The laser-assisted cold spray process

Thick metal coatings are currently deposited via two well established routes, Laser or arc based cladding, and thermal spray. A new coating technique known as Laser-assisted Cold Spray (LCS), which aims to expand on the capabilities of the two process routes currently available, is under development at the University of Cambridge in the UK. LCS is a development of the Cold Spray process (CS) in which coatings are built up from powder particles which are entrained within a gas stream and accelerated through a de Laval nozzle, impacting the substrate at supersonic speeds that exceed a material dependent critical velocity.

Mapeamento das regiões radiantes em placas retangulares vibrantes via método dos elementos de contorno com velocidade média e intensidade útil

Em engenharia, a modelagem computacional desempenha um papel importante na concepção de produtos e no desenvolvimento de técnicas de atenuação de ruído. Nesse contexto, esta tese investiga a intensidade acústica gerada pela radiação sonora de superfícies vibrantes. De modo específico, a pesquisa enfoca a identificação das regiões de uma fonte sonora que contribuem efetivamente para potência sonora radiada para o campo afastado, quando a frequência de excitação ocorre abaixo da frequência crítica de coincidência. São descritas as fundamentações teóricas de duas diferentes abordagens. A primeira delas, denominada intensidade supersônica (analítica) é calculada via transformadas de Fourier para fontes sonoras com geometrias separáveis. A segunda, denominada intensidade útil (numérica) é calculada através do método dos elementos de contorno clássico para fontes com geometrias arbitrárias. Em ambas, a identificação das regiões é feita pela filtragem das ondas não propagantes (evanescentes). O trabalho está centrado em duas propostas, a saber. A primeira delas, é a apresentação implementação e análise de uma nova técnica numérica para o cálculo da grandeza intensidade útil. Essa técnica constitui uma variante do método dos elementos de contorno (MEC), tendo como base o fato de as aproximações para as variáveis acústicas pressão e velocidade normal serem tomadas como constantes em cada elemento. E também no modo peculiar de obter a velocidade constante através da média de um certo número de velocidades interiores a cada elemento. Por esse motivo, a técnica recebe o nome de método de elemento de contorno com velocidade média (AVBEMAverage Velocity Boundary Element Method). A segunda, é a obtenção da solução forma fechada do campo de velocidade normal para placas retangulares com oito diferentes combinações de condições contorno clássicas. Então, a intensidade supersônica é estimada e comparada à intensidade acústica. Nos ensaios numéricos, a comparação da intensidade útil obtida via MEC clássico e via AVBEM é mostrada para ilustrar a eficiência computacional da técnica aqui proposta, que traz como benefício adicional o fato de poder ser utilizada uma malha menos refinada para as simulações e, consequentemente, economia significativa de recursos computacionais.

Vortex filament simulation of trailing vortex merger

Aircraft in high-lift configuration shed multiple vortices. These generally merge to form a downstream wake consisting of two counter-rotating vortices of equal strength. The understanding of the merger of two co-rotating trailing vortices is important in evaluating the separation criteria for different aircraft to prevent wake vortex hazards during landing and take-off. There is no existing theoretical method on the basis of which such norms can be set. The present study is aimed at gaining a better understanding of the behaviour of wake vortices behind the aircraft. Two dimensional studies are carried out using the vortex blob method and compared with Bertenyi's experiment. It is shown that inviscid two dimensional effects are insufficient to explain the observations. Three dimensional studies, using the vortex filament method, are applied to the same test case. Two Lamb-Oseen profile vortices of the same dimensions and initial separation as the experiment are allowed to evolve from a straight starting condition until a converged steady flow is achieved. The results obtained show good agreement with the experimental distance to merger. Core radius and separation behaviour is qualitatively similar to experiment, with the exception of rapid increases at first. This may be partially attributable to the choice of filament-element length, and recommended further work includes a convergence study for this parameter. Copyright © 2005 by the American Institute of Aeronautics and Astronautics, Inc. All rights reserved.

Vortex generators near shock/ boundary layer interactions

Experiments have been performed in a blowdown supersonic wind tunnel to investigate the effect of arrays of sub-boundary layer vortex generators placed upstream of a normal shock/ boundary layer interaction. The investigation makes use of a recovery shock wave and the naturally grown turbulent boundary layer on the wind tunnel floor. Experiments were performed at Mach numbers of 1.5 and 1.3 and a freestream Reynolds number of 28 × 106. Two types of vortex generators were investigated - wedge-shaped and arrays of counter-rotating vanes. It was found that at Mach 1.5 the vane-type VGs eliminated and the wedge-type VGs greatly reduced the separation bubble under the shock. When placed in the supersonic part of the flow both VGs caused a wave pattern consisting of a shock, re-expansion and shock. The re-expansion and double shocks are undesirable features since they equate to increased total pressure losses and hence increased -wave drag. Furthermore there are indications that the vortex intensity is reduced by the normal shock/ boundary layer interaction. When the shock was located directly over the VGs there was no re-expansion present, but the 'damping' effect of the shock on the vortex persisted. It appears that the vortices produced by the wedge-shaped VGs lift off the surface more rapidly. Similar results were observed at Mach 1.3, where the flow was unseparated.

