Convective heat dissipation with lattice-frame materials

This paper presents experimental results on heat transfer and pressure drop for a compact heat sink made of fully triangulated, lightweight (porosity∼0.938), aluminum lattice-frame materials (LFMs). Due to the inherent structural anisotropy of the LFMs, two mutually perpendicular orientations were selected for the measurements. Constant heat flux was applied to the heat sink under steady state conditions, and dissipated by forced air convection. The experimental data were compared with those predicted from an analytical model based on fin analogy. The experimental results revealed that pressure drop is strongly dependent upon the orientation of the structure, due mainly to the flow blockage effect. For heat transfer measurements, typical local temperature distributions on the substrate under constant heat flux conditions were captured with infrared camera. The thermal behavior of LFMs was found to follow closely that of cylinder banks, with early transition Reynolds number (based on strut diameter) equal to about 300. The Nusselt number prediction from the fin-analogy correlates well with experimental measurements, except at low Reynolds numbers where a slightly underestimation is observed. Comparisons with empty channels and commonly used heat exchanger media show that the present LFM heat sink can remove heat approximately seven times more efficient than an empty channel and as efficient as a bank of cylinders at the same porosity level. The aluminum LFMs are extremely stiff and strong, making them ideal candidates for multifunctional structures requiring both heat dissipation and mechanical load carrying capabilities. © 2003 Elsevier Ltd. All rights reserved.

Laboratory-scale fluidized bed rig for high-temperature tube wastage studies

As part of a study of the wear of candidate heat exchanger tube materials for use in fluidized bed combustors, two similar laboratory-scale rigs have been built and characterized. Specimens of selected alloys are carried on counter-rotating rotors immersed in a fluidized bed, and are exposed to particle impact velocities of up to approximately 3 ms-1 at temperatures up to 1000°C. The performance of this design of apparatus has been investigated in detail. The effects of several experimental variables have been studied, including angle of particle impact, specimen speed, position of the rotor within the fluidized bed, duration of exposure, bed material particle size, degradation of the bed material, degree of fluidization of the bed, and size of specimen. In many cases the results obtained with steel specimens at elevated temperatures are similar to those observed with polymeric specimens at low temperatures.

Critical current anisotropy in high temperature superconductors

After nearly 15 years of research effort, High Temperature Superconductors (HTS) are finding a wide range of practical applications. A clear understanding of the factors controlling the current carrying capacity of these materials is a prerequisite to their successful technological development. The critical current density (Jc) in HTS is directly dependent on the structure and pinning of the Flux Line Lattice (FLL) in these materials. This thesis presents an investigation of the Jc anisotropy in HTS. The use of thin films grown on off c-axis (vicinal) substrates allowed the effect of current directions outside the cuprate planes to be studied. With this experimental geometry Berghuis, et al. (Phys. Rev. Lett. 79, 12, pg. 2332) observed a striking flux channelling effect in vicinal YBa2Cu3O7-δ (YBCO) films. By confirming, and extending, this observation, it is demonstrated that this is an intrinsic effect. The results obtained, appear to fit well with the predictions of a field angle dependent cross-over from a three dimensional rectilinear FLL to a kinked lattice of strings and pancakes. The pinning force density for movement of strings inside the cuprate planes is considerably less than that on vortex pancake elements. When the FLL is entirely string-like this reduced pinning leads to the observed channelling minima. It is observed that anti-phase boundaries enhance the Jc in vicinal YBCO films by strongly pinning vortex strings. The effect on the FLL structure cross-over of increasing anisotropy has been elucidated using de-oxygenated vicinal YBCO films. Intriguingly, the counter intuitive prediction that the range of applied field angle for which the kinked lattice is fully developed reduces with increasing anisotropy, appears to be confirmed. Although vortex channelling cannot be observed in c-axis YBCO films, the pinning force density for vortex string channelling has been extracted by observing string dragging. By studying the effect of rotating the applied field at a constant angle to the cuprate planes, it is possible to observe the cross-over into the string pancake regime in c-axis films. In the 3D region, the observed behaviour is well explained by the anisotropic Ginzburg-Landau model. Measurements were also made on thin films of the much more anisotropic Bi 2Sr2CaCu2O8+x material, grown on vicinal substrates. The absence of any flux channelling effect and clear adherence to the expected Kes-Law behaviour in the observed Jc characteristics does not provide evidence for the existence of the predicted ‘crossing lattice’ in Bi 2Sr2CaCu2O8+x .

