A novel multiphase shock tube has been constructed to test the interaction of a planar shock wave with a dense gas-solid field of particles. The particle field is generated by a gravity-fed method that results in a spanwise curtain of 100-micron particles producing a volume fraction of about 15%. Interactions with incident shock Mach numbers of 1.67 and 1.95 are reported. High-speed schlieren imaging is used to reveal the complex wave structure associated with the interaction. After the impingement of the incident shock, transmitted and reflected shocks are observed, which lead to differences in flow properties across the streamwise dimension of the curtain. Tens of microseconds after the onset of the interaction, the particle field begins to propagate downstream, and disperse. The spread of the particle field, as a function of its position, is seen to be nearly identical for both Mach numbers. Immediately downstream of the curtain, the peak pressures associated with the Mach 1.67 and 1.95 interactions are about 35% and 45% greater than tests without particles, respectively. For both Mach numbers tested, the energy and momentum fluxes in the induced flow far downstream are reduced by about 30-40% by the presence of the particle field.
We have developed a mature laboratory at Sandia to measure interfacial rheology, using a combination of home-built, commercially available, and customized commercial tools. An Interfacial Shear Rheometer (KSV ISR-400) was modified and the software improved to increase sensitivity and reliability. Another shear rheometer, a TA Instruments AR-G2, was equipped with a du Nouey ring, bicone geometry, and a double wall ring. These interfacial attachments were compared to each other and to the ISR. The best results with the AR-G2 were obtained with the du Nouey ring. A Micro-Interfacial Rheometer (MIR) was developed in house to obtain the much higher sensitivity given by a smaller probe. However, it was found to be difficult to apply this technique for highly elastic surfaces. Interfaces also exhibit dilatational rheology when the interface changes area, such as occurs when bubbles grow or shrink. To measure this rheological response we developed a Surface Dilatational Rheometer (SDR), in which changes in surface tension with surface area are measured during the oscillation of the volume of a pendant drop or bubble. All instruments were tested with various surfactant solutions to determine the limitations of each. In addition, foaming capability and foam stability were tested and compared with the rheology data. It was found that there was no clear correlation of surface rheology with foaming/defoaming with different types of surfactants, but, within a family of surfactants, rheology could predict the foam stability. Diffusion of surfactants to the interface and the behavior of polyelectrolytes were two subjects studied with the new equipment. Finally, surface rheological terms were added to a finite element Navier-Stokes solver and preliminary testing of the code completed. Recommendations for improved implementation were given. When completed we plan to use the computations to better interpret the experimental data and account for the effects of the underlying bulk fluid.
Thermal accommodation coefficients have been derived for a variety of gas-surface combinations using an experimental apparatus developed to measure the pressure dependence of the conductive heat flux between parallel plates at unequal temperature separated by a gas-filled gap. The heat flux is inferred from temperature-difference measurements across the plates in a configuration where the plate temperatures are set with two carefully controlled thermal baths. Temperature-controlled shrouds provide for environmental isolation of the opposing test plates. Since the measured temperature differences in these experiments are very small (typically 0.3 C or less over the entire pressure range), high-precision thermistors are used to acquire the requisite temperature data. High-precision components have also been utilized on the other control and measurement subsystems in this apparatus, including system pressure, gas flow rate, plate alignment, and plate positions. The apparatus also includes the capability for in situ plasma cleaning of the installed test plates. Measured heat-flux results are used in a formula based on Direct Simulation Monte Carlo (DSMC) code calculations to determine the thermal accommodation coefficients. Thermal accommodation coefficients have been determined for three different gases (argon, nitrogen, helium) in contact with various surfaces. Materials include metals and alloys such as aluminum, gold, platinum, and 304 stainless steel. A number of materials important to fabrication of Micro Electro Mechanical Systems (MEMS) devices have also been examined. For most surfaces, coefficient values are near 0.95, 0.85, and 0.45 for argon, nitrogen, and helium, respectively. Only slight differences in accommodation as a function of surface roughness have been seen. Surface contamination appears to have a more significant effect: argon plasma treatment has been observed to reduce thermal accommodation by as much as 0.10 for helium. Mixtures of argon and helium have also been examined, and the results have been compared to DSMC simulations incorporating thermal-accommodation values from single-species experiments.
A novel multiphase shock tube to study particle dynamics in gas-solid flows has been constructed and tested. Currently, there is a gap in data for flows having particle volume fractions between the dusty and granular regimes. The primary purpose of this new facility is to fill that gap by providing high quality data of shock-particle interactions in flows having dense gas particle volume fractions. Towards this end, the facility aims to drive a shock into a spatially isotropic field, or curtain, of particles. Through bench-top experimentation, a method emerged for achieving this challenging task that involves the use of a gravity-fed contoured particle seeder. The seeding method is capable of producing fields of spatially isotropic particles having volume fractions of about 1 to 35%. The use of the seeder in combination with the shock tube allows for the testing of the impingement of a planar shock on a dense field of particles. The first experiments in the multiphase shock tube have been conducted and the facility is now operational.
