ALBERT

Description: Fourteen years after completion of Ford's 39-foot space simulation chamber, leaks began to appear in its LN2 shroud. Although the shroud had been tight since its acceptance, cracks appeared in 1983 in some of the field welds of the one inch tubes which interconnect the LN2 panels. The resulting leaks were large enough to prevent pump down to high vacuum and could be heard easily when the chamber was at ambient conditions. New cracks appeared during each thermal cycle making it impossible to utilize the chamber for thermal vacuum testing. The analysis presented here implies that many, if not all, of the aluminum LN2 shrouds now in use may be in various stages of fatigue failure. The probability is high that fatigue cracks are working through the aluminum tubing in heat-affected zones of some field welds. The cracks may not be apparent yet, but after the shroud has experienced a certain number of thermal cycles these cracks will work through the material and become serious leaks. Fortunately, appropriate planning, analysis, and checking can, with a relatively small expenditure of money, help to avoid large and unexpected shroud failures and keep the chamber operational as long as it is needed.

Description: The sources of degradation of in state of the art and newly developed components and testing the usefulness of the concept of storing experiment samples in dry nitrogen under launch and space vacuum conditions during reentry mission phase were investigated. Ultraviolet (UV) and extreme ultraviolet (EUV) experiments suffer degradations during space missions of even 1 month duration. It is suggested that the degradation is due to condensation of outgassing products, followed by solar induced polymerization, however, penetrating charged particles are also known to produce volume effects. Degradation may also start immediately after manufacturing of the component due to oxidation, moisture, or chemical corrosion by atmospheric constituents such as CO2 and SO2. When the filters are used as windows for gas absorption cells or gas filters, or when they define the instrumental bandwidth by themselves. The effects of mechanical degradation by thermal cycling and/or dust may cause a dramatic impact.

Description: The present understanding of the mechanisms responsible for macrosegregation occurring in ingots produced by electroslag remelting (ESR), vacuum arc remelting (VAR), direct chill (DC), and continuous casting is reviewed. A detailed description is given of laboratory experiments on model Sn-Pb and Al-Cu alloys. The experimental findings are compared with theoretical predictions. Data are also presented on a high-temperature Ni-27 wt % Mo alloy ESR ingot and 2000 series aluminum alloy DC ingots. Comparison is made to theoretical predictions where appropriate.

Description: A theoretical model of the semicontinuous DC casting method is developed to predict the positive segregation observed at the subsurface and the negative segregation commonly found at the center of large commercial-size aluminum alloy ingot. Qualitative analysis of commercial-size aluminum alloy semicontinuous cast direct chill (DC) ingot is carried out. In the analysis, both positive segregation in the ingot subsurface and negative segregation at the center of the ingot are examined. Ingot subsurface macrosegregation is investigated by considering steady state casting of a circular cross-section binary alloy ingot. Nonequilibrium solidification is assumed with no solid diffusion, constant equilibrium partition ratio, and constant solid density.

Description: The use of induced flow as a means to control solidification structures in strand cast steel is investigated. The quality problems in strand cast steel stemming from columnar growth can be partially controlled, by Electro Magnetic Stirring (EMS). Induced flow changes the normal morphology of dendrites. Solids grown under intense stirring conditions show both negative and positive segregation which is considered unacceptable by some steel producers. The inclusion size and population is strongly affected by induced flow (EMS). Laboratory and industrial data show substantial reduction in inclusion size and content, but the overall effect of flow on inclusions is affected by the particular type of flow patterns utilized in each case. Productivity and quality are raised substantially in steel strand casting by utilizing EMS.

Description: During the directional solidification of alloys, solute inhomogeneities transverse to the growth direction arise due to morphological instabilities (leading to cellular or dendritic growth) and/or due to convection in the melt. In the absence of convection, the conditions for the onset of morphological instability are given by the linear stability analysis of Mullins and Sekerka. For ordinary solidification rates, the predictions of linear stability analysis are similar to the constitutional supercooling criterion. However, at very rapid solidification rates, linear stability analysis predicts a vast increase in stabilization in comparison to constitutional supercooling.

Description: Aspects of macrosegregation theory, such as dendrite arm spacing, pool profile and mushy zone depth are beneficial to developing consumable melting process for Ion Nickel IN-718, Electro-Slag Refining, especially ESR. Aspects of microsegregation theory, such as correlation of dendrite arm spacing with heat transfer mechanisms and local solidification time, are used to minimize remnant dendritism in both ESR and Vacuum Arc Remelting VAR IN-718. Specifically, ESR IN-718 must be optimized by developing practices which maximize ingot cooling rate and minimize the steepness of the solidus and liquidus isotherms. The knowledge concerning macrosegregation in consumable melted IN-718 is in the form of correlations. Since the isotherm steepness is undoubtedly involved, investigations which include a microgravity environment might separate microsegregation effects from macrosegregation effects. Accounting for the effects of gravity and density differences between the metal pool and the interdendritic fluid, in combination with the pool and mushy zone profiles, can lead to improved melting solidification practices for IN-718, and allow prediction of macrosegregation tendency to be incorporated into high temperature alloy design.

Description: The properties and casting behavior of metals are significantly affected by their cast structure. This structure is optimized by producing columnar versus equiaxed grains and coarse versus fine grains by controlling solidification conditions. The transition from columnar to equiaxed grains is favored by: constitutional supercooling with effective nucleation of free dendrites; melting off and transport of dendrite tips and arms; mechanical vibration; falling down of free dendrites from a chilled top surface; and induced flow in the solidifying structure by oscillation of rotation.

