High-speed Gas Research Articles

Effects of Laser Irradiation in High-Speed Gas Flow for Surface Treatments of Copper

In this study, the impacts of laser irradiation on the surface morphology and hardness of copper (Cu) are investigated under various environments, including air, vacuum, and high-pressure gas flow through a supersonic nozzle. After irradiating Cu targets with laser pulses with energy of 30, 60, and 90 mJ/pulse, the surface structures of the targets are analyzed by scanning electron microscopy (SEM) and X-ray diffraction (XRD). The SEM analysis reveals diverse surface morphologies, including micro-cones, cavities, droplets, ripples, and island-like structures, depending on laser energy and environments. The XRD analysis provides insights into the structural changes induced by laser irradiation. The results indicate a significant enhancement in microhardness by a factor of 2.77, which is attributed to the surface and structural modifications incurred under various environments. In addition, the XRD analysis reveals a shift in the residual stress in the surface layers of copper from tensile before laser irradiation to compressive afterwards, highlighting the effectiveness of laser surface treatment in inducing favorable mechanical properties.

An evaluation of the hybrid Fokker–Planck-DSMC approach for high-speed rarefied gas flows

The Direct Simulation Monte Carlo (DSMC) method has been widely used for simulations of rarefied gas flows. It has been proven that the numerical solution of the DSMC method converges to the Boltzmann equation, providing a solid physical foundation for high Knudsen numbers. However, many aerospace engineering problems include both low and high-density regions in a single domain, making the DSMC method computationally expensive. Over the past decade, the particle Fokker–Planck (FP) method has been studied as a means to reduce computational costs near the continuum regime. While enhancing efficiency, the FP method loses physical accuracy at high Knudsen numbers. Aiming for universal accuracy and efficiency across the whole range of Knudsen numbers, the hybrid FP-DSMC method has been studied. Nevertheless, consistent comparisons among the DSMC, FP, and hybrid FP-DSMC methods have received limited attention so far. This paper presents a consistent comparative study of the DSMC, FP, and hybrid FP-DSMC methods to assess the accuracy and efficiency of the hybrid FP-DSMC method. The hybrid FP-DSMC solver is developed based on the open-source SPARTA framework. The benchmark problems include supersonic flow in a planar nozzle, hypersonic flow around a cylinder, and hypersonic flow around a THAAD-like missile. The results demonstrate that the hybrid FP-DSMC method can be more efficient than the DSMC method while being more accurate than the FP method. The speed-up achieved by the FP-DSMC method ranged from 1.5 to 14 times compared to the converged DSMC simulation.

Modification of temperature jump condition for modified Navier-Stokes equations included molecular diffusivity in high-speed rarefied gas flows

Modification of temperature jump condition for modified Navier-Stokes equations included molecular diffusivity in high-speed rarefied gas flows

Morphology and dynamics of the liquid jet in high-speed gas-assisted atomization retrieved through synchrotron-based high-speed X-ray imaging

The breakup of a liquid jet by a surrounding high-speed gas jet with different liquid Reynolds numbers and gas Weber numbers was studied using high speed phase-contrast X-ray imaging technique. Focusing on the liquid core, the portion of liquid that is connected to the nozzle, four distinct morphologies were observed and can be associated with changes in the large-scale configurations of the two-phase flow are reported in a phase diagram. Gas-to-liquid kinetic energy balance arguments capture several transitions between the liquid core regimes. The temporal evolution of the center of mass of the liquid core is extracted to quantify its motion, whose statistics can be utilized as a signature to distinguish different regimes. At low to moderate gas Weber numbers, the dynamics are strongly influenced by flapping, while long-time dynamics develop at high Weber numbers, that give way to quasi-periodic motions when swirl is impeded to the gas jet.

An Open-Source Code for High-Speed Non-Equilibrium Gas–Solid Flows in OpenFOAM

This paper details the development and verification tests of an open-source code named hy2LPTFoam intended for solving high-speed non-equilibrium gas-particle flows in OpenFOAM. The solver, based on hy2Foam for high-speed non-equilibrium gas flow, integrates multiple particle force models, heat transfer models, the diffusion-based smoothing method, and the MPPIC method. The verification tests incorporate interactions between shock waves and particle curtains with varying particle volume fractions, a JPL nozzle generating a two-phase gas–particle flow, and a Mars entry body with two particle inflow mass fractions. The tests yield good physical agreement with numerical and experimental data from the literature.

