Publications

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This experimental study explores the fluid-structure interactions occurring between a control surface and the hypersonic flow deflected by it. The control surface is simplified for this work as a spanwise finite wedge placed on a longitudinally sliced part of the cone. The front surface of the wedge is a thin panel which is designed to respond to the unsteady fluid loading arising from the shock-wave/boundary layer interactions. Experiments have been conducted in the Sandia Hypersonic Wind Tunnel at Mach 5 and Mach 8 at wedge angles of 10◦, 20◦ and 30◦ . High-speed schlieren and backside panel accelerometer measurements capture the unsteady flow dynamics and structural response of the thin panel, respectively. For attached or small separation interactions, the transitional regime has the strongest panel fluctuations with convective shock undulations induced by the boundary layer disturbance shown to be associated with dominant panel vibrations. For large separated interactions, shear layer flapping can excite select panel modes. Heating of the panel causes a downward shift in natural mode frequencies.

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Two techniques have extended the effective frequency limits of postage-stamp PIV, in which a pulse-burst laser and very small fields of view combine to achieve high repetition rates. An interpolation scheme reduced measurement noise, raising the effective frequency response of previous 400-kHz measurements from about 120 kHz to 200 kHz. The other technique increased the PIV acquisition rate to very nearly MHz rates (990 kHz) by using a faster camera. Charge leaked through the camera shift register at these framing rates but this was shown not to bias the measurements. The increased framing rate provided oversampled data and enabled use of multi-frame correlation algorithms for a lower noise floor, increasing the effective frequency response to 240 kHz where the interrogation window size begins to spatially filter the data. Good agreement between the interpolation technique and the MHz-rate PIV measurements was established. The velocity spectra suggest turbulence power-law scaling in the inertial subrange steeper than the theoretical-5/3 scaling, attributed to an absence of isotropy.

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Bench-top tests are conducted to characterize Femtosecond Laser Electronic Excitation Tagging (FLEET) in static low pressure (35 mTorr-760 Torr) conditions, and to measure the acoustic disturbance caused by the resulting filament as a function of tagging wavelength and energy. The FLEET line thickness as a function of pressure and delay is described by a simple diffusion model. Initial FLEET measurements in a Mach 8 flow show that gate times of ≥ 1µs can produce visible smearing of the FLEET emission and challenge the traditional Gaussian fitting methods used to find the line center. To minimize flow perturbations and uncertainty of the final line position, several recommendations are offered: using third harmonic FLEET at 267 nm for superior signal levels with lower energy deposition than both 800 nm and 400 nm FLEET, and short camera delays and exposure times to reduce fitting uncertainty. This guidance is implemented in a Mach 8 test condition and results are presented.

An experimental characterization of the flow environment for the Sandia Axisymmetric Transonic Hump is presented. This is an axisymmetric model with a circular hump tested at a transonic Mach number, similar to the classic Bachalo-Johnson configuration. The flow is turbulent approaching the hump and becomes locally supersonic at the apex. This leads to a shock-wave/boundary-layer interaction, an unsteady separation bubble, and flow reattachment downstream. The characterization focuses on the quantities required to set proper boundary conditions for computational efforts described in the companion paper, including: 1) stagnation and test section pressure and temperature; 2) turbulence intensity; and 3) tunnel wall boundary layer profiles. Model characterization upstream of the hump includes: 1) surface shear stress; and 2) boundary layer profiles. Note: Numerical values characterizing the experiment have been redacted from this version of the paper. Model geometry and boundary conditions will be withheld until the official start of the Validation Challenge, at which time a revised version of this paper will become available. Data surrounding the hump are considered final results and will be withheld until completion of the Validation Challenge.

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A new wind tunnel experiment is underway to provide a comprehensive CFD validation dataset of an unsteady, transonic flow. The experiment is based on the work of Bachalo and Johnson; an axisymmetric model with a spherical hump is tested at a transonic Mach number. The flow is turbulent approaching the hump and becomes locally supersonic at the apex. This leads to a shock-wave/boundary-layer interaction, an unsteady separation bubble, and flow reattachment downstream. A suite of diagnostics characterizes the flow: oil-flow surface visualization for shock and reattachment locations, particle image velocimetry for mean flow and turbulence properties, fast pressure-sensitive paint for model pressure distributions and unsteadiness, high-speed Schlieren for shock position and motion, and oil-film interferometry for surface shear stress. This will provide a new level of detail for validation studies; therefore, a blind comparison, or ‘CFD Challenge’ is proposed to the community. Participants are to be provided the geometry, incoming boundary layer, and boundary conditions, and are free to simulate with their method of choice and submit their results. A blind comparison will be made to the new experimental data, with the goal of evaluating the state of various CFD methods for use in unsteady, transonic flows.