Description: Significant progress was achieved when it was realized that porosity could be analyzed successfully by considering not only heat flow, but also fluid flow within the solidifying casting. Sound castings may be produced by lowering pressure during melting (to allow dissolved gas to escape the melt) and increasing pressure during solidification (to force liquid metal into the mushy zone to feed shrinkage). Such techniques are especially effective if they are combined with chilling of parts of the casting to produce progressive solidification, which shortens the mushy zone and, hence, the distance that metal must travel to feed porosity.

Description: The problems of shrinkage and gas porosity are discussed. Gravity forces enhance the removal of gas bubbles from a metal melt and contribute to the feeding of shrinkage porosity in castings. Experiments are reviewed which determine how large a density difference is required for metal particles to float or sink in a metal melt and to what extent do factors not considered in Stokes Law influence particle movement in a real system. As to the interaction of particles with an advancing solid-liquid interface, the results indicate that the metal particles are not rejected in a metal melt, and that concentrations of particles in a metal following solidification are due to other factors.

Description: The main focus is on solidification occurring in highly supercooled melts. Solidification rates in such melts are extremely high, an attractive feature from a commercial standpoint. Thus, the reported growth velocities for pure Ni and Co dendrites at a supercooling of 175 K are in excess of 180 km/hr. Rapidly quenched crystalline alloys produced by various atomization processes (e.g., centrifugal atomization or inert gas atomization) or melt spinning are examples of solidification processes, currently being intensively explored commercially, wherein extremely high solidification rates are achieved. Estimated dendrite tip growth rates are about 2 km/hr in a binary Al-4.5 wt % alloy, with a heat transfer coefficient of 6.4x10 sub 5 w/sq cm K or 15 cal/cu cm sK. In the limit, when the solidification rate exceeds a critical value, a glassy microstructure is obtained even in highly alloyed melts, which under normal conditions would solidity to form one or more crystalline phases. Glassy metals, also called metallic glasses, are candidate materials for distribution transformers because of their very low energy losses and are also being used in brazing and soldering applications.

Description: Bulk undercooling methods and procedures will first be reviewed. Measurement of various parameters which are necessary to understand the solidification mechanism during and after recalescence will be discussed. During recalescence of levitated, glass-encased large droplets (5 to 8 mm diam) high speed temperature sensing devices coupled with a rapid response oscilloscope are now being used at MIT to measure local thermal behavior in hypoeutectic and eutectic binary Ni-Sn alloys. Dendrite tip velocities were measured by various investigators using thermal sensors or high speed cinematography. The confirmation of the validity of solidification models of bulk-undercooled melts is made difficult by the fineness of the final microstructure, the ultra-rapid evolution of the solidifying system which makes measurements very awkward, and the continuous modification of the microstructure which formed during recalescence because of precipitation, remelting and rapid coarsening.

Description: The formation by melt quenching of such metastable structures as glassy or microcrystalline solids and highly supersaturated solutions is made possible by the extreme resistance of most melts to homophase crystal nucleation at deep undercooling. This nucleation resistance contrasts sharply with the very low kinetic resistance to the movement of crystal-melt interfaces, once formed, in metals and other fluid systems at even minute undercooling. The methods of nucleation study which have proven especially effective in bypassing nucleation by heterophase impurities thereby exposing the high resistance of melts to homophase nucleation may be summarized as follows: observation of the crystallization behavior of dispersed small droplets; drop tube experiments in which liquid drops solidify, under containerless conditions, during their fall in the tube; and observation of the crystallization of bulk specimens immersed in fluxes chosen to dissolve or otherwise deactivate (e.g., by wetting) heterophase nucleants. This method has proven to be remarkably effective in deactivating such nucleants in certain pure metals.

Description: An ongoing research program aims to characterize the solidification of several Ni- and Co-based commercial wrought type alloys. The techniques used and the data items sought are: (1) thermal analysis, liquidus, nonequilibrium solidus as a function of cooling rate, secondary reactions temperatures, incipient melting, progress of solidification as a function of temperature; (2) optical metallography, characteristic structures and secondary dendrite arm spacing as a function of cooling rate; (3) X-ray diffraction, identification of precipitates; and (4) SEM/EDAX, measure of microsegregation.

Description: The importance of understanding and modeling the unsteady flow phenomena in turbomachinery is discussed. Historical events in the application and development of gas turbines for aircraft propulsion are traced. Technology advancements over the years are highlighted with focus on the compression system components. Trends in compressor research within the National Advisory Committee for Aeronautics (NACA)/National Aeronautics and Space Administration (NASA) are noted. The impact of technology advancements on the increased occurrences of unsteady flow related problems in advanced engine development programs is discussed. The impact of the new and more demanding requirements being imposed on the propulsion system to meet advanced aircraft mission needs are also noted. Brief discussions on the present day understanding and modeling capability of the unsteady flow phenomena are presented to include discussions on rotating stall, surge, flutter, forced response and noise generation.

Description: The objective is to verify the capability of a cascade variable conductance heat pipe (CVCHP) system to provide precise temperature control of long life spacecraft without the need for a feedback heater or other power sources for temperature adjustment under conditions of widely varying power input and ambient environment. Solar energy is the heat source and space the heat sink for thermally loading two series connected variable conductance heat pipes. Electronics and power supply equipment requirements are minimal. A 7.5 V lithium battery supplies the power for thermistor type temperature sensors for monitoring system performance, and a 28 V lithium battery supplies power for valve actuation.

Description: The objective of this experiment is to evaluate the zero-g performance of a number of transverse flat plate heat pipe modules. Performance will include the transport capability of the pipes, the temperature drop, and the ability to maintain temperature over varying duty cycles and environments. Additionally, performance degradation, if any, will be monitored over the length of the Long Duration Exposure Facility (LDEF) mission. This information is necessary if heat pipes are to be considered for system designs where they offer benefits not available with other thermal control techniques.