Three-dimensional particle-scale investigation of transient gas–solid flow characteristics in the propulsion system with a complex charge structure

This work is focused on researching the particle behavior of the transient gas–solid flow in the propulsion system with the modular charge structure, which has a great effect on the temporal-spatial distribution of energy release. Based on the coupling method of computational fluid dynamics and the discrete element method, an efficient three-dimensional unsteady gas–solid model is developed to provide a detailed means of capturing particle behavior in the propulsion system with a complex structure. Comparisons of the particle distribution of simulation results are done with experimental research, and a reasonable match has been obtained. Furthermore, the particle behavior characteristics can be divided into three stages. In the first stage, the particle behavior is dominated by the high-pressure, high-speed gas from the igniter. In the other two stages, the particle behavior is dominated by the complex gas flow generated by the opening of the module and the groove structure of the vehicle. The results show that the distribution of particles consists of slope accumulation and horizontal accumulation. The slope accumulation with a large gradient contains 84% of the total particles, and the height of the slope accumulation is increased exponentially along the axis.

Deformation and mutual influence of two cylindrical water columns in tandem subjected to shock wave

Abstract The interaction between shock waves and multiple cylinders, referred to as shock–cylinder interaction (SCI), is an important phenomenon in science and engineering. However, its underlying physical mechanisms remain unclear. This study entailed the numerical simulation of the aerobreakup of two tandem water columns subjected to a high-speed gas flow by using an adaptive mesh refinement (AMR)-based diffusion-interface model. The objective was to elucidate the changes in water–column deformation patterns over a wide range of Weber numbers. Statistical analysis was performed to examine the deformation of the water columns in vertical directions. Results reveal distinct deformation patterns between the two columns as the Weber number increases. Additionally, an extended exponential stretching law model was devised, and its improved capability to predict the deformation patterns was demonstrated.

Fuel property modeling by high-speed gas chromatography coupled with partial least squares data analysis

Partial least squares (PLS) regression is a valuable chemometric tool for property prediction when coupled with gas chromatography (GC). Since the separation run time and stationary phase selection are crucial for effective PLS modeling, we study these GC parameters on the prediction of viscosity, density and hydrogen content for 50 aerospace fuels. Due to the diversity of compounds in the fuels (primarily alkanes, cycloalkanes, and aromatics), we explore both polar and non-polar stationary phase columns. The robustness for the PLS models was evaluated by their normalized root mean square error of cross-validation (NRMSECV). PLS models built for viscosity across 1-min, 3-min, 7-min, and 10-min time window (TW) high-speed GC separations produced nearly the same NRMSECV with the polar column data with an average (standard deviation) of 4.41 % (0.34 %) versus the non-polar column data of 4.69 % (0.15 %). In contrast, while the NRMSECV of density modeling with the polar column data varied more than the viscosity models, averaging 7.54 % (0.67 %), the non-polar column data produced a significantly higher average NRMSECV of 10.06 % (0.35 %). Similarly, for hydrogen content, the NRMSECV with the polar column data averaged 9.50 % (0.87 %), which was significantly lower than the NRMSECV with the non-polar column data averaging 12.10 % (0.88 %). We also investigated the impact of smoothing the GC data on the corresponding PLS models. By applying varying degrees of smoothing, we can effectively obtain similar chromatographic peak patterns in a shorter TW. For example, a 10-min smoothed chromatogram appears like the 1-min separation with no smoothing but resulted in nearly the same NRMSECV. Overall, the fast separation with a 1-min TW produced robust PLS models for viscosity with either stationary phase column, whereas for density and hydrogen content the polar stationary phase column produced superior PLS models, thus with proper stationary phase selection, a fast separation run time could be readily applied with optimal PLS property modeling results.

