Powder stream characteristics in cold spray nozzles

The exponential increase of industrial demand in the past two decades has led scientists to the development of alternative technologies for the fast manufacturing of engineering components, aside from standard and time consuming techniques such as casting or forging.Cold Spray (CS) is a newly developed manufacturing technique, based upon the deposition of metal powder on a substrate due to high energy particle impacts. In this process, the powder is accelerated up to considerable speed in a converging-diverging nozzle, typically using air, nitrogen or helium as a carrier gas. Recent developments have demonstrated significant process capabilities, from the building of mold-free 3D shapes made of various metals, to low porosity and corrosion resistant titanium coatings.In CS, the particle stream characteristics during the acceleration process are important in relation to the final geometry of the coating. Experimental studies have shown the tendency of particles to spread over the nozzle acceleration channel, resulting in a wide exit stream and in the difficulty of producing narrow tracks.This paper presents an investigation on the powder stream characteristics in CS supersonic nozzles. The powder insertion location was varied within the carrier gas flow, along with the geometry of the powder injector, in order to identify their relation with particle trajectories. Computational Fluid Dynamics (CFD) results by Fluent v6.3.26 are presented, along with experimental observations. Different configurations were tested and modeled, giving deposited track geometries of copper and tin ranging from 1. mm to 8. mm in width on metal and polymer substrates. © 2011 Elsevier B.V.

Simulations of the SCHOLAR scramjet experiment

The DDES method is employed to investigate the complex physics involved in supersonic combustion and in particular in the SCHOLAR scramjet test case. The influence on computational results of prescribing turbulent fluctuations at the entrance to the combustion chamber is investigated. The interaction of shock waves, vortices, turbulence and combustion is studied and the existence of secondary vortices on the upper will of the combustor is proposed. © 2012 by Peter Cocks.

Corner separation effects for normal shock wave/turbulent boundary layer interactions in rectangular channels

Experiments are conducted to examine the mechanisms behind the coupling between corner separation and separation away from the corner when holding a high-Machnumber M∞ = 1.5 normal shock in a rectangular channel. The ensuing shock wave interaction with the boundary layer on the wind tunnel floor and in the corners was studied using laser Doppler anemometry, Pitot probe traverses, pressure sensitive paint and flow visualization. The primary mechanism explaining the link between the corner separation size and the other areas of separation appears to be the generation of compression waves at the corner, which act to smear the adverse pressure gradient imposed upon other parts of the flow. Experimental results indicate that the alteration of the -region, which occurs in the supersonic portion of the shock wave/boundary layer interaction (SBLI), is more important than the generation of any blockage in the subsonic region downstream of the shock wave. © Copyright 2012 Cambridge University Press.

THE SENSITIVITY OF 2D COMPRESSOR INCIDENCE RANGE TO IN-SERVICE GEOMETRIC VARIATION

The loss mechanisms which control 2D incidence range are discussed with an emphasis on determining which real in-service geometric variations will have the largest impact. For the majority of engine compressor blades (Minlet>0.55) both the negative and positive incidence limits are controlled by supersonic patches. It is shown that these patches are highly sensitive to the geometric variations close to, and around the leading edge. The variations used in this study were measured from newly manufactured as well as ex-service blades. Over most the high pressure compressor considered, it was shown that manufacture variations dominated. The first part of the paper shows that, despite large geometric variations (~10% of leading edge thickness), the incidence range responded in a linear way. The result of this is that the geometric variations have little effect on the mean incidence range of a row of blades. In the second part of the paper a region of the design space is identified where non-linear behavior can result in a 10% reduction in positive incidence range. The mechanism for this is reported and design guidelines for its avoidance offered. In the final part of the paper, the linear behavior at negative incidence and the transonic nature of the flow is exploited to design a robust asymmetric leading edge with a 5% increase in incidence range.

