Nanostructured carbon films from supersonic cluster beam deposition: Structure and morphology

Nanostructured carbon thin films have been grown by deposition of cluster beams produced by a supersonic expansion. Due to separation effects typical of supersonic beams, films with different nanostructures can be grown by the simple intercepting of different regions of the cluster beam with a substrate. Films show a low-density porous structure, which has been characterized by Raman and Brillouin spectroscopy. Film morphology suggests that growth processes are similar to those occurring in a ballistic deposition regime.

Micro-vortex generator flow control for supersonic engine inlets

To investigate the flow control potential of micro-vortex generators for supersonic mixed-compression inlets, a basic model experiment has been designed which combines a normal shock wave with a subsonic diffuser. The diffuser is formed by a simple expansion corner, with a divergence angle of 6 degrees. The diffuser entry Mach numbers were M=1.3 and M=1.5 and a number of shock locations relative to the corner position were tested. Flow control was applied in the form of counter-rotating micro-vanes with heights of approximately 20% of boundary layer thickness. Furthermore, corner fences where employed to reduce sidewall effects. It was found that micro-vortex generators were able to significantly reduce the extent of flow separation under all conditions, but could not eliminate it altogether. Corner fences also demonstrated potential for improving the flow in rectangular cross section channels and the combination of corner fences with micro-vortex generators was found to give the greatest benefits. At M=1.3 the combination of corner fences and micro-vanes placed close to the diffuser entry could prevent separation for a wide range of conditions. At the higher diffuser entry Mach number the benefits of flow control were less significant although a reduction of separation size and an improved pressure recovery was observed. It is thought that micro-vortex generators can have significant flow control potential if they are placed close to the expected separation onset and when the adverse pressure gradient is not too far above the incipient separation level. The significant beneficial effects of corner fences warrant a more comprehensive further investigation. It is thought that the control methods suggested here are capable of reducing the bleed requirement on an inlet, which could provide significant performance advantages.

Towards jet flow LES of conceptual nozzles for acoustic predictions

Progress in simulating chevron nozzle jet flows using ILES/RANS-ILES approaches and using the Ffowcs Williams and Hawkings (FW-H) surface integral method to predict the radiated far field sound is presented in this paper. With the focus on the realistic chevron geometries, SMC001 and SMC006, coarse and fine meshes are generated in the range of 3∼13 million mesh cells. Throughout this work, to minimize numerical dissipation introduced by mesh quality issues, the hexahedral cell type is used. Numerical simulations are then carried out with cell-vertex and cell-centered codes. Despite the modest grids, mean velocities and turbulent statistics are found to be in reasonable accord with measurements. Also, far field sound levels predicted by the FW-H post processor are encouraging. Copyright © 2008 by the American Institute of Aeronautics and Astronautics, Inc.

Performance of choked unsteady ejector-nozzles for use in pressure-gain combustors

If the conventional steady flow combustor of a gas turbine is replaced with a device which achieves a pressure gain during the combustion process then the thermal efficiency of the cycle is raised. All such 'Pressure Gain Combustors' (e.g. PDEs, pulse combustors or wave rotors) are inherently unsteady flow devices. For such a device to be practically installed in a gas turbine it is necessary to design a downstream row of turbine vanes which will both accept the combustors unsteady exit flow and deliver a flow which the turbine rotor can accept. The design requirements of such a vane are that its exit flow both retains the maximum time-mean stagnation pressure gain (the pressure gain produced by the combustor is not lost) and minimises the amplitude of unsteadiness (reduces unsteadiness entering the downstream rotor). In this paper the exit of the pressure gain combustor is simulated with a cold unsteady jet. The first stage vane is simulated by a one-dimensional choked ejector nozzle with no turning. The time-mean and rms stagnation pressure at nozzle exit is measured. A number of geometric configurations are investigated and it is shown that the optimal geometry both maximizes time mean stagnation pressure gain (75% of that in the exit of the unsteady jet) and minimizes the amplitude of unsteadiness (1/3 of that in the primary jet). The structure of the unsteady flow within the ejector nozzle is determined computationally. Copyright © 2009 by J Heffer and R Miller.