Plume active control in high-power fiber laser welding based on high-speed shielding gas microbeam

Plume is an inherent physical phenomenon in fiber laser keyhole welding, negatively affecting welding quality. This paper proposes a new type of high-speed shielding gas microbeam (HSGM) based on the limitation of conventional shielding gas regulating plumes. The gas flow characteristics of the HSGM on the molten pool surface were explored using numerical simulation. Then, the coaxial double-layer shielding nozzle was trial-manufactured to clarify the regulation law for the HSGM on the plume. The gas velocity and pressure produced by the HSGM on the molten pool surface were positively correlated with the shielding gas flow rate, and the gas flow pattern was an acute triangle shape. The suitable HSGM can significantly restrain plume formation, improve the weld surface forming quality, increase the weld penetration depth (about 15.4%), and reduce the mass loss of the weld (about 58.7%). The significant blowing pressure effect of HSGM on plumes and splashes was the key to regulating the welding process. Compared with conventional shielding gas, the use of HSGM was significantly reduced.

Experimental study of jet and cavity coupling under vertical motion of underwater vehicle

After the underwater vehicle detaches from the launch tube and starts its engine, the interaction between the tail cavity and the high-speed jet significantly impacts its motion stability and engine efficiency. Therefore, it is crucial to study the evolution mechanism of cavities in vertical motion. However, in traditional water tunnel experiments, the evolution of the cavity differs from the actual situation of vertical launch due to the influence of buoyancy. This study investigates the dynamics and motion trajectories of tail cavities and high-speed gas jets in the vertical movement of vehicles under different Froude numbers and nozzle stagnation pressure ratios through experimentation. The experimental results show two modes of tail cavity evolution: intact cavity (IC) and foam-conical cavity (FC-CC). Increasing the Froude numbers and stagnation pressure ratios facilitates the transition of the cavity from the IC mode to the FC-CC mode, effectively suppressing the formation and intensity of re-entrant jets, thereby reducing its impact on the bottom of the vehicle and enhancing motion stability. By deriving the formula for the length of the jet core area, it was found that the jet length is linearly related to the nozzle stagnation pressure, further revealing the mechanism of cavity evolution. These findings offer a new perspective for a deeper understanding and prediction of the dynamic behavior of underwater vehicles.

Velocity And Concentration Measurements Of Supersonic Underexpanded Jets

The release of high-speed gas jets due to a tank leakage can pose a substantial safety hazard, as it can give rise to flammable, explosive, or toxic mixtures. Hence, understanding jet dispersion in real-world conditions is crucial for designing effective safety measures. Existing targeted or traceable studies provide velocity field data, but limitations in source-driven-pressures, nozzle geometries, or cross-flow conditions restrict their representativeness under real conditions. Indeed, an exhaustive experimental dataset for supersonic underexpanded gas jet dispersion under the influence of an Atmospheric Boundary Layer (ABL) is currently lacking. As part of a collaboration with the CEA, the von Karman Institute is continuing research efforts towards the development of high quality nonintrusive, optical measurement techniques for the characterization of the velocity and the concentration of a supersonic underexpanded jet submitted to different cross-flow conditions. The research explicitly targets measurements far from the release point within the self-similar region. Such measurements have already been tried on a supersonic jet without cross-flow and with a uniform velocity low-speed cross-flow [2], but never under the influence of an ABL. By filling this gap, the objective of the present work is to further improve the dispersion characterization by combining different techniques, such as Laser Mie Scattering and Light Extinction Spectroscopy (LES). To evaluate the dispersion within the self-similar region up to x/D ≈ 100, a significant FOV 1 is required. Therefore, Large-Scale Particle Image Velocimetry (LS-PIV) has been adapted and successfully applied to measure the velocity field. Prominent results have been obtained and comparable to standard PIV measurements. The pronounced variation in velocity magnitude observed while transitioning from the potential core to the self-similar region requires collecting multiple datasets to cover the broad spectrum of velocities comprehensively. A Mie scattering theory-based technique has been used to retrieve a relative concentration field. It is a non-intrusive technique that operates on the same experimental images produced by the LS-PIV campaign, assuming that light scattered by particles within a specific volume is proportional to the number of particles within this volume. The algorithm for concentration retrieval was adapted from and consequently improved for the present case. Discrepancies in the scaled concentration evolution among different nozzle diameters highlighted the necessity for refining the technique. This emphasizes accurately determining the reference concentration in a region free from intricate phenomena such as multiple scattering. The absolute and independent concentration measurement is done via Light Extinction Spectroscopy (LES). The LES technique measures the transmittance spectrum T of a collimated light beam passing through the particle-laden flow. This method has successfully been applied to several types of flows with similar seeding particles and concentration quantities (e.g. PSD 2 ). The extrapolation of absolute concentration parameters relies on the regularized solution of an ill-conditioned inverse problem. This solution is derived using the transmittance recorded during the test as the primary input parameter. The system to solve exhibits high sensitivity to small perturbations, making it challenging to employ numerical techniques confidently. Due to the substantial impact of minor perturbations in initial conditions on the system solution, a meticulous adaptation of the technique to the demands of compressible flows is necessary and still ongoing. The setup consists of a Deuterium-Tungsten Halogen UV-NIR light source emitting a divergent beam of light towards a 90◦ off-axis parabolic mirror, which collimates and deviates it into a beam to the jet. After passing through the jet, the resulting attenuated light beam goes into a collector mirror, redirecting it into a composite grating spectrometer UV-NIR with a 200 − 1100 nm wavelength range with 0.5 nm optical resolution. The results will examine the dispersion pattern and feature in terms of velocity and concentration of a supersonic underexpanded jet produced by an upstream tank with total pressure ranging from 5 to 9 bar without cross-flows. The latter will provide a foundation for successive studies on supersonic underexpanded jets subjected to an ABL.