A body force-based method for prediction of multiple-pure-tone noise: Validation

Emissions, fuel burn, and noise are the main drivers for innovative aircraft design. Embedded propulsion systems, such as for example used in hybrid-wing body aircraft, can offer fuel burn and noise reduction benefits but the impact of inlet flow distortion on the generation and propagation of turbomachinery noise has yet to be assessed. A novel approach is used to quantify the effects of non-uniform flow on the creation and propagation of multiple pure tone (MPT) noise. The ultimate goal is to conduct a parametric study of S-duct inlets to quantify the effects of inlet design parameters on the acoustic signature. The key challenge is that the effects of distortion transfer, noise source generation and propagation through the non-uniform flow field are inherently coupled such that a simultaneous computation of the aerodynamics and acoustics is required to capture the mechanisms at play. The technical approach is based on a body force description of the fan blade row that is able to capture the distortion transfer and the blade-to-blade flow variations that cause the MPT noise while reducing computational cost. A single, 3-D full-wheel CFD simulation, in which the Euler equations are solved to second-order spatial and temporal accuracy, simultaneously computes the MPT noise generation and its propagation in distorted inlet flow. A new method of producing the blade-to-blade variations in the body force field for MPT noise generation has been developed and validated. The numerical dissipation inherent to the solver is quantified and used to correct for non-physical attenuation in the far-field noise spectra. Source generation, acoustic propagation and acoustic energy transfer between modes is examined in detail. The new method is validated on NASA's Source Diagnostic Test fan and inlet, showing good agreement with experimental data for aerodynamic performance, acoustic source generation, and far-field noise spectra. The next steps involve the assessment of MPT noise in serpentine inlet ducts and the development of a reduced order formulation suitable for incorporation into NASA's ANOPP framework. © 2010 by Jeff Defoe, Alex Narkaj & Zoltan Spakovszky.

A novel MPT noise prediction methodology for highly-integrated propulsion systems with inlet flow distortion

Embedded propulsion systems, such as for example used in advanced hybrid-wing body aircraft, can potentially offer major fuel burn and noise reduction benefits but introduce challenges in the aerodynamic and acoustic integration of the high-bypass ratio fan system. A novel approach is proposed to quantify the effects of non-uniform flow on the generation and propagation of multiple pure tone noise (MPTs). The new method is validated on a conventional inlet geometry first. The ultimate goal is to conduct a parametric study of S-duct inlets in order to quantify the effects of inlet design parameters on the acoustic signature. The key challenge is that the mechanism underlying the distortion transfer, noise source generation and propagation through the non-uniform flow field are inherently coupled such that a simultaneous computation of the aerodynamics and acoustics is required. The technical approach is based on a body force description of the fan blade row that is able to capture the distortion transfer and the MPT noise generation mechanisms while greatly reducing computational cost. A single, 3-D full-wheel unsteady CFD simulation, in which the Euler equations are solved to second-order spatial and temporal accuracy, simultaneously computes the MPT noise generation and its propagation in distorted mean flow. Several numerical tools were developed to enable the implementation of this new approach. Parametric studies were conducted to determine appropriate grid and time step sizes for the propagation of acoustic waves. The Ffowcs-Williams and Hawkings integral method is used to propagate the noise to far field receivers. Non-reflecting boundary conditions are implemented through the use of acoustic buffer zones. The body force modeling approach is validated and proof-of-concept studies demonstrate the generation of disturbances at both blade-passing and shaft-order frequencies using the perturbed body force method. The full methodology is currently being validated using NASA's Source Diagnostic Test (SDT) fan and inlet geometry. Copyright © 2009 by Jeff Defoe, Alex Narkaj & Zoltan Spakovszky.

Normal shock interactions in rectangular channels

Experiments have been conducted to examine the mechanisms behind the coupling between corner separation and centreline separation when holding a normal shock in a rectangular channel. The study has focused on a M ∞ = 1.5 normal shock held in a wind tunnel with a parallel rectangular cross-section. The primary mechanism explaining the link between the corner separation size and the centreline separation appears to be the generation of compression waves which act to smear the adverse pressure gradient imposed upon other parts of the flow. In addition, the origin of the λ-foot leading leg appears to be depended upon the size of the corner separations. Experimental results indicate that the alteration of the λ-region, which occurs in the supersonic portion of the SBLI, is more important than the generation of any blockage in the subsonic region downstream of the shock wave. Copyright © 2012 by H. Babinsky, D.M.F. Burton.