The rheology at gas-liquid interfaces strongly influences the stability and dynamics of foams and emulsions. Several experimental techniques are employed to characterize the rheology at liquid-gas interfaces with an emphasis on the non-Newtonian behavior of surfactant-laden interfaces. The focus is to relate the interfacial rheology to the foamability and foam stability of various aqueous systems. An interfacial stress rheometer (ISR) is used to measure the steady and dynamic rheology by applying an external magnetic field to actuate a magnetic needle suspended at the interface. Results are compared with those from a double wall ring attachment to a rotational rheometer (TA Instruments AR-G2). Micro-interfacial rheology (MIR) is also performed using optical tweezers to manipulate suspended microparticle probes at the interface to investigate the steady and dynamic rheology. Additionally, a surface dilatational rheometer (SDR) is used to periodically oscillate the volume of a pendant drop or buoyant bubble. Applying the Young-Laplace equation to the drop shape, a time-dependent surface tension can be calculated and used to determine the effective dilatational viscosity of an interface. Using the ISR, double wall ring, SDR, and MIR, a wide range of sensitivity in surface forces (fN to nN) can be explored as each experimental method has different sensitivities. Measurements will be compared to foam stability.
A joint temperature/soot laser-based optical diagnostic was developed for the determination of the joint temperature/soot probability density function (PDF) for hydrocarbon-fueled meter-scale turbulent pool fires. This Laboratory Directed Research and Development (LDRD) effort was in support of the Advanced Simulation and Computing (ASC) program which seeks to produce computational models for the simulation of fire environments for risk assessment and analysis. The development of this laser-based optical diagnostic is motivated by the need for highly-resolved spatio-temporal information for which traditional diagnostic probes, such as thermocouples, are ill-suited. The in-flame gas temperature is determined from the shape of the nitrogen Coherent Anti-Stokes Raman Scattering (CARS) signature and the soot volume fraction is extracted from the intensity of the Laser-Induced Incandescence (LII) image of the CARS probed region. The current state of the diagnostic will be discussed including the uncertainty and physical limits of the measurements as well as the future applications of this probe.
A series of experiments has been performed to allow observation of the foaming process and the collection of temperature, rise rate, and microstructural data. Microfocus video is used in conjunction with particle image velocimetry (PIV) to elucidate the boundary condition at the wall. Rheology, reaction kinetics and density measurements complement the flow visualization. X-ray computed tomography (CT) is used to examine the cured foams to determine density gradients. These data provide input to a continuum level finite element model of the blowing process.
As part of an effort to reduce costs and improve quality control in encapsulation and potting processes the Technology Initiative Project ''Defect Free Manufacturing and Assembly'' has completed a computational modeling study of flows representative of those seen in these processes. Flow solutions are obtained using a coupled, finite-element-based, numerical method based on the GOMA/ARIA suite of Sandia flow solvers. The evolution of the free surface is solved with an advanced level set algorithm. This approach incorporates novel methods for representing surface tension and wetting forces that affect the evolution of the free surface. In addition, two commercially available codes, ProCAST and MOLDFLOW, are also used on geometries representing encapsulation processes at the Kansas City Plant. Visual observations of the flow in several geometries are recorded in the laboratory and compared to the models. Wetting properties for the materials in these experiments are measured using a unique flowthrough goniometer.
An experimental apparatus is described that measures gas-surface thermal accommodation coefficients from the pressure dependence of the conductive heat flux between parallel plates separated by a gas-filled gap. Heat flux between the plates is inferred from measurements of temperature drop between the plate surface and an adjacent temperature-controlled water bath. Thermal accommodation coefficients are determined from the pressure dependence of the heat flux at a fixed plate separation. The apparatus is designed to conduct tests with a variety of gases in contact with interchangeable, well-characterized surfaces of various materials (e.g., metals, ceramics, semiconductors) with various surface finishes (e.g., smooth, rough). Experiments are reported for three gases (argon, nitrogen, and helium) in contact with pairs of 304 stainless steel plates prepared with one of two finishes: lathe-machined or mirror-polished. For argon and nitrogen, the measured accommodation coefficients for machined and polished plates are near unity and independent of finish to within experimental uncertainty. For helium, the accommodation coefficients are much lower and show a slight variation with surface roughness. Two different methods are used to determine the accommodation coefficient from experimental data: the Sherman-Lees formula and the GTR formula. These approaches yield values of 0.87 and 0.94 for argon, 0.80 and 0.86 for nitrogen, 0.36 and 0.38 for helium with the machined finish, and 0.40 and 0.42 for helium with the polished finish, respectively, with an uncertainty of ±0.02. The GTR values for argon and nitrogen are generally in better agreement with the results of other investigators than the Sherman-Lees values are, and both helium results are in reasonable agreement with values in the literature.