Sources of variability in the free-ball micro-scale abrasion test

In the 'free-ball' version of the micro-scale abrasion or ball-cratering test the rotating ball rests against a tilted sample and a grooved drive shaft. Tests under nominally identical conditions with different apparatus commonly show small but significant differences in measured wear rate. An indirect method has been developed and demonstrated for continuous on-line measurement of the coefficient of friction in the free-ball test. Experimental investigation of the effects of sample tilt angle and drive shaft groove width shows that both these factors influence the stability of the rotation of the ball, and the shape of the abrasive slurry pool, which in turn affect the coefficient of friction in the wear scar area and the measured wear rate. It is suggested that in order to improve the reproducibility of this method the geometry of the apparatus should be specified. For the apparatus used in this work with a steel ball of 25 mm diameter, a sample tilt angle of 60-75° and a shaft groove width of about 10mm provided the most stable ball motion and a wear rate which showed least variability. © 2004 Elsevier B.V. All rights reserved.

Modelling the entrainment and motion of particles in a gap: Application to abrasive wear

The microscale abrasion or ball-cratering test is being increasingly applied to a wide range of bulk materials and coatings. The response of materials to this test depends critically on the nature of the motion of the abrasive particles in the contact zone: whether they roll and produce multiple indentations in the coating, or slide causing grooving abrasion. Similar phenomena also occur when hard contaminant particles enter a lubricated contact. This paper presents simple quantitative two-dimensional models which describe two aspects of the interaction between a hard abrasive particle and two sliding surfaces. The first model treats the conditions under which a spherical abrasive particle of size d can be entrained into the gap between a rotating sphere of radius R and a plane surface. These conditions are determined by the coefficients of friction between the particle and the sphere, and the particle and the plane, denoted by μs and μp respectively. This model predicts that the values of (μs + μp) and 2μs should both exceed √2d/R for the particles to be entrained into the contact. If either is less than this value, the particle will slide against the sphere and never enter the contact. The second model describes the mechanisms of abrasive wear in a contact when an idealized rhombus-sectioned prismatic particle is located between two parallel plane surfaces separated by a certain distance, which can represent either the thickness of a fluid film or the spacing due to the presence of other particles. It is shown that both the ratio of particle size to the separation of the surfaces and the ratio of the hardnesses of the two surfaces have important influences on the particle motion and hence on the mechanism of the resulting abrasive wear. Results from this model are compared with experimental observations, and the model is shown to lead to realistic predictions. © IMechE 2003.

Microstructural optimization of cellular acoustic materials

A microstructure based acoustic model is introduced, which can be used to optimize the microstructure of cellular materials and thus to obtain their optimal acoustic property. This acoustic model is an unsteady one which is appropriate in the limit of low Reynolds numbers. The model involves three elements. This first involves the propagation of acoustic waves passing the cylinders whose axes are aligned parallel to the direction of propagation. The second model relates to the propagation of acoustic waves passing the cylinders whose axes are aligned perpendicular to the direction of propagation. In both cases the interaction between adjacent cylinders is taken into account by considering the effect of polygonal periodic boundary conditions. As these two models are linear they are combined to give the characteristics of propagation at arbitrary incidence. The third model involves propagation passing spheres in order to represent the joints. Heat transfer is also included. These three models are then used to expand the design space and calculate the optimum cell structure for desired acoustic performance in a number of different applications. Moreover, the application fields are also analyzed.