Description: The principal objectives of the experiment are to determine zero-g start-up performance for conventional and diode low temperature heat pipes, to evaluate heat pipe performance in zero-g for an extended period of time, to determine zero-g transport capability of each heat pipe, and to determine diode operation, including forward conductance, turndown ratio, and transient behavior. Two heat pipes, a fixed conductance transporter heat pipe and a thermal diode heat pipe, are coupled with a radiant cooler system. Both pipes are charged with ethane. Also integrated with the radiator is a phase change material (PCM) canister which provides temperature stability during transport tests. N-heptane, which has a melting/freezing point of 182 K, is used as the PCM. The high heat capacity (28 W-hr of latent heat) provided by the canister permits high power heat pipe testing at constant temperature.

Description: In the space vacuum environment, the spacecraft mechanisms are liable to sustain damaging effects from microwelds due to molecular diffusion of the spacecraft constituent metals. Such microwelds result in a continuing increase in the friction factors and are even liable to jam the mechanisms altogether. The object of this experiment is to check the metal surfaces representative of the mechanism constituent metals (treated or untreated, lubricated or unlubricated) for microwelds afater an extended stay in the space environment. The experimental approach is to passively expose inert metal specimens to the space vacuum and to conduct end-of-mission verification of the significance of microwelds between various pairs of metal washers. The experiment will be located in one of the FRECOPA boxes in a 12-in. -deep peripheral tray that contains nine other experiments from France.

Description: Numerical experiments are used to study thermally driven flows which occur during vertical Bridgman crystal growth of a single component fluid. The solid-liquid interface was specified as parabolic and flow patterns were calculated for various insulation thicknesses, Grashof, Prandtl, and Biot numbers. When the melt is on top and the gravity vector is axially downward it is shown that flow persists as long as a radial temperature gradient is present. If the interface is convex, as viewed from the liquid, a single cell is observed. A concave interface exhibits multiple counterrotating cells. The insulation thickness and Grashof, Prandtl, and Biot numbers influence the flow in a quantitative manner.

Description: The stability of the parallel flow between a vertical crystal-melt interface and a vertical wall held at a temperature above the melting point of the crystal is analyzed for Prandtl numbers, P, ranging from 0.01 to 100. Three modes of instability occur: (1) a buoyant mode, (2) a shear mode, and (3) a coupled crystal-melt mode. The buoyant and shear modes are similar to those that occur for flow between two vertical rigid walls held at different temperatures. For Prandtl numbers greater than approximately two, the coupled crystal-melt mode occurs at a lower Grashof number than the other two modes. Specific results are given for succinonitrile (P = 22.8) and lead (P = 0.0225). These calculations and similar calculations for a cylindrical geometry were motivated by and are in general agreement with recent experiments on succinonitrile.

Description: The solid-liquid interface position and the temperature gradients in both the solid and liquid at the interface have been studied in a modified Bridgman-Stockbarger crystal growth furnace. These crystal growth factors have been studied as a function of ampoule translation rate, materials properties, and the size and temperature of a small auxiliary heater placed at the edge of the furnace hot zone. It has been found that the interface position with respect to a furnace reference point is essentially constant during a run for a low thermal conductivity material whereas the interface position changes continuously during a run with high thermal conductivity material. However, the ampoule translation rate and auxiliary heater conditions produce interface position changes in both high and low thermal conductivity materials.

Description: The motion of two and four rectilinear vortices inside a cylindrical pipe is studied under the restriction that the total circulation be zero. In the two-vortex case, it is shown that the motion is always periodic and an expression for the period is derived. In the four-vortex case, the motion is determined not to be periodic in general. However, a class of solutions where the motion is periodic is found. Several sample calculations of the vortex motion are included.

Description: Some turbulent solutions of the unaveraged Navier-Stokes equations (equations of fluid motion) are reviewed. Those equations are solved numerically in order to study the nonlinear physics of incompressible turbulent flow. Initial three-dimensional cosine velocity fluctuations and periodic boundary conditions are used in most of the work considered. The three components of the mean-square velocity fluctuations are initially equal for the conditions chosen. The resulting solutions show characteristics of turbulence such as the linear and nonlinear excitation of small-scale fluctuations. For the stronger fluctuations, the initially nonrandom flow develops into an apparently random turbulence. Thus randomness or turbulence can arise as a consequence of the structure of the Navier-Stokes equations. The cases considered include turbulence which is statistically homogeneous or inhomogeneous and isotropic or anisotropic. A mean shear is present in some cases. A statistically steady-state turbulence is obtained by using a spatially periodic body force. Various turbulence processes, including the transfer of energy between eddy sizes and between directional components, and the production, dissipation, and spatial diffusion of turbulence, are considered. It is concluded that the physical processes occurring in turbulence can be profitably studied numerically.

Description: An experiment was conducted to measure the heat transfer from a heated cylinder in crossflow in an array of circular cylinders. All cylinders had a length-to-diameter ratio of 3.0. Both in-line and staggered array patterns were studied. The cylinders were spaced 2.67 diameters apart center-to-center in both the axial and transverse directions to the flow. The row containing the heated cylinder remained in a fixed position in the channel and the relative location of this row within the array was changed by adding up to five upstream rows. The working fluid was nitrogen gas at pressures from 100 to 600 kPa. The Reynolds number range based on cylinder diameter and average unobstructed channel velocity was from 5,000 to 125,000. Turbulence intensity profiles were measured for each case at a point one half space upstream of the row containing the heated cylinder. The basis of comparison for all the heat transfer data was the single row with the heated cylinder. For the in-line cases the addition of a single row of cylinders upstream of the row containing the heated cylinder increased the heat transfer by an average of 50 percent above the base case. Adding up to five more rows caused no increase or decrease in heat transfer. Adding rows in the staggered array cases resulted in average increases in heat transfer of 21, 64, 58, 46, and 46 percent for one to five upstream rows, respectively. Previously announced in STAR as N82-19493

