A high heat flux experiment for verification of thermostructural analysis

A major concern in advancing the state of the art technologies for hypersonic vehicles is the development of an aeropropulsion system capable of handling the high heat fluxes during flight. The leading edges of such systems must not only tolerate the maximum heating rates, but must also minimize distortions to the flow field due to excessive blunting and/or thermal warping of the compression surface to achieve the high inlet performance required. A combined analytical and experimental effort to study the aerothermodynamic loads on actively cooled structures for hypersonic applications was established. A hydrogen/oxygen rocket engine was modified to establish a high enthalpy high heat flux environment. The facility provides heat flux levels from about 200 up to 10000 Btu/sq ft/sec. Cross flow and parallel flow regeneratively cooled model can be tested and analyzed by using cooling fluids of water and hydrogen. Results are presented of the experiment and the characteristics of the Hot Gas Test Facility. The predicted temperature results of the cross flow model are compared with the experimental data on the first monolithic specimens and are found to be in good agreement. Thermal stress analysis results are also presented

A unique high heat flux facility for testing hypersonic engine components

A major concern in advancing the state-of-the-art technologies for hypersonic vehicles is the development of an aeropropulsion system capable of withstanding high thermal loads expected during hypersonic flights. Consequently, there is a need for experimental facilities capable of providing a high heat flux environment for testing compound concepts and verifying analyses. A hydrogen/oxygen rocket engine was developed to provide a high enthalpy/high heat flux environment for component evaluation. This Hot Gas Facility is capable of providing heat fluxes ranging from 200 (on flat surfaces) up to 8000 Btu per sq ft per sec (at a leading edge stagnation point). Gas temperatures up to 5500 R can be attained as well as Reynolds numbers up to 360,000 per ft. Test articles such as cowl leading edges, transpiration-cooled seals, fuel injectors, and cooled panel concepts can be evaluated with gaseous hydrogen as coolant. This facility and its configuration and test capabilities are discussed. Results from flow characterization experiments are also shown and their implications considered

Measured and calculated wall temperatures on air-cooled turbine vanes with boundary layer transition

Convection cooled turbine vane metal wall temperatures experimentally obtained in a hot cascade for one vane design were compared with wall temperatures calculated with TACT1 and STAN5 computer codes which incorporated various models for predicting laminar-to-turbulent boundary layer transition. Favorable comparisons on both vane surface were obtained at high Reynolds number with only one of these transition models. When other models were used, temperature differences between calculated and experimental data obtained at the high Reynolds number were as much as 14 percent in the separation bubble region of the pressure surface. On the suction surface and at lower Reynolds number, predictions and data unsatisfactorily differed by as much as 22 percent. Temperature differences of this magnitude can represent orders of magnitude error in blade life prediction

Thermal/structural analyses of several hydrogen-cooled leading-edge concepts for hypersonic flight vehicles

The aerodynamic heating at high flight Mach numbers, when shock interference heating is included, can be extremely high and can exceed the capability of most conventional metallic and potential ceramic materials available. Numerical analyses of the heat transfer and thermal stresses are performed on three actively cooled leading-edge geometries (models) made of three different materials to address the issue of survivability in a hostile environment. These analyses show a mixture of results from one configuration to the next. Results for each configuration are presented and discussed. Combinations of enhanced internal film coefficients and high material thermal conductivity of copper and tungsten are predicted to maintain the maximum wall temperature for each concept within acceptable operating limits. The exception is the TD nickel material which is predicted to melt for most cases. The wide range of internal impingement film coefficients (based on correlations) for these conditions can lead to a significant uncertainty in expected leading-edge wall temperatures. The equivalent plastic strain, inherent in each configuration which results from the high thermal gradients, indicates a need for further cyclic analysis to determine component life

Hypersonic Engine Leading Edge Experiments in a High Heat Flux, Supersonic Flow Environment