Absorption of sound in cellular foams

To further enhance the sound absorption of metal foams via combining the high sound absorption and good heat conductivity of the cellular foam metals, the use and acoustic modeling of these materials are reviewed. The predictions made by three viscous models developed by the authors for the propagation of sound through open-cell metal foams are compared with an experiment both for the metal foams and for the polymer substrates used to manufacture the foam. All models are valid in the limit of low Reynold's number which is valid for the typical cell dimensions found in metal foams provided the amplitude of the waves is below 160 dB. The first model considers the drag experienced by acoustic waves as they propagate passing rigid cylinders parallel to their axes, the second considers the propagation normal to their axes, and the third considers the propagation passing the spherical joints. All three are combined together to give a general model of the acoustic behavior of the foams. In particular, the sound absorption is found to be significant and well predicted by the combined model. In addition, a post-processing technique is described for the experiment used to extract the fundamental wave propagation characteristics of the material.

Long-range interactions in turbulence and the energy decay problem.

We discuss the long-range interactions that arise in homogeneous turbulence as a consequence of the Biot-Savart law. We note that, somewhat surprisingly, these long-range correlations are very weak in decaying, isotropic turbulence, and we argue that this should also be true for magnetohydrodynamic, rotating and stratified turbulence. If this is indeed the case, it is possible to make explicit predictions for the rate of decay of energy in these anisotropic systems, and it turns out that these predictions are consistent with the available numerical and experimental evidence.

Evolution of localized blobs of swirling or buoyant fluid with and without an ambient magnetic field.

We investigate the evolution of localized blobs of swirling or buoyant fluid in an infinite, inviscid, electrically conducting fluid. We consider the three cases of a strong imposed magnetic field, a weak imposed magnetic field, and no magnetic field. For a swirling blob in the absence of a magnetic field, we find, in line with others, that the blob bursts radially outward under the action of the centrifugal force, forming a thin annular vortex sheet. A simple model of this process predicts that the vortex sheet thins exponentially fast and that it moves radially outward with constant velocity. These predictions are verified by high-resolution numerical simulations. When an intense magnetic field is applied, this phenomenon is suppressed, with the energy and angular momentum of the blob now diffusing axially along the magnetic field lines, converting the blob into a columnar structure. For modest or weak magnetic fields, there are elements of both types of behavior, with the radial bursting dominating over axial diffusion for weak fields. However, even when the magnetic field is very weak, the flow structure is quite distinct to that of the nonmagnetic case. In particular, a small but finite magnetic field places a lower bound on the thickness of the annular vortex sheet and produces an annulus of counter-rotating fluid that surrounds the vortex core. The behavior of the buoyant blob is similar. In the absence of a magnetic field, it rapidly develops the mushroomlike shape of a thermal, with a thin vortex sheet at the top and sides of the mushroom. Again, a simple model of this process predicts that the vortex sheet at the top of the thermal thins exponentially fast and rises with constant velocity. These predictions are consistent with earlier numerical simulations. Curiously, however, it is shown that the net vertical momentum associated with the blob increases linearly in time, despite the fact that the vertical velocity at the front of the thermal is constant. As with the swirling blob, an imposed magnetic field inhibits the formation of a vortex sheet. A strong magnetic field completely suppresses the phenomenon, replacing it with an axial diffusion of momentum, while a weak magnetic field allows the sheet to form, but places a lower bound on its thickness. The magnetic field does not, however, change the net vertical momentum of the blob, which always increases linearly with time.

Stall inception in axial compressors

Detailed measurements have been made of the transient stalling process in an axial compressor stage. The stage is of high hub-casing ratio and stall is initiated in the rotor. If the rotor tip clearance is small stall inception occurs at the hub, but at clearances typical for a multistage compressor the inception is at the tip. The crucial quantity in both cases is the blockage caused by the endwall boundary layer. Prior to stall disturbances rotate around the inlet flow in sympathy with rotating variations in the endwall blockage; these can persist for some time prior to stall, rising and falling in amplitude before the final increase which occurs as the compressor stalls.