Description: The microstructures of commercial VIM-cast and rheocast (Apelian and Cheng, 1983) IN-100 superalloy are investigated optically and by two-stage replica TEM, with an emphasis on the nature of the gamma-prime (GP) precipitates. Photomicrographs at magnifications of 39, 390, 2145, and 6630 are presented and discussed. VIM-cast IN-100 has dendritic structure, 10-20-micron primary GP particles, and uniformly distributed cuboid GP precipitates of a uniform size (about 0.5 micron). Rheocast IN-100 (stirred 20 min at 350 rpm, 1291 C, and 0.0006 torr) has a nondendritic structure, 20-100-micron primary GP particles, and a smaller volume fraction of cuboid GP precipitates with a bimodal (either 1-1.5 microns or less than 0.5 micron) size distribution. Such distribution should increase fatigue-crack-nucleation resistance.

Description: Sliding friction experiments, X-ray photoelectron spectroscopy (XPS) analysis, and electron microscopy and diffraction studies were conducted with ferrous base metallic glasses (amorphous alloys) in contact with aluminium oxide at temperatures to 750 C in a vacuum. Sliding friction experiments were also conducted in argon and air atmospheres. The results of the investigation indicate that the coefficient of friction increases with increasing temperature to 350 C in vacuum. The increase in friction is due to an increase in adhesion resulting from surface segregation of boric oxide and/or silicon oxide to the surface of the foil. Above 500 C the coefficient of friction decreased rapidly. The decrease correlates with the segregation of boron nitride to the surface. Contaminants can come from the bulk of the material to the surface upon heating and impart boric oxide and/or silicon oxide at 350 C and boron nitride above 500 C. The segregation of contaminants is responsible for the friction behavior. The amorphous alloys have superior wear resistance to crystalline 304 stainless steel. The relative concentrations of the various constituents at the surfaces of the amorphous alloys are very different from the nominal bulk compositions.

Description: The effects of mass injection and pressure gradients on the drag of surfaces were studied theoretically with the aid of boundary-layer and Navier-Stokes codes. The present investigation is concerned with the effects of spatially varying the injection in the case of flat-plate drag. Effects of suction and injection on wavy wall surfaces are also explored. Calculations were performed for 1.2 m long surfaces, one flat and the other sinusoidal with a wavelength of 30.5 cm. Attention is given to the study of the effect of various spatial blowing variations on flat-plate skin friction reduction, local skin friction coefficient calculated by finite difference boundary-layer code and Navier-Stokes code, and the effect of phase-shifting sinusoidal mass transfer on the drag of a sinusoidal surface.

Description: The numerical aspects of simulation unsteady flows which arise in turbomachinery are addressed. In particular the simulation of rotating stall and surge is discussed.

Description: It is pointed out that environment-assisted subcritical crack growth in high-strength steels and other high-strength alloys (particularly in hydrogen and in hydrogenous environments) is an important technological problem of long standing. This problem is directly related to issues of structural integrity, durability, and reliability. The terms 'hydrogen embrittlement' and 'stress corrosion cracking' have been employed to describe the considered phenomenon. This paper provides a summary of contributions made during the past ten years toward the understanding of environmentally assisted crack growth. The processes involved in crack growth are examined, and details regarding crack growth and chemical reactions are discussed, taking into account crack growth in steels exposed to water/water vapor, the effect of hydrogen, reactions involving hydrogen sulfide, and aspects of fracture surface morphology and composition. Attention is also given to the modeling of crack growth response, crack growth in gas mixtures, and the interaction of solute atoms with the crack-tip stress field.

Description: The effects of water vapor on fatigue crack growth in 7475-T651 aluminum alloy plate at frequencies of 1 Hz and 10 Hz were investigated. Twenty-five mm thick compact specimens were subjected to constant amplitude fatigue testing at a load ratio of 0.2. Fatigue crack growth rates were calculated from effective crack lengths determined using a compliance method. Tests were conducted in hard vacuum and at water vapor partial pressures ranging from 94 Pa to 3.8 kPa. Fatigue crack growth rates were frequency insensitive under all environment conditions tested. For constant stress intensity factor ranges crack growth rate transitions occurred at low and high water vapor pressures. Crack growth rates at intermediate pressures were relatively constant and showed reasonable agreement with published data for two Al-Cu-Mg alloys. The existence of two crack growth rate transitions suggests either a change in rate controlling kinetics or a change in corrosion fatigue mechanism as a function of water vapor pressure. Reduced residual deformation and transverse cracking specimens tested in water vapor versus vacuum may be evidence of embrittlement within the plastic zone due to environmental interaction.

Description: Since the pioneer work of Brown (1966), precracked specimens and related fracture mechanics analyses have been extensively used to study stress corrosion cracking. Certain questions arose in connection with initial attempts to prepare standardized recommended practices by ASTM Committee G-1 on Corrosion of Metals. These questions were related to adequacy of test control as it pertains to acceptable limits of variability, and to validity of expressions for stress intensity and crack-surface displacements for both specimen configurations. An interlaboratory test program, was, therefore, planned with the objective to examine the validity of KIscc testing for selected specimen configurations, materials,and environmental systems. The results reported in the present paper include details of a single laboratory test program. The program was conducted to determine if the threshold value of stress intensity for onset and arrest of stress corrosion cracking was independent for the two specimen configurations examined.