A major concern in advancing the state-of-the-art technologies for hypersonic vehicles is the development of an aeropropulsion system capable of withstanding the sustained high thermal loads expected during hypersonic flight. Three aerothermal load related concerns are the boundary layer transition from laminar to turbulent flow, articulating panel seals in high temperature environments, and strut (or cowl) leading edges with shock-on-shock interactions. A multidisciplinary approach is required to address these technical concerns. A hydrogen/oxygen rocket engine heat source has been developed at the NASA Lewis Research Center as one element in a series of facilities at national laboratories designed to experimentally evaluate the heat transfer and structural response of the strut (or cowl) leading edge. A recent experimental program conducted in this facility is discussed and related to cooling technology capability. The specific objective of the experiment discussed is to evaluate the erosion and oxidation characteristics of a coating on a cowl leading edge (or strut leading edge) in a supersonic, high heat flux environment. Heat transfer analyses of a similar leading edge concept cooled with gaseous hydrogen is included to demonstrate the complexity of the problem resulting from plastic deformation of the structures. Macro-photographic data from a coated leading edge model show progressive degradation over several thermal cycles at aerothermal conditions representative of high Mach number flight

Analysis of developing laminar flows in circular pipes using a higher-order finite-difference technique

A higher-order finite-difference technique is developed to calculate the developing-flow field of steady incompressible laminar flows in the entrance regions of circular pipes. Navier-Stokes equations governing the motion of such a flow field are solved by using this new finite-difference scheme. This new technique can increase the accuracy of the finite-difference approximation, while also providing the option of using unevenly spaced clustered nodes for computation such that relatively fine grids can be adopted for regions with large velocity gradients. The velocity profile at the entrance of the pipe is assumed to be uniform for the computation. The velocity distribution and the surface pressure drop of the developing flow then are calculated and compared to existing experimental measurements reported in the literature. Computational results obtained are found to be in good agreement with existing experimental correlations and therefore, the reliability of the new technique has been successfully tested

FULL-SCALE TREATMENT WETLANDS FOR METAL REMOVAL FROM INDUSTRIAL WASTEWATER

The A-01 NPDES outfall at the Savannah River Site receives process wastewater discharges and stormwater runoff from the Savannah River National Laboratory. Routine monitoring indicated that copper concentrations were regularly higher than discharge permit limit, and water routinely failed toxicity tests. These conditions necessitated treatment of nearly one million gallons of water per day plus storm runoff. Washington Savannah River Company personnel explored options to bring process and runoff waters into compliance with the permit conditions, including source reduction, engineering solutions, and biological solutions. A conceptual design for a constructed wetland treatment system (WTS) was developed and the full-scale system was constructed and began operation in 2000. The overall objective of our research is to better understand the mechanisms of operation of the A-01 WTS in order to provide better input to design of future systems. The system is a vegetated surface flow wetland with a hydraulic retention time of approximately 48 hours. Copper, mercury, and lead removal efficiencies are very high, all in excess of 80% removal from water passing through the wetland system. Zinc removal is 60%, and nickel is generally unaffected. Dissolved organic carbon in the water column is increased by the system and reduces toxicity of the effluent. Concentrations of metals in the A-01 WTS sediments generally decrease with depth and along the flow path through the wetland. Sequential extraction results indicate that most metals are tightly bound to wetland sediments

The structure and mechanistic impact of carbon deposits in dehydrogenation reactions

The catalytic dehydrogenation (DH) and oxidative dehydrogenation (ODH) of light alkanes is widely studied as a route to the formation of alkenes and di-alkenes, important precursor molecules for synthetic rubbers, plastics and a variety of other products [1-4]. Recent studies have focused on the non-oxidative DH of butane over alumina-supported vanadia catalysts [5-7]. In the present work, we provide a detailed understanding of both the role and structure of coke deposited on VOx/Al2O3 during reaction. A range of characterisation techniques have been employed including the first application of terahertz time domain spectroscopy (THz-TDS) to the study of coke. Complementary THz-TDS characterisation of carbonaceous materials including carbon nanofibres (CNFs) has also been conducted

The role and structure of carbonaceous materials in dehydrogenation reactions

The catalytic dehydrogenation (DH) and oxidative dehydrogenation (ODH) of light alkanes is widely studied as a route to the formation of alkenes and di-alkenes, important precursor molecules for synthetic rubbers, plastics and a variety of other products [1,2]. Recent studies have focused on the non-oxidative DH of butane over alumina-supported vanadia catalysts [3-5]. In the present work, we provide a detailed understanding of both the role and structure of coke deposited on VOx/Al2O3 during reaction. A range of characterisation techniques have been employed including the first application of terahertz time domain spectroscopy (THz-TDS) to the study of coke. Complementary THz-TDS characterisation of carbonaceous materials including carbon nanofibres (CNFs) has also been conducted. For such materials THz-TDS spectra can be correlated with their catalytic performance in the oxidative dehydrogenation of ethylbenzene to form styrene