Femtosecond Laser Electronic Excitation Tagging (FLEET) is used to measure velocity flowfields in the wake of a sharp 7◦ half-angle cone in nitrogen at Mach 8, over freestream Reynolds numbers from 4.3∗106 /m to 13.8∗106 /m. Flow tagging reveals expected wake features such as the separation shear layer and two-dimensional velocity components. Frequency-tripled FLEET has a longer lifetime and is more energy efficient by tenfold compared to 800 nm FLEET. Additionally, FLEET lines written with 267 nm are three times longer and 25% thinner than that written with 800 nm at a 1 µs delay. Two gated detection systems are compared. While the PIMAX 3 ICCD offers variable gating and fewer imaging artifacts than a LaVision IRO coupled to a Photron SA-Z, its slow readout speed renders it ineffective for capturing hypersonic velocity fluctuations. FLEET can be detected to 25 µs following excitation within 10 mm downstream of the model base, but delays greater than 4 µs have deteriorated signal-to-noise and line fit uncertainties greater than 10%. In a hypersonic nitrogen flow, exposures of just several hundred nanoseconds are long enough to produce saturated signals and/or increase the line thickness, thereby adding to measurement uncertainty. Velocity calculated between the first two delays offer the lowest uncertainty (less than 3% of the mean velocity).

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In this report, we investigate how manufacturing conditions result in the warpage of moderate density PMDI polyurethane foam (12-50 lb/ft 3 ) when they are released from a mold. We have developed a multiphysics modeling framework to simulate the manufacturing process including resin injection, foaming and mold filling, gelation of the matrix, elevated cure, vitrification, cool down, and demolding. We have implemented this framework within the Sierra Mechanics Finite Element Code Suite. We couple Aria for flow, energy conservation, and foaming/curing kinetics with Adagio for the nonlinear viscoelastic solid response in a multi-staged simulation process flow. We calibrate a model for the PMDI-10S (10 lb/ft 3 free rise foam) through a suite of characterization data presented here to calibrate the solid cure behavior of the foam. The model is then used and compared to a benchmark experiment, the manufacturing and warpage over 1 year of a 10 cm by 10 cm by 2.5 cm foam "staple'. This component features both slender and thick regions that warp considerably differently over time. Qualitative agreement between the model and the experiment is achieved but quantitative accuracy is not. 2

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Kinetic models have been developed to understand the manufacturing of polymeric foams, which evolve from low viscosity Newtonian liquids, to bubbly liquids, finally producing solid foam. Closed-form kinetics are formulated and parameterized for PMDI-10, a fast curing polyurethane, including polymerization and foaming. PMDI-10 is chemically blown, where water and isocyanate react to form carbon dioxide. The isocyanate reacts with polyol in a competing reaction, producing polymer. Our approach is unique, although it builds on our previous work and the polymerization literature. This kinetic model follows a simplified mathematical formalism that decouples foaming and curing, including an evolving glass transition temperature to represent vitrification. This approach is based on IR, DSC, and volume evolution data, where we observed that the isocyanate is always in excess and does not affect the kinetics. The kinetics are suitable for implementation into a computational fluid dynamics framework, which will be explored in subsequent articles. © 2017 American Institute of Chemical Engineers AIChE J, 63: 2945–2957, 2017.

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Physical property measurements including viscosity, density, thermal conductivity, and heat capacity of low-molecular weight polydimethylsiloxane (PDMS) fluids were measured over a wide temperature range (-50°C to 150°C when possible). Properties of blends of 1 cSt and 20 cSt PDMS fluids were also investigated. Uncertainties in the measurements are cited. These measurements will provide greater fidelity predictions of environmental sensing device behavior in hot and cold environments.

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Polyurethane is a complex multiphase material that evolves from a viscous liquid to a system of percolating bubbles, which are created via a CO2 generating reaction. The continuous phase polymerizes to a solid during the foaming process generating heat. Foams introduced into a mold increase their volume up to tenfold, and the dynamics of the expansion process may lead to voids and will produce gradients in density and degree of polymerization. These inhomogeneities can lead to structural stability issues upon aging. For instance, structural components in weapon systems have been shown to change shape as they age depending on their molding history, which can threaten critical tolerances. The purpose of this project is to develop a Cradle-to-Grave multiphysics model, which allows us to predict the material properties of foam from its birth through aging in the stockpile, where its dimensional stability is important.