Nanometric aluminum (123nm, spherical) was mixed with two different sieve-cut sizes of HMX (106-150 μm and 212-300 μm), and a series of gas gun tests were conducted to compare reactive wave development in pure HMX to that of aluminized HMX. In the absence of added metal, 4-mm-thick, low-density (68% of theoretical maximum density) pressings of the 106-150 μm HMX respond to modest shock loading by developing distinctive reactive waves that exhibit both temporal and meso-scale spatial fluctuations. Similar pressings of Al/HMX containing 10% aluminum (by mass) show an initial suppression of the usual wave growth seen in HMX samples. The suppression is then followed by an induction period where it is hypothesized that a phase change in the aluminum may occur. Data from VISAR, line-ORVIS, and 2-color pyrometry are given and discussed, and numerical modeling of inert sucrose is used to aid the explanation of the resulting data.
To reduce costs and hazardous wastes associated with the production of lead-based active ceramic components, an injection molding process is being investigated to replace the current machining process. Here, lead zirconate titanate (PZT) ceramic particles are suspended in a thermoplastic resin and are injected into a mold and allowed to cool. The part is then bisque fired and sintered to complete the densification process. To help design this new process we use a finite element model to describe the injection molding of the ceramic paste. Flow solutions are obtained using a coupled, finite-element based, Newton-Raphson numerical method based on the GOMA/ARIA suite of Sandia flow solvers. The evolution of the free surface is solved with an advanced level set algorithm. This approach incorporates novel methods for representing surface tension and wetting forces that affect the evolution of the free surface. Thermal, rheological, and wetting properties of the PZT paste are measured for use as input to the model. The viscosity of the PZT is highly dependent both on temperature and shear rate. One challenge in modeling the injection process is coming up with appropriate constitutive equations that capture relevant phenomenology without being too computationally complex. For this reason we model the material as a Carreau fluid and a WLF temperature dependence. Two-dimensional (2D) modeling is performed to explore the effects of the shear in isothermal conditions. Results indicate that very low viscosity regions exist near walls and that these results look similar in terms of meniscus shape and fill times to a simple Newtonian constitutive equation at the shear-thinned viscosity for the paste. These results allow us to pick a representative viscosity to use in fully three-dimensional (3D) simulation, which because of numerical complexities are restricted to using a Newtonian constitutive equation. Further 2D modeling at nonisothermal conditions shows that the choice of representative Newtonian viscosity is dependent on the amount of heating of the initially room temperature mold. An early 3D transient model shows that the initial design of the distributor is sub-optimal. However, these simulations take several months to run on 4 processors of an HP workstation using a preconditioner/solver combination of ILUT/GMRES with fill factors of 3 and PSPG stabilization. Therefore, several modifications to the distributor geometry and orientations of the vents and molds have been investigated using much faster 3D steady-state simulations. The pressure distribution for these steady-state calculations is examined for three different distributor designs to see if this can indicate which geometry has the superior design. The second modification, with a longer distributor, is shown to have flatter, more monotonic isobars perpendicular to the flow direction indicating a better filling process. The effects of the distributor modifications, as well as effects of the mold orientation, have also been examined with laboratory experiments in which the flow of a viscous Newtonian oil entering transparent molds is recorded visually. Here, the flow front is flatter and voids are reduced for the second geometry compared to the original geometry. A horizontal orientation, as opposed to the planned vertical orientation, results in fewer voids. Recently, the Navier-Stokes equations have been stabilized with the Dohrman-Bochev PSPP stabilization method, allowing us to calculate transient 3D simulations with computational times on the order of days instead of months. Validation simulations are performed and compared to the experiments. Many of the trends of the experiments are captured by the level set modeling, though quantitative agreement is lacking mainly due to the high value of the gas phase viscosity necessary for numerical stability, though physically unrealistic. More correct trends are predicted for the vertical model than the horizontal model, which is serendipitous as the actual mold is held in a vertical geometry. The full, transient mold filling calculations indicate that the flow front is flatter and voids may be reduced for the second geometry compared to the original geometry. The validated model is used to predict mold filling for the actual process with the material properties for the PZT paste, the original distributor geometry, and the mold in a vertical orientation. This calculation shows that voids may be trapped at the four corners of the mold opposite the distributor.