Turbine blade tip heat transfer in low speed and high speed flows

In this paper, high and low speed tip flows are investigated for a high-pressure turbine blade. Previous experimental data are used to validate a CFD code, which is then used to study the tip heat transfer in high and low speed cascades. The results show that at engine representative Mach numbers the tip flow is predominantly transonic. Thus, compared to the low speed tip flow, the heat transfer is affected by reductions in both the heat transfer coefficient and the recovery temperature. The high Mach numbers in the tip region (M>1.5) lead to large local variations in recovery temperature. Significant changes in the heat transfer coefficient are also observed. These are due to changes in the structure of the tip flow at high speed. At high speeds, the pressure side corner separation bubble reattachment occurs through supersonic acceleration which halves the length of the bubble when the tip gap exit Mach number is increased from 0.1 to 1.0. In addition, shock/boundary-layer interactions within the tip gap lead to large changes in the tip boundary-layer thickness. These effects give rise to significant differences in the heat-transfer coefficient within the tip region compared to the low-speed tip flow. Compared to the low speed tip flow, the high speed tip flow is much less dominated by turbulent dissipation and is thus less sensitive to the choice of turbulence model. These results clearly demonstrate that blade tip heat transfer is a strong function of Mach number, an important implication when considering the use of low speed experimental testing and associated CFD validation in engine blade tip design. Copyright © 2009 by ASME.

Shock wave/boundary-layer interaction control using a combination of vortex generators and bleed

To investigate whether vortex generators can be an effective form of passive flow control an experimental investigation has been conducted in a small-scale wind tunnel. With specific emphasis on supersonic inlet applications flow separation was initiated using a combined terminal shock wave and subsonic diffuser: a configuration that has been developed as a part of a program to produce a more inlet-relevant flowfield in a small-scale wind tunnel than previous studies. When flow control was initially introduced little overall flow improvement was obtained as the losses tended to be redistributed instead of removed. It became apparent that there existed a strong coupling between the center-span flow and the corner flows. As a consequence, only when flow control was applied to both the corner flows and center-span flow was a significant flow improvement obtained. When corner suction and center-span vortex generators were employed in tandem separation was much reduced and wall-pressure and stagnation pressure were notably improved. As a result, when applied appropriately, it is thought that vortex generators do have the potential to reduce the dependence on boundary-layer bleed for the purpose of separation suppression. Copyright © 2012 by Neil Titchener and Holger Babinsky. Published by the American Institute of Aeronautics and Astronautics, Inc.

Fluid-structure interaction simulations of a tension-cone inflatable aerodynamic decelerator

A series of fluid-structure interaction simulations of an aerodynamic tension-cone supersonic decelerator prototype intended for large mass payload deployment in planetary explorations are discussed. The fluid-structure interaction computations combine large deformation analysis of thin shells with large-eddy simulation of compressible turbulent flows using a loosely coupled approach to enable quantification of the dynamics of the vehicle. The simulation results are compared with experiments carried out at the NASA Glenn Research Center. Reasonably good agreement between the simulations and the experiment is observed throughout a deflation cycle. The simulations help to illuminate the details of the dynamic progressive buckling of the tension-cone decelerator that ultimately results in the collapse of the structure as the inflation pressure is decreased. Furthermore, the tension-cone decelerator exhibits a transient oscillatory behavior under impulsive loading that ultimately dies out. The frequency of these oscillations was determined to be related to the acoustic time scale in the compressed subsonic region between the bow shock and the structure. As shown, when the natural frequency of the structure and the frequency of the compressed subsonic region approximately match, the decelerator exhibits relatively large nonaxisymetric oscillations. The observed response appears to be a fluid-structure interaction resonance resulting from an acoustic chamber (pistonlike) mode exciting the structure. Copyright © 2013 by Christopher Porter, R. Mark Rennie, Eric J. Jumper.

A canonical normal SBLI flow relevant to external compression inlets

The normal shock wave / boundary layer interaction (normal SBLI) is important to the operation and performance of a supersonic inlet, and the normal SBLI is particularly prominent in external compression inlets. To improve our understanding of such interactions, it is helpful to make use of fundamental flows which capture the main elements of inlets, without resorting to the level of complexity and system integration associated with full-geometry inlets. In this paper, several fundamental fiow-fleld configurations have been considered as possible test cases to represent the normal SBLI aspects found in typical external compression inlets, and it was found that the spillage-diffuser more closely retains the basic flow features of an external compression inlet than the other configurations. In particular, this flow-fleld allows the normal shock Mach number as well as the amount and rate of subsonic diffusion to be all held approximately constant mid independent of the application of flow control. In addition, a survey of several external compression inlets was conducted to quantify the flow and geometric parameters of the spillage-diffuser relevant to actual inlets. The results indicated that such a flow may be especially relevant if the terminal Mach number is about 1.3 to 1.4, the confinement parameter is around 10%, the width around twice or three times the height, and with the area expansion just downstream of the shock on the conservative side of the stall limit for incompressible diffusers. © 2013 by the American Institute of Aeronautics and Astronautics, Inc. All rights reserved.