Abrasive wear of steel during rolling-sliding contact with rock counterfaces

In many mining operations (e.g. excavation, drilling, tunnelling, rock crushing) metallic components are forced against abrasive rocks in a complex motion. This study examines the relative importance of combined rolling and sliding motion in the two-body abrasive wear of a low carbon tempered martensitic steel against rock counterfaces. A novel wear test rig has been used to vary the amount of rolling and sliding motion between a rotating steel cylinder and a counter-rotating sandstone (highly abrasive) or limestone (much less abrasive) disc. Weight-loss measurements reveal that the wear rate of the steel increases as the amount of motion against the rock counterface is reduced from pure sliding to approximately 50% sliding (and approximately 50% rolling). Scanning electron microscopy shows that when the amount of motion is reduced from pure sliding to approximately 50% sliding the topographical and sub-surface physical properties of the worn steel and rock surfaces are modified.

Stall inception in axial compressors

Detailed measurements have been made of the transient stalling process in an axial compressor stage. The stage is of high hub-casing ratio and stall is initiated in the rotor. If the rotor tip clearance is small stall inception occurs at the hub, but at clearances typical for a multistage compressor the inception is at the tip. The crucial quantity in both cases is the blockage caused by the endwall boundary layer. Prior to stall, disturbances rotate around the inlet flow in sympathy with rotating variations in the endwall blockage.

Three-dimensional interactions in the rotor of an axial turbine

This article presents a study of the development of the three-dimensional flowfield within the rotor blades of a low-speed, large-scale axial flow turbine. Measurements have been performed in the rotating and stationary frames of reference. Time-mean data have been obtained using miniature five-hole pneumatic probes, whereas the unsteady development of the flow has been determined using three-axis subminiature hot-wire anemometers. Additional information is provided by the results of blade-surface flow-visualization experiments and surface-mounted hot-film anemometers. The development of the stator exit flow, as it passes through the rotor blades, is described. Unsteady data suggest that the presence of the rotor secondary and tip leakage flows restricts the region of unsteady interaction to near midspan when the stator wakes and secondary flows are adjacent to the suction surface. Surface-mounted hot-film data show that this affects the suction-side laminar-turbulent transition process.

The effect of an upstream turbine on a low-aspect ratio vane

The interaction between a high-pressure rotor and a downstream vane is dominated by vortex-blade interaction. Each rotor blade passing period two co-rotating vortex pairs, the tip-leakage and upper passage vortex and the lower passage and trailing shed vortex, impinge on, and are cut by, the vane leading edge. In addition to the streamwise vortex the tip-leakage flow also contains a large velocity deficit. This causes the interaction of the tip-leakage flow with a downstream vane to differ from typical vortex blade interaction. This paper investigates the effect these interaction mechanisms have on a downstream vane. The test geometry considered was a low aspect ratio second stage vane located within a S-shaped diffuser with large radius change mounted downstream of a shroudless high-pressure turbine stage. Experimental measurements were conducted at engine-representative Mach and Reynolds numbers, and data was acquired using a fast-response aerodynamic probe upstream and downstream of the vane. Time-resolved numerical simulations were undertaken with and without a rotor tip gap in order to investigate the relative magnitude of the interaction mechanisms. The presence of the upstream stage is shown to significantly change the structure of the secondary flow in the vane and to cause a small drop in its performance.

Vortex Transport and Blade Interactions in High Pressure Turbines

This paper presents a study of the three-dimensional flow field within the blade rows of a high-pressure axial flow steam turbine stage. Half-delta wings were fixed to a rotating hub to simulate an upstream rotor passage vortex. The flow field is investigated in a Low-Speed Research Turbine using pneumatic and hot-wire probes downstream of the blade row. The paper examines the impact of the delta wing vortex transport on the performance of the downstream blade row. Steady and unsteady numerical simulations were performed using structured 3D Navier-Stokes solver to further understand the flow field. The loss measurements at the exit of the stator blade showed an increase in stagnation pressure loss due to the delta wing vortex transport. The increase in loss was 21% of the datum stator loss, demonstrating the importance of this vortex interaction. The transport of the stator viscous flow through the rotor blade row is also described. The rotor exit flow was affected by the interaction between the enhanced stator passage vortex and the rotor blade row. Flow underturning near the hub and overturning towards the mid-span was observed, contrary to the classical model of overturning near the hub and underturning towards the mid-span. The unsteady numerical simulation results were further analysed to identify the entropy producing regions in the unsteady flow field.