Experimental investigation of 3D shock / boundary layer interaction control in transonic flows

A novel supersonic wind tunnel setup is proposed to enable the investigation of control on a normal shock wave. Previous experimental arrangements were found to suffer from shock instability. Wind tunnel tests with and without control have confirmed the capability of the new setup to stabilise a shock structure at a target position without changing the nature of the shock wave / boundary layer interaction flow at M∞ = 1.3 and M ∞ = 1.5. Flow visualisation and pressure measurements with the new setup have revealed detailed characteristics of shock wave / boundary layer interactions and a λ-shock structure as well as benefits of control in total drag reduction in the presence of 3D bump control.

Micro-ramp control for oblique shock wave / boundary layer interactions

Supersonic engine intakes operating supercritically feature shock wave / boundary layer interactions (SBLIs), which are conventionally controlled using boundary layer bleed. The momentum loss of bleed flow causes high drag, compromising intake performance. Micro-ramp sub-boundary layer vortex generators (SBVGs) have been proposed as an alternative form of flow control for oblique SBLIs in order to reduce the bleed requirement. Experiments have been conducted at Mach 2.5 to characterise the flow details on such devices and investigate their ability to control the interaction between an oblique shock wave and the naturally grown turbulent boundary layer on the tunnel floor. Micro-ramps of four sizes with heights ranging from 25% to 75% of the uncontrolled boundary layer thickness were tested. The flow over all sizes of microramp was found to be similar, featuring streamwise counter-rotating vortices which entrain high momentum fluid, locally reducing the boundary layer displacement thickness. When installed ahead of the shock interaction it was found that the positioning of the micro-ramps is of limited importance. Micro-ramps did not eliminate flow separation. However, the previously two-dimensional separation was broken up into periodic three-dimensional separation zones. The interaction length was reduced and the pressure gradient across the interaction was increased.

Laminar to turbulent flow transition measurements using an array of SOI-CMOS MEMS wall shear stress sensors

The successful utilization of an array of silicon on insulator complementary metal oxide semiconductor (SOICMOS) micro thermal shear stress sensors for flow measurements at macro-scale is demonstrated. The sensors use CMOS aluminum metallization as the sensing material and are embedded in low thermal conductivity silicon oxide membranes. They have been fabricated using a commercial 1 μm SOI-CMOS process and a post-CMOS DRIE back etch. The sensors with two different sizes were evaluated. The small sensors (18.5 ×18.5 μm2 sensing area on 266 × 266 μm2 oxide membrane) have an ultra low power (100 °C temperature rise at 6mW) and a small time constant of only 5.46 μs which corresponds to a cut-off frequency of 122 kHz. The large sensors (130 × 130 μm2 sensing area on 500 × 500 μm2 membrane) have a time constant of 9.82 μs (cut-off frequency of 67.9 kHz). The sensors' performance has proven to be robust under transonic and supersonic flow conditions. Also, they have successfully identified laminar, separated, transitional and turbulent boundary layers in a low speed flow. © 2008 IEEE.

Recent developments of the Laser-assisted Cold Spray process and deposit characterisation

Laser-assisted Cold Spray (LCS) is a new coating and fabrication process which combines the supersonic powder beam found in Cold Spray (CS) with laser heating of the deposition zone. LCS retains the advantages of CS; solid-state deposition, high build rate and the ability to deposit onto a range of substrates, while reducing operating costs by removing the need to use gas heating and helium as the process gas. Recent improvements in powder delivery and laser energy coupling to workpiece have been undertaken to improve deposition efficiency (DE) and build rate, while real-time temperature logging allows greater management of deposition conditions and deposit characteristics.

Computational fluid-structure interaction methods for simulation of inflatable aerodynamic decelerators

Inflatable aerodynamic decelerators have potential advantages for planetary re-entry in robotic and human exploration missions. It is theorized that volume-mass characteristics of these decelerators are superior to those of common supersonic/subsonic parachutes and after deployment they may suffer no instabilities at high Mach numbers. A high fidelity computational fluid-structure interaction model is employed to investigate the behavior of tension cone inflatable aeroshells at supersonic speeds up to Mach 2.0. The computational framework targets the large displacements regime encountered during the inflation of the decelerator using fast level set techniques to incorporate boundary conditions of the moving structure. The preliminary results indicate large but steady aeroshell displacement with rich dynamics, including buckling of the inflatable torus that maintains the decelerator open under normal operational conditions, owing to interactions with the turbulent wake. Copyright © 2009 by the American Institute of Aeronautics and Astronautics, Inc.