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We are studying PMDI polyurethane with a fast catalyst, such that filling and polymerization occur simultaneously. The foam is over-packed to tw ice or more of its free rise density to reach the density of interest. Our approach is to co mbine model development closely with experiments to discover new physics, to parameterize models and to validate the models once they have been developed. The model must be able to repres ent the expansion, filling, curing, and final foam properties. PMDI is chemically blown foam, wh ere carbon dioxide is pr oduced via the reaction of water and isocyanate. The isocyanate also re acts with polyol in a competing reaction, which produces the polymer. A new kinetic model is developed and implemented, which follows a simplified mathematical formalism that decouple s these two reactions. The model predicts the polymerization reaction via condensation chemis try, where vitrification and glass transition temperature evolution must be included to correctly predict this quantity. The foam gas generation kinetics are determined by tracking the molar concentration of both water and carbon dioxide. Understanding the therma l history and loads on the foam due to exothermicity and oven heating is very important to the results, since the kinetics and ma terial properties are all very sensitive to temperature. The conservation eq uations, including the e quations of motion, an energy balance, and thr ee rate equations are solved via a stabilized finite element method. We assume generalized-Newtonian rheology that is dependent on the cure, gas fraction, and temperature. The conservation equations are comb ined with a level set method to determine the location of the free surface over time. Results from the model are compared to experimental flow visualization data and post-te st CT data for the density. Seve ral geometries are investigated including a mock encapsulation part, two configur ations of a mock stru ctural part, and a bar geometry to specifically test the density model. We have found that the model predicts both average density and filling profiles well. However, it under predicts density gradients, especially in the gravity direction. Thoughts on m odel improvements are also discussed.

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A study was undertaken to determine the viscosity of liquefied 20 lb/ft³ poly methylene diisocyanate (PMDI) foam and the stress required to puncture solid PMDI foam at elevated temperatures. For the rheological measurements the foam was a priori liquefied in a pressure vessel such that the volatiles were not lost in the liquefaction process. The viscosity of the liquefied PMDI foam was found to be Newtonian with a power law dependence on temperature log₁₀(μ/Pa s) = 20.6 – 9.5 log₁₀(T/°C) for temperatures below 170 °C. Above 170 °C, the viscosity was in the range of 0.3 Pa s which is close to the lower measurement limit (≈ 0.1 Pa s) of the pressurized rheometer. The mechanical pressure required to break through 20lb/ft³ foam was 500-800 psi at temperatures from room temperature up to 180 °C. The mechanical pressure required to break through 10 lb/ft³ was 170-300 psi at temperatures from room temperature up to 180 °C. We have not been able to cause gas to break through the 20 lb/ft³ PMDI foam at gas pressures up to 100 psi.

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We are developing computational models to elucidate the expansion and dynamic filling process of a polyurethane foam, PMDI. The polyurethane of interest is chemically blown, where carbon dioxide is produced via the reaction of water, the blowing agent, and isocyanate. The isocyanate also reacts with polyol in a competing reaction, which produces the polymer. Here we detail the experiments needed to populate a processing model and provide parameters for the model based on these experiments. The model entails solving the conservation equations, including the equations of motion, an energy balance, and two rate equations for the polymerization and foaming reactions, following a simplified mathematical formalism that decouples these two reactions. Parameters for the polymerization kinetics model are reported based on infrared spectrophotometry. Parameters describing the gas generating reaction are reported based on measurements of volume, temperature and pressure evolution with time. A foam rheology model is proposed and parameters determined through steady-shear and oscillatory tests. Heat of reaction and heat capacity are determined through differential scanning calorimetry. Thermal conductivity of the foam as a function of density is measured using a transient method based on the theory of the transient plane source technique. Finally, density variations of the resulting solid foam in several simple geometries are directly measured by sectioning and sampling mass, as well as through x-ray computed tomography. These density measurements will be useful for model validation once the complete model is implemented in an engineering code.

We show that it is possible to manufacture strong macroporous ceramic films that can be backfilled with electrolyte to form rigid separator pellets suitable for use in thermal batteries. Several new ceramic manufacturing processes are developed to produce sintered magnesium oxide foams with connected porosities of over 80% by volume and with sufficient strength to withstand the battery manufacturing steps. The effects of processing parameters are quantified, and methods to imbibe electrolyte into the ceramic scaffold demonstrated. Preliminary single cell battery testing show that some of our first generation pellets exhibit longer voltage life with comparable resistance at the critical early times to that exhibited by a traditional pressed pellets. Although more development work is needed to optimize the processes to create these rigid separator pellets, the results indicate the potential of such ceramic separator pellets to be equal, if not superior to, current pressed pellets. Furthermore, they could be a replacement for critical material that is no longer available, as well as improving battery separator strength, decreasing production costs, and leading to shorter battery stacks for long-life batteries.

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