Numerical studies of the breakup of the water jet by a shock wave in the barrel of the fire extinguishing installation

This scientific paper delves into the numerical studies of the process of filling the barrel with water and the subsequent breakup of the water jet and water atomization in the barrel of the fire extinguishing installation. The numerical model of the process of water injection into the barrel with the subsequent breakup of water by a shock wave was substantiated. To simulate these processes, the ANSYS software was used. VOF (volume of fluid) method-based model was applied where it is assumed that there is no penetration of one medium into another. The solution is based on the surface tracking method applied to a fixed Eulerian grid. According to the results of the numerical study, it was established that the water injection time significantly exceeds the duration of the gas detonation cycle in the fire extinguishing installation. In particular, we found out that it takes 8 ms just to spread the water jet from one side of the barrel to the other. It was observed that a high quality of water atomization under the action of a high-speed gas flow including the water located along the barrel wall. We stated that it is unreasonable to use the pulse injection of water into the barrel in the designed fire extinguishing installation due to a high fregiency of the shock wave generation exceeding 23 Hz.

Research on the cooling mechanism of low-temperature liquid jet mixing in high-temperature and high-speed airflow

The multi-stage water spray cooling system of the space launch site involves a complex gas–liquid two-phase mixed cooling problem in the process of spraying water onto the rocket engine gas jet. To investigate the complex multiphase flow field of the interaction between the airflow and liquid water jet, the Mixture multiphase flow model is adopted, which is coupled with the vaporization equation and component transport model of liquid water. The computational fluid dynamics method is used to numerically analyze the mixing and cooling mechanism of low-temperature liquid jet in high-temperature and high-speed gas flow. The results show that mixing low-temperature liquid jets in high-temperature and high-speed airflow can cause the exchange of momentum and energy, resulting in pressure loss and temperature reduction in the gas phase flow field. Due to the acceleration of transverse airflow, the diffusion flow range of the jet is significantly increased, and violent vaporization occurs, which further consume a large amount of airflow energy. The mixing cooling effect of transverse airflow and liquid water jet is directly related to the mass flow rate ratio of the jet to airflow. In addition, directly designing liquid water jet orifices on the solid wall of the guiding device can achieve the effect of improving the gas flow field environment. This conclusion can provide theoretical reference for the thermal protection design of ground launch devices in space launch site.

High-speed tilting-pad gas journal bearing flow field analysis

Tilting-pad gas journal bearing are widely used in the field of high-speed turbine machinery, especially in the special environment of low temperature. However, the performance is limited by structure, so a clear understanding of the field is particularly important. In this paper, finite volume method is used to simulate the three-dimensional flow field of high-speed tilting-pad gas bearing, then the effects of shaft speed, eccentricity and gas film thickness on the bearing capacity are studied. The simulation results show that the two factors of shaft speed and gas film clearance play a decisive role in producing sufficient bearing capacity of tilting tile radial gas bearings compared with other factors.