Description: Sodium-sulfate-induced hot corrosion of preoxidized IN-738 was studied at 975 C with special emphasis placed on the processes occurring during the long induction period. Thermogravimetric tests were run for predetermined periods of time, and then one set of specimens was washed with water. Chemical analysis of the wash solutions yielded information about water soluble metal salts and residual sulfate. A second set of samples was cross sectioned dry and polished in a nonaqueous medium. Element distributions within the oxide scale were obtained from electron microprobe X-ray micrographs. Evolution of SO was monitored throughout the thermogravimetric tests. Kinetic rate studies were performed for several pertinent processes; appropriate rate constants were obtained from the following chemical reactions; Cr203 + 2 Na2S04(1) + 3/2 02 yields 2 Na2Cr04(1) + 2 S03(g)n TiO2 + Na2S04(1) yields Na20(T102)n + 503(g)n T102 + Na2Cro4(1) yields Na2(T102)n + Cr03(g).

Description: Experimental results are presented from a study of the effects of precracked specimen configuration and initial starting stress intensity on crack growth rate and threshold stress intensity, for both onset of cracking and crack arrest. Attention is given to AISI 4340 steel in a 3.5-percent NaCl solution, for configurations of a single edge-cracked specimen tested in cantilever bending under constant load, and a modified compact specimen bolt loaded to a constant deflection. The threshold stress intensity value determined was independent of specimen configuration, if the stress intensity value associated with the compact specimen is taken where the discontinuous break occurs in the velocity-stress intensity curve.

Description: A numerical algorithm that is second-order accurate in time has been developed for the conjugated problem of a separated, compressible flow field and a conductive solid body. The full two-dimensional time-dependent Navier-Stokes equations are coupled with the time-dependent energy equation for the solid body and are solved simultaneously. using implicit algorithms. The energy equation for the solid body may include arbitrarily distributed heat sources. The algorithm has been exmined for the case of two-dimensional supersonic compression-corner interaction, with a heat source embedded in the wall in the vicinity of the separation bubble and the attached boundary layer. The effect of the heat source on the flow field is studied for steady and transient cases.

Description: A power-law relationship between the average erosion rate and cumulative erosion is presented. Data analyses from Venturi, magnetostriction, and liquid-impingement devices conform to this unified relation. A normalization technique is also suggested for prediction purposes.

Description: The coil planet centrifuge designed by Ito employs flow of a single liquid phase, through a rotating coiled tube in a centrifugal force field, to provide a separation of particles based on sedimentation rates. Mathematical solutions are derived for the linear differential equations governing particle behavior in the coil planet centrifuge device. These solutions are then applied as the basis of a model for optimizing particle separations.

Description: For the past 25 years, there has existed in the Thermosciences Laboratory of the Mechanical Engineering Department of Stanford University a research program, primarily experimental, concerned with heat transfer through turbulent boundary layers. In the early phases of the program, the topics considered were the simple zero-pressure-gradient turbulent boundary layer with constant and with varying surface temperature, and the accelerated boundary layer. Later equilibrium boundary layers were considered along with factors affecting the boundary layer, taking into account transpired flows, flows with axial pressure gradients, transpiration, acceleration, deceleration, roughness, full-coverage film cooling, surface curvature, free convection, and mixed convection. A description is provided of the apparatus and techniques used, giving attention to the smooth plate rig, the rough plate rig, the full-coverage film cooling rig, the curvature rig, the concave wall rig, the mixed convection tunnel, and aspects of data reduction and uncertainty analysis.

Description: Friction and wear tests were conducted with 3.2- and 6.4-millimeter-diameter aluminum oxide spheres sliding, in reciprocating motion, on a Fe67Co18B14Si1 metallic foil. Crystallites with a size range of 10 to 150 nanometers were produced on the wear surface of the amorphous alloy. A strong interaction between transition metals and metalloids such as silicon and boron results in strong segregation during repeated sliding, provides preferential transition metal-metalloid clustering in the amorphous alloy, and subsequently produces the diffused honeycomb structure formed by dark grey bands and primary crystals, that is, alpha-Fe in the matrix. Large plastic flow occurs on an amorphous alloy surface with sliding and the flow film of the alloy transfers to the aluminum oxide pin surface. Multiple slip bands due to shear deformation are observed on the side of the wear track. Two distinct types of wear debris were observed as a result of sliding: an alloy wear debris, and/or powdery-whiskery oxide debris.

Description: The current investigation has the objective to provide data which will make it possible to obtain a better estimate regarding the roughness drag for surface waviness. The data employed for this investigation were acquired in connection with a wavy wall study which was conducted as part of an overall program to reduce the skin friction of turbulent boundary layers in external flows. The results of the present investigation show that the low-speed roughness drag of small-amplitude sinusoidal wave trains having wavelengths of the order of the boundary-layer thickness is not only a function of h/lambda (h = total wave height, lambda = wavelength), but, in addition, is also a function of the roughness Reynolds number.

Description: Tensile properties of a directionally solidified (DS) eutectic alloy of the nominal composition Ni-33 Mo-5.7 Al (weight percent) have been investigated both at room temperature and elevated temperatures. The microstructure-mechanical property relationship has been studied for the alloy both in the as-DS and heat-treated conditions. Changes in the yield strength, the work hardening behavior, and the fracture morphology have been explained in terms of the microstructural changes due to the heat treatment. The yield drops observed have been attributed to the microdebonding due to the possible segregation of impurities at the fiber-matrix interface, and partly to the strain aging. The deformation mechanism has been identified to be the cutting of gamma prime particles.

Description: Experimental investigations have been conducted to determine the early stages of cavitation attack on 6061-T6 aluminum alloy, electrolytic tough pitch copper, brass, and bronze, all having polycrystalline fcc matrices. The surface profiles and scanning electron micrographs show that the pits are initially formed at the grain boundaries, while the grain surfaces are progressively roughened by multiple slip and twinning. The initial erosion is noted to have occurred from the material in the grain boundaries, as well as by fragmentation of part of the grains. Further erosion occurred by shearing and necking of the surface undulations caused by plastic deformation. The mean penetration depth, computed on the basis of mass loss, was lowest on the bronze and greatest on the copper. Attention is given to the relation of cavitation attack to grain size, glide stress and stacking fault energy.