Experimental studies of an accelerating, pitching, flat plate at low Reynolds number

The understanding of low Reynolds number aerodynamics is becoming increasingly prevalent with the recent surge in interest in advanced Micro-Air Vehicle (MAV) technology. Research in this area has been primarily stimulated by a military need for smaller, more versatile, autonomous, surveillance aircraft. The mechanism for providing the high lift coefficient required forMAV applications is thought to be largely influenced by the formation of a Leading Edge Vortex (LEV). This paper analyses experimentally, the influence of the LEV effect for a flat plate wing (AR = 4) under fast and slow pitch-up motions at Re =10,000 using a combination of dye flow visualisation and PIV measurements. It is found that a fast pitch over 1c shows a flow topology dominant LEV, while for a slow pitch case over 6c, the flow is largely separated. The development of the suction surface flow and the LEV was strongly correlated with the kinematics of the leading edge, suggesting that the effective local angle of incidence at the Leading Edge (LE) is of considerable significance in unsteady pitching motions. © 2013 by P.R.R.J Stevens.

Canonical normal shock wave/boundary-layer interaction flows relevant to external compression inlets

The normal shock wave/boundary-layer interaction is important to the operation and performance of a supersonic inlet, and the normal shock wave/boundary-layer interaction is particularly prominent in external compression inlets. To improve understanding of such interactions, it is helpful to make use of fundamental flows that capture the main elements of inlets, without resorting to the level of complexity and system integration associated with full-geometry inlets. In this paper, several fundamental flowfield configurations have been considered as possible test cases to represent the normal shock wave/boundary-layer interaction aspects found in typical external compression inlets, and it was found that the spillage diffuser more closely retains the basic flow features of an external compression inlet than the other configurations. In particular, this flowfield allows the normal shock Mach number as well as the amount and rate of subsonic diffusion to all be held approximately constant and independent of the application of flow control. In addition, a survey of several external compression inlets was conducted to quantify the flow and geometric parameters of the spillage diffuser relevant to actual inlets. The results indicated that such a flow may be especially relevant if the terminal Mach number is about 1.3 to 1.4, the confinement parameter is around 10%, and the width is around twice or three times the height. In addition, the area expansion downstream of the shock should be limited to the conservative side of incipient stall based on incompressible diffusers. Copyright © 2013 by the authors.

A computational fluid-structure interaction study of inflation cycles of a tension cone decelerator

Inflatable aerodynamic decelerators present potential advantages for planetary entry in missions of robotic and human exploration. The design of these structures face many engineering challenges, including complex deformable geometries, anisotropic material response, and coupled shockturbulence interactions. In this paper, we describe a comprehensive computational fluid-structure interaction study of an inflation cycle of a tension cone decelerator in supersonic flow and compare the simulations with earlier published experimental results. The aeroshell design and flow conditions closely match recent experiments conducted at Mach 2.5. The structural model is a 16-sided polygonal tension cone with seams between each segment. The computational model utilizes adaptive mesh refinement, large-eddy simulation, and shell mechanics with self-contact modeling to represent the flow and structure interaction. This study focuses on the dynamics of the structure as the inflation pressure varies gradually, and the behavior of forces experienced by the flexible and rigid (the payload capsule) structures. © 2011 by the American Institute of Aeronautics and Astronautics, Inc. All rights reserved.

Cabaret finite-difference schemes for the one-dimensional Euler equations

In the present paper we consider second order compact upwind schemes with a space split time derivative (CABARET) applied to one-dimensional compressible gas flows. As opposed to the conventional approach associated with incorporating adjacent space cells we use information from adjacent time layer to improve the solution accuracy. Taking the first order Roe scheme as the basis we develop a few higher (i.e. second within regions of smooth solutions) order accurate difference schemes. One of them (CABARET3) is formulated in a two-time-layer form, which makes it most simple and robust. Supersonic and subsonic shock-tube tests are used to compare the new schemes with several well-known second-order TVD schemes. In particular, it is shown that CABARET3 is notably more accurate than the standard second-order Roe scheme with MUSCL flux splitting.