Supersonic laser deposition of Ti and Ti64 alloys

The importance of metal coating technologies drives the continuous improvement of metal deposition techniques for application in a wide range of industrial sectors. This work presents the foundations of a new process technology for the deposition of Ti and Ti64 coatings on various substrates using supersonic powder streams and impact site laser heating. Full density metallic deposits are obtained under appropriate impact conditions without the need for transiting the melting point of the deposited material or substrate leading to large energy savings. Details of the experimental approach will be presented along with the general characteristics of the titanium coatings produced using this novel coatings method.

High speed titanium coatings by supersonic laser deposition

The importance of metal coating technologies drives the continuous improvement of metal deposition techniques for application in a wide range of industrial sectors. This work presents the foundations of a new process technology for the deposition of titanium coatings on steel tube substrates using supersonic powder streams and impact site laser heating, known as Supersonic Laser Deposition (SLD). Metallic deposits are obtained under appropriate impact conditions without the need for exceeding the melting point of the deposited material or substrate leading to improved coating quality. Details of the experimental approach are presented along with the general characteristics of the titanium coating produced using this novel coatings method. © 2011 Elsevier B.V. All rights reserved.

Hardfacing using supersonic laser depostion of stellite-6

The capability of manufacturing coatings is of central importance in engineering design. Many components require nowadays the application of additional layers, to enhance mechanical properties and protect against hostile environments. Supersonic Laser Deposition (SLD) is a novel coating method, based upon Cold Spray (CS) principles. In this technique the deposition velocities can be significantly lower than those required for effective bonding in CS applications. The addition of laser heat energy permits a change in the thermodynamic experience of impacting particles, thereby offering a greater opportunity for metallurgical bonding at lower velocities compared to the CS process technology. The work reported in this paper demonstrates the ability of the SLD process to deliver hard facing materials to engineering surfaces. Stellite-6 has been deposited on low carbon steel tubes over a range of process parameters, determining the appropriate target power and traverse speeds for coating deposition. Coating properties and parameters were examined to determine the main properties, micro-structure and processing cost. Their morphology was studied through optical microscopy, SEM and X-Ray Diffraction. The results have shown that SLD is capable of depositing Stellite-6, with enhanced properties compared to laser clad counterparts.

DDES of a supersonic coaxial helium jet

The mixing of a light gas in a scramjet combustion chamber is replicated through the simulation of a supersonic coaxial helium jet. Sensitivities of the RANS method to model constants is presented and the DDES method is employed to try and alleviate this modelling weakness. A significant delay in the shear layer transition is found to occur in the DDES simulation and it is suggested this may be due to the absence of inlet turbulence. The influence of the introduction of inflow turbulence is investigated and computational results are compared to experimental data. The influence of model constants on the DDES results are presented. © 2012 by Peter Cocks.

A novel method to produce small droplets from large nozzles.

This work presents a new method to generate droplets with diameters significantly smaller than the nozzle from which they emerge. The electrical waveform used to produce the jetting consists of a single square negative pulse. The negative edge of the pressure wave pulls the meniscus in, overturning the surface in such a way that a cavity is created. This cavity is then forced to collapse under the action of the positive edge of the pressure wave. This violent collapse produces a thin jet that eventually breaks up and produces droplets. Four droplet generator prototypes that demonstrate the capabilities of this novel mechanism are described. It is also shown that the proposed mechanism extends the existing limits of the commonly accepted inkjet operating regime.

Performance comparison of Stellite 6® deposited on steel using supersonic laser deposition and laser cladding

Stellite 6® powders were deposited on carbon steel using Supersonic Laser Deposition. The microstructure and performance of the coatings were examined using SEM, optical microscopy, EDS, XRD, microhardness testing and pin-on-disc wear testing. The results showed that the microstructure and wear behaviour of the most successful SLD deposition conditions with N2 at a pressure of 30bar, a temperature of 450°C and a deposition power of 1.5kW were compared with that of optimised laser cladding. © 2012 Elsevier B.V.