Description: The compressive flow strength-strain rate behavior of the oxide-dispersion-strengthened alloy MA 6000E has been studied in the temperature range 1144-1366 K, with strain rates ranging from 2.1 x 10 to the -5th to 2.1 x 10 to the -7th per s. It is found that the inherent strength of the alloy is essentially the same in all test directions and that the low strength observed in tensile tests results from the inability of grain boundaries to support high tensile stresses. The failure of MA 6000E under high-temperature, slow plastic flow conditions is shown to be the result of concentrated slip. Slow plastic deformation in MA 6000E can be described by a threshold stress model of creep where threshold stresses are calculated from relatively fast testing procedures and the effective stress exponent for creep is assumed to be 3.5.

Description: Galerkin finite-element approximations are combined with computer-implemented perturbation methods for tracking families of solutions to calculate the steady axisymmetric flows in a differentially rotated cylindrical drop as a function of Reynolds number Re, drop aspect ratio and the rotation ratio between the two end disks. The flows for Reynolds numbers below 100 are primarily viscous and reasonably described by an asymptotic analysis. When the disks are exactly counter-rotated, multiple steady flows are calculated that bifurcate to higher values of Re from the expected solution with two identical secondary cells stacked symmetrically about the axial midplane. The new flows have two cells of different size and are stable beyond the critical value Re sub c. The slope of the locus of Re sub c for drops with aspect ratio up to 3 disagrees with the result for two disks of infinite radius computed assuming the similarity form of the velocity field. Changing the rotation ratio for exact counter-rotation ruptures the junction of the multiple flow fields into two separated flow families.

Description: A new system of approximation equations is derived for three-dimensional steady viscous compressible flows in which a primary-flow direction is present, but in which both transverse velocity components can be large. Previous approaches which address simplification of the steady Navier-Stokes equations are discussed, and a new approach is proposed. The transverse velocity vector which corrects a given potential flow has been decomposed into potential and rotational components. It is found that the potential-velocity vector may be assumed small, whereas the rotational-velocity vector may be assumed small, whereas the rotational velocity vector and hence the composite secondary flow can be of order unity. This assumption leads to a system of governing equations whose characteristic polynomial has a non-elliptic form for arbitrary Mach numbers. The resulting non-elliptic approximation equations can be solved as an initial/boundary-value problem. Computed results confirm the small scalar-potential approximation.

Description: Thermal barrier coatings, consisting of a plasma sprayed calcium silicate ceramic layer and a CoCrAlY or NiCrAlY bond coat, were applied on B-1900 coupons and cycled hourly in air in a rapid-response furnace to maximum temperatures of 1030, 1100, or 1160 C. Eight specimens were tested for each of the six conditions of bond-coat composition and temperature. Specimens were removed from test at the onset of failure, which was taken to be the formation of a fine surface crack visible at 10X magnification. Specimens were weighed periodically, and plots of weight gain vs time indicate that weight is gained at a parabolic rate after an initial period where weight was gained at a much greater rate. The high initial oxidation rate is thought to arise from the initially high surface area in the porous bond coat. Specimen life (time to first crack) was found to be a strong function of temperature. However, while test lives varied greatly with time, the weight gain at the time of specimen failure was quite insensitive to temperature. This indicates that there is a critical weight gain at which the coating fails when subjected to this test.

Description: Impulsive versus steady jet impingement of spherical glass bead particles on metal surfaces was studied using a gas gun facility and a commercial sand blasting apparatus. Crushed glass particles were also used in the sand blasting apparatus as well as glass beads. Comparisons of the different types of erosion patterns were made. Scanning electron microscopy, surface profilometry and energy dispersive X-ray spectroscopy analysis were used to characterize erosion patterns. The nature of the wear can be divided into cutting and deformation, each with its own characteristic features. Surface chemistry analysis indicates the possiblity of complex chemical and/or mechanical interactions between erodants and target materials.

Description: A cooled porous insert in a curved wall has a specified spatially varying heat flux applied to one side. It is desired to control the distribution of coolant flow out through this curved surface so that the surface will be kept at a desired uniform temperature. The flow regulation is accomplished by shaping the surface through which the coolant enters the region to obtain the required variation of flow resistance within the region. The proper surface shape is found by solving a Cauchy boundary value problem. Analytical solutions are given in two dimensions for various shapes of the heated boundary subjected to different heating distributions.

Description: Galerkin finite-element approximations and Newton's method for solving free boundary problems are combined with computer-implemented techniques from nonlinear perturbation analysis to study solidification problems with natural convection in the melt. The Newton method gives rapid convergence to steady state velocity, temperature and pressure fields and melt-solid interface shapes, and forms the basis for algebraic methods for detecting multiple steady flows and assessing their stability. The power of this combination is demonstrated for a two-phase Rayleigh-Benard problem composed of melt and solid in a veritical cylinder with the thermal boundary conditions arranged so that a static melt with a flat melt-solid interface is always a solution. Multiple cellular flows bifurcating from the static state are detected and followed as Rayleigh number is varied. Changing the boundary conditions to approach those appropriate for the vertical Bridgman solidification system causes imperfections that eliminate the static state. The flow structure in the Bridgman system is related to those for the Rayleigh-Benard system by a continuous evolution of the boundary conditions.

Description: Computational models of turbulence in incompressible Newtonian fluids governed by the Navier-Stokes equations are reviewed. The governing equations are presented, and both direct and large-eddy-simulations are examined. Resolution requirements and numerical techniques of spatial representation, definition of initial and boundary conditions, and time advancement are considered. Results of simulations of homogeneous turbulence in uniform shear, the evolution of a turbulent mixing layer, and turbulent channel flow are presented graphically and discussed.