Ceramization of coordinated Zr4+ and Hf4+ in polysiloxane conferring silicone/phenolic hybrid resin with excellent thermal protection

Silicon/phenolic hybrid resins are one of the most commonly used materials for thermal protection. However, the weak ability of SiO2 generated by silicone during ablation to resist the impact of high-speed hot gas flow hinders further improvement of the performance. Therefore, in this work, the ultrahigh-temperature ceramic elements Zr4+ and Hf4+ were integrated into hyperbranched polysiloxanes in the form of coordination bond and then introduced into phenolic resin (PR), obtaining hybrid resin with excellent ablative resistance. During ablation, Zr4+ and Hf4+ will first undergo ceramization, producing ZrO2 and HfO2. Subsequently, they will undergo a solid solution sintering reaction to produce complex-phase ceramic particles (ZrxHf1-x)O2, which are embedded in the SiO2 liquid film and provide excellent pinning effect. This gives the hybrid resin excellent ablation resistance, whose linear ablation rate can be as low as 0.038 mm/s, a 58 % decrease compared to pure PR. This work not only provides a new pathway for ceramization through metal ion coordination bonding, but also provides a new way to prepare high-performance TPS materials.

A high temperature engine materials test facility.

Gas turbine engines subject materials to extreme conditions. Their high temperature materials and co-developed coatings must survive combustion gas temperatures currently approaching 1800 °C, large thermal gradients, severe thermal shock, and static and fatigue inducing applied stresses, all the while operating in highly reactive, high-pressure, high-speed combustion gas flows containing significant partial pressures of water vapor, oxygen, and other reactive species for many tens of thousands of hours. We describe the design and development of a test facility for the study of materials under individual and combinations of test parameters similar to those experienced within legacy and future engines. A hydraulic load frame capable of applying static or cyclic tension-compression stresses up to 400 MPa to flat-dog bone-shaped test specimens is integrated within an environmental test chamber capable of sustaining gas pressures from 0.1 to 1.2 MPa (1-12 atm). An adjustable0.1-2 kW power CO2 laser whose 10.6 µm wavelength radiation is strongly absorbed by ceramic coating materials is used to heat sample surfaces to temperatures of 1800 °C and above, while rear surface air jet cooling establishes through-thickness thermal gradients. Rapid laser heating in conjunction with transiently applied front and/or rear-side air cooling is used to create hot or cold thermal shock effects. This is accompanied by the impingement of a high pressure (up to 1.3 MPa) reactive gas jet upon the sample with speeds up to 300m/s by preheating dry air, mixing it with steam to the desired humidity, heating to 850 °C, and then expanding it through a converging nozzle. Thermal imaging pyrometers measure specimen front and back surface temperature fields, while environmental test chamber view ports permit digital image correlation and strain mapping.

Variations in gas temperature and average velocity during laminar-turbulent transition in high-speed gas flow through microtubes

The primary objective of this study is to investigate variations in gas temperature and average velocity during the laminar-turbulent transition of compressible flow. This investigation encompasses an exploration of the effect of Mach number on transitional Reynolds number. Experiments were conducted utilizing a pair of adiabatic stainless steel microtubes with a diameter (D) of 131.6 μm. The first microtube was dedicated to measuring local pressure to obtain friction factor, local Mach number, and bulk temperature. The second microtube was employed for measuring local wall temperature. Additionally, a stainless steel microtube with a diameter (D) of 124 μm and a rectangular microchannel with a hydraulic diameter (Dh) of 99.36 μm were incorporated in the study. Friction factor, Mach number, and bulk temperature were determined by measuring mass flow rate and local pressure near the outlet. The measured mass flow rate exhibited a slight increase that plateaued during the laminar-turbulent transition as the Reynolds number increased. In laminar flow, an increase in the Reynolds number resulted in an increase of the Mach number and a reduction in bulk temperature. Conversely, during the laminar-turbulent transition, the Mach number either remained constant or decreased, and the bulk temperature increased due to the conversion of kinetic energy to thermal energy. Experimental validation of this phenomenon was achieved by measuring the wall temperature of an adiabatic microtube.

