the mylar/compressor foam compliant surface.

Weinstein, L. M.↗