Description: The possibility of undercooling Ni-Al alloys below the liquidus in order to produce a single phase peritectic structure by containerless drop tube solidification was studied. Containerless process is a technique for both high purity contamination free studies as well as for investigating the undercooling and rapid solidification of alloys by suppression of heterogeneous nucleation on container walls. In order to achieve large undercoolings one must avoid heterogeneous nucleation of crystallization. It was shown that the Marshall Space Flight Center drop tubes ae unique facilities for containerless solidification experiments and large undercoolings are possible with some alloys. The original goal of undercooling the liquid metal well below the liquidus to the peritectic temperature during containerless free to form primarily NiAl3 was achieved. The microstructures were interesting from another point of view. The microstructure from small diameter samples is greatly refined. Small dendrite arm spacings such as these could greatly facilitate the annealing and solid state transformation of the alloy to nearly 10% NiAl3 by reducing the distance over which diffusion needs to occur. This could minimize annealing time and might make it economically feasible to produce NiAl3 alloy.

Description: Alloys solidified in a low-gravity environment can, due to the elimination of sedimentation and convection, form unique and often desirable microstructures. One method of studying the effects of low-gravity (low-g) on alloy solidification was the use of the NASA KC-135 aircraft flying repetitive low-g maneuvers. Each maneuver gives from 20 to 30 seconds of low-g which is between about 0.1 and 0.001 gravity. A directional solidification furnace was used to study the behavior of off eutectic composition case irons in a low-g environment. The solidification interface of hypereutectic flake and spheroidal graphite case irons was slowly advanced through a rod sample, 5 mm in diameter. Controlled solidification was continued through a number of aircraft parabolas. The known solidification rate of the sample was then correlated with accelerometer data to determine the gravity level during solidification for any location of the sample. The thermal gradient and solidification rate were controlled independently. Samples run on the KC-135 aircraft exhibited bands of coarser graphite or of larger nodules usually corresponding to the regions solidified under low-g. Samples containing high phosphorous (used in order to determine the eutectic cell) exhibited larger eutectic cells in the low-g zone, followed by a band of coarser graphite.

Description: The structural materials and potential failure modes for high technology aircraft gas turbine bearings are reviewed. Among the failure modes discussed for iron-base through-hardened bearing materials are fatigue, surface distress, and corrosion. It is shown that the sub-surface initiated rolling-contact fatigue failure mode is reasonably well understood and in most cases can be controlled by proper material selection and design. Current bearing materials provide long life and high reliability in existing applications. A new generation of materials are being developed which will provide improved fracture toughness, better corrosion resistance, and a further extension of bearing fatigue life. Bearing problems due to surface distress, caused by a variety of surface and near surface anomalies, are less well understood. This area will require the implementation of an interdisciplinary effort to improve the level of understanding of metallic surface-lubricant reactions and interactions.

Description: The strength of the interface between metals and aluminum oxide is an important factor in the successful operation of devices found throughout modern technology. One finds the interface in machine tools, jet engines, and microelectronic integrated circuits. The strength of the interface, however, should be strong or weak depending on the application. The diverse technological demands have led to some general ideas concerning the origin of the interfacial strength, and have stimulated fundamental research on the problem. Present status of our understanding of the source of the strength of the metal - aluminum oxide interface in terms of interatomic bonds are reviewed. Some future directions for research are suggested.

Description: Although metallic adhesion has played a central part in much tribological speculation, few quantitative theoretical calculations are available. This is in part because of the difficulties involved in such calculations and in part because the theoretical physics community is not particularly involved with tribology. The calculations currently involved in metallic adhesion are summarized and shown that these can be generalized into a scaled universal relationship. Relationships exist to other types of covalent bonding, such as cohesive, chemisorptive, and molecular bonding. A simple relationship between surface energy and cohesive energy is offered.

Description: Some physical, analytical, and computational aspects of viscous flow are examined with reference to examples of computed flows. The discussion of the physical aspects covers the development of important scales used to reference flow phenomena in laminar and turbulent shear layers; the usefulness of the concepts of circulation and vorticity; and some relatively large-scale organized structures that have recently been identified in transitional and fully developed turbulent flows. Among the analytical aspects discussed are a compact presentation of the compressible Navier-Stokes equations, the Reynolds-averaged form of these equations, and a simplified description of some forms of turbulent models. Finally, results of a simulation of the onset of transition, direct turbulence simulations, and large-eddy simulations are given.

Description: It is pointed out that most practical power generation and propulsion systems involve the burning of different types of fuel sprays, taking into account aircraft propulsion, industrial furnaces, boilers, gas turbines, and diesel engines. There has been a lack of data which can serve as a basis for spray model development and validation. A major aim of the present investigation is to fill this gap. Experimental apparatus and techniques for studying the characteristics of fuel sprays are discussed, taking into account two-dimensional still photography, cinematography, holography, a laser diffraction particle sizer, and a laser anemometer. The considered instruments were used in a number of experiments, taking into account three different types of fuel spray. Attention is given to liquid fuel sprays, high pressure pulsed diesel sprays, and coal-water slurry sprays.

Description: The solution by multigrid techniques of the steady inviscid compressible equations of gas dynamics, the Euler equations is investigated. Steady two dimensional transonic flow over an airfoil section is studied intensively. Most of the material is applicable to three dimensional flow problems of aerodynamic interest.