Fluid-structure interaction simulation of an inflatable aerodynamic tension-cone decelerator

Inflatable aerodynamic decelerators have potential advantages for planetary re-entry in robotic and human exploration missions. In this paper, we focus on an inflatable tension cone design that has potential advantages over other geometries. A computational fluid-structure interaction model of a tension cone is employed to investigate the behavior of the inflatable aeroshell at supersonic speeds for conditions matching recent experimental results. A parametric study is carried out to investigate the deflections of the tension cone as a function of inflation pressure of the torus at a Mach of 2.5. Comparison of the behavior of the structure, amplitude of deformations, and determined loads are reported. © 2010 by the American Institute of Aeronautics and Astronautics, Inc.

Behaviour of unsteady transonic shock / boundary layer interactions with three-dimensional effects

An experimental investigation into the response of transonic SBLIs to periodic down-stream pressure perturbations in a parallel walled duct has been conducted. Tests have been carried out with a shock strength of M ∞ = 1.5 for pressure perturbation frequencies in the range 16-90 Hz. Analysis of the steady interaction at M∞ = 1.5 has also been made. The principle measurement techniques were high speed schlieren photography and laser Doppler anemometry. The structure of the steady SBLI was found to be highly three-dimensional, with large corner flows and sidewall SBLIs. These aspects are thought to influence the upstream transmission of pressure information through the interaction by affecting the post-shock flow field, including the extent of regions of secondary supersonic flow. At low frequency, the dynamics of shock motion can be predicted using an inviscid analytical model. At increased frequencies, viscous effects become significant and the shock exhibits unexpected dynamic behaviour, due to a phase lag between the upstream transmission of pressure information in the core flow and in the viscous boundary layers. Flow control in the form of micro-vane vortex generators was found to have a small impact on shock dynamics, due to the effect it had on the post-shock flow field outside the viscous boundary layer region. The relationship between inviscid and viscous effects is developed and potential destabilising mechanisms for SBLIs in practical applications are suggested. Copyright © 2009 by Paul Bruce and Holger Babinsky.

Experimental investigation into parameters governing corner interactions for transonic shock wave/ boundary layer interactions

Experiments were conducted investigating the interaction between a normal shock wave and a corner boundary layer in a constant area rectangular duct. Active corner suction and passive blowing were applied to manipulate the natural corner flows developing in the working section of the Cambridge University supersonic wind tunnel. In addition robust vane micro-vortex generators were applied to the corners of the working section. Experiments were conducted at Mach numbers of M∞=1.4 and 1.5. Flow visualisation was carried out through schlieren and surface oil flow, while static pressures were recorded via floor tappings. The results indicate that an interplay occurs between the corner flow and the centre line flow. It is believed that corner flow separation acts to induce a shock bifurcation, which in turn leads to a smearing of the adverse pressure gradient elsewhere. In addition the blockage effect from the corners was seen to result in a reacceleration of the subsonic post-shock flow. As a result manipulation of the corner regions allows a separated or attached centre line flow to be observed at the same Mach number. Copyright © 2010 by Babinsky, Burton, Bruce.

Microvortex generators applied to flowfield containing a normal shock wave and diffuser

The flow through a terminating shock wave and the subsequent subsonic diffuser typically found in supersonic inlets has been simulated using a small-scale wind tunnel. Experiments have been conducted at an inflow Mach number of 1.4 using a dual-channel working section to produce a steady near-normal shock wave. The setup was designed so that the location of the shock wave could be varied relative to the diffuser. As the near-normal shock wave was moved downstream and into the diffuser, an increasingly distorted, three-dimensional, and separated flow was observed. Compared with the interaction of a normal shock wave in a constant area duct, the addition of the diffuser resulted in more prominent corner interactions. Microvortex generators were added to determine their potential for removing flow separation. Although these devices were found to reduce the extent of separation, they significantly increased three-dimensionality and even led to a large degree of flow asymmetry in some configurations. Copyright © 2011 by Neil Titchener and Holger Babinsky.

Computational fluid-structure interaction of DGB parachutes in compressible fluid flow

This paper describes large-scale simulations of compressible flows over a supersonic disk-gap-band parachute system. An adaptive mesh refinement method is used to resolve the coupled fluid-structure model. The fluid model employs large-eddy simulation to describe the turbulent wakes appearing upstream and downstream of the parachute canopy and the structural model employed a thin-shell finite element solver that allows large canopy deformations by using subdivision finite elements. The fluid-structure interaction is described by a variant of the Ghost-Fluid method. The simulation was carried out at Mach number 1.96 where strong nonlinear coupling between the system of bow shocks, turbulent wake and canopy is observed. It was found that the canopy oscillations were characterized by a breathing type motion due to the strong interaction of the turbulent wake and bow shock upstream of the flexible canopy. Copyright © 2010 by ASME.