An ELM data-driven model for predicting erosion rate of string in underground compressed air storage

Underground compressed air storage has experienced rapid development in recent years. The string, as a critical component of underground compressed air storage, serves as a channel for gas injection and production. The high-speed gas flow can cause string failure due to erosion. This study presents a data-driven model to predict the erosion rate of string in underground compressed air storage. A Computational Fluid Dynamics (CFD) model coupling discrete phase and continuous phase is developed to estimate the erosion rate of string. The effect of gas velocity, bending angle of string, string diameter, sand diameter and sand mass flow rate is investigated by implementing numerous simulations to generate a datasets of string erosion rate and its influencing factors. This dataset is used to develop a data-driven model based on extreme learning machine (ELM) algorithm for rapidly predicting the erosion rate of string. The developed model exhibits advantages in robustness and prediction accuracy.

Simulation of flow and debris migration in extreme ultraviolet source vessel

Practical extreme ultraviolet (EUV) sources yield the desired 13.5 nm radiation but also generate debris, significantly limiting the lifespan of the collector mirror in lithography. In this study, we explore the role of buffer gas in transporting debris particles within an EUV source vessel using direct numerical simulations. Our study involves a 2 × 1 × 1m3 rectangular cavity with an injecting jet flow subjected to sideward outlet. Debris particles are introduced into the cavity with specified initial velocities, simulating a spherical radiating pattern with particle diameters ranging from 0.1 to 1 μm. Varying the inflow velocity (from 1 to 50 m/s) of the buffer gas reveals a morphological transition in the flow field. At low inflow velocities, the flow remains steady, whereas higher inflow velocities induce the formation of clustered corner rolls. Upon reaching sufficiently high inflow velocities, the jet flow can penetrate the entire cavity, impacting the end wall. Interestingly, the resulting recirculation flow leads to the spontaneous formation of spiraling outflow. The distinct flow structures at various inflow velocities lead to distinct patterns of particle transport. For low-speed gas, it is efficient in expelling all particles smaller than 0.4 μm, while for high-speed gas, those fine particles accumulate near the end wall and are challenging to be extracted. Our findings highlight the significance of controlling flow conditions for effective debris particle transport and clearance in diverse applications especially in EUV source vessels.

Evolution of a shock-impacted reactive liquid fuel droplet with evaporation effects: A numerical study

We describe detailed numerical simulations of a liquid fuel droplet impacted by a Mach 5 shock wave, considering the effects of chemical reactions and phase change due to evaporation. In our baseline case, a 5μm, n-Dodecane fuel droplet is preheated to 460K, and surrounded by preheated O2 gas at 700K. The simulations investigate the low Ohnesorge number regime (Oh<0.1), where viscous effects are insignificant and therefore not considered in this work. The fuel droplet undergoes significant deformation and morphological changes following shock impingement, as the droplet surface becomes unstable to the Kelvin-Helmholtz instability. The droplet core is also observed to eject a thin sheet near the equatorial plane, which is then stretched by the high-speed post-shock gas flow, affecting the late-time behavior. We find the observed dominant modes associated with the Kelvin–Helmholtz instability are in reasonable agreement with inviscid linear theory (Chandrasekhar, 1981; Jepsen et al., 2006), when the local conditions at the droplet surface are considered. Furthermore, an evaporation-induced Stefan flow is established which blows off the hot post-shock gases surrounding the droplet, leading to droplet cooling. As the fuel vapors react, a diffusion flame is formed on the droplet-windward side, leading to intense droplet heating and enhanced vapor production in this region. We investigated the effect of the Damkohler number on droplet evolution by varying the fuel reactivity, and found the flame thickness decreased with increasing reactivity in agreement with trends predicted by laminar diffusion flame theory. At the highest reactivity, secondary burning of fuel vapors was observed in the droplet wake, while the resulting flame eventually reattached to the droplet surface. Our results show significant spatial inhomogeneities are present in the droplet flowfield in all the cases investigated, which must be considered in the development of reduced order point-particle models for system-level simulations of detonation engines.