Description: Thermal barrier coatings were exposed to the high temperature and high heat flux produced by a 30 kW plasma torch. Analysis of the specimen heating rates indicates that the temperature drop across the thickness of the 0.038 cm ceramic layer was about 1100 C after 0.5 sec in the flame. An as-sprayed ZrO2-8 percent Y203 specimens survived 3000 of the 0.5 sec cycles with failing. Surface spalling was observed when 2.5 sec cycles were employed but this was attributed to uneven heating caused by surface roughness. This surface spalling was prevented by smoothing the surface with silicon carbide paper or by laser glazing. A coated specimen with no surface modification but which was heat treated in argon also did not surface spall. Heat treatment in air led to spalling in as early as 2 cycle from heating stresses. Failures at edges were investigated and shown to be a minor source of concern. Ceramic coatings formed from ZrO2-12 percent Y2O3 or ZrO2-20 percent Y2O3 were shown to be unsuited for use under the high heat flux conditions of this study.

Description: Friction and wear tests were conducted with 3.2- and 6.4-millimeter-diameter aluminum oxide spheres sliding, in reciprocating motion, on a Fe67Co18B14Si1 metallic foil. Crystallites with a size range of 10 to 150 nanometers were produced on the wear surface of the amorphous alloy. A strong interaction between transition metals and metalloids such as silicon and boron results in strong segregation during repeated sliding, provides preferential transition metal-metalloid clustering in the amorphous alloy, and subsequently produces the diffused honeycomb structure formed by dark grey bands and primary crystals, that is, alpha-Fe in the matrix. Large plastic flow occurs on an amorphous alloy surface with sliding and the flow film of the alloy transfers to the aluminum oxide pin surface. Multiple slip bands due to shear deformation are observed on the side of the wear track. Two distinct types of wear debris were observed as a result of sliding: an alloy wear debris, and/or powdery-whiskery oxide debris.

Description: Rotating baroclinic flow for Richardson number lower than about 1 is studied by means of a finite difference Navier-Stokes model assuming no variations except in the vertical plane that completely contains the density gradient vector. The horizontally infinite channel to which attention is given further assumes periodic boundary conditions at the vertical computational boundaries and no-slip conducting horizontal boundaries. Two configurations are considered. Symmetric baroclinic waves developed in the flows in a manner consistent with linear theory, and it is noted that the structures and energetics of the fully developed waves were dependent on the Prandtl number Pr. For Pr greater than 1, the conversion from potential energy to wave kinetic energy was direct, via temperature and vertical motion correlation, while for Pr of less than 1, conversion proceeded from potential energy to average kinetic energy by means of an induced meridional flow, and then to wave kinetic energy.

Description: Linear stability of the one-dimensional flow between infinite vertical coaxial cylinders induced by heating the inner cylinder is considered for various ratios (kappa) of the inner radius to the outer radius, and for Prandtl numbers (P) appropriate to air and water. For air with P = 0.71 the least stable disturbance is nonaxisymmetric for kappa less than 0.44 and is axisymmetric for kappa greater than 0.44, and in either case the instability is due to the action of the shear forces. For P = 3.5, the situation is similar, except that the asymmetric shear mode is superseded by an axisymmetric instability driven by buoyancy forces for kappa = 0.03-0.16. Wave speeds, wavenumbers, and critical Grashof numbers for these cases and for the case of zero Prandtl number are given.

Description: One of the simpler methods available to accomplish rapid solidification processing is free jet melt spinning. With only a modest expenditure of time, effort, and capital, an apparatus suitable for preliminary experimentation can be assembled. Wheel and crucible materials, process atmospheres, crucible design, heating methods, and process parameters and their relationship to melt composition are described. Practical solutions to processing problems, based on 'hands-on' experience, are offered. Alloys with melting points up to 3000 F have been rapidly solidified using the techniques described.

Description: The extent of convective and radiative heating for a Saturn entry probe is investigated in the absence and presence of ablation mass injection. The flow in the shock layer is assumed to be axisymmetric, viscous and in local thermodynamic equilibrium. The importance of chemical nonequilibrium effects for both the radiative and convective nonblowing surface heating rates is demonstrated for prescribed entry conditions. Results indicate that the nonequilibrium chemistry can significantly influence the rate of radiative heating to the entry probes. With coupled carbon-phenolic ablation injection, the convective heating rates are reduced substantially. Turbulence has little effect on radiative heating but it increases the convective heating considerably.

Description: Ames Research Center has the lead role among NASA centers to conduct research in computational fluid dynamics. The past, the present, and the future prospects in this field are reviewed. Past accomplishments include pioneering computer simulations of fluid dynamics problems that have made computers valuable in complementing wind tunnels for aerodynamic research. The present facilities include the most powerful computers built in the United States. Three examples of viscous flow simulations are presented: an afterbody with an exhaust plume, a blunt fin mounted on a flat plate, and the space shuttle. The future prospects include implementation of the Numerical Aerodynamic Simulation Processing System that will provide the capability for solving the viscous flow field around an aircraft in a matter of minutes.

Description: The influence of high frequency excitations (HFE) on a fluid is investigated. The response to these excitations is decomposed in two parts: 'slow' motion, which practically remains unchanged during the vanishingly small period tau, and 'fast' motion whose value during this period is negligible in terms of displacements, but is essential in terms of the kinetic energy. After such a decomposition the 'slow' and 'fast' motions become nonlinearly coupled by the corresponding governing equations. This coupling leads to an 'effective' potential energy which imparts some 'elastic' properties to the fluid and stabilizes laminar flows.

Description: A solution method for finding the unknown solidification interface in manufacturing slab ingots as a continuous casting is presented, which involves a product solution in the potential plane and the use of conjugate harmonic functions. It is argued that the method may be more direct for some geometries than the Cauchy boundary value method. Moreover, the usefulness of the Cauchy boundary value method is demonstrated through the example of a nonsymmetric horizontal mold where the walls are offset to support the lower ingot boundary.

Description: A method for approximately analyzing the feedback between downstream and upstream edges in incompressible shear flow is described. The shear flow is modeled by a vortex sheet. Equations for resonance eigenvalues are derived. After the reduction of growth rate by finite shear layer thickness is allowed for, agreement is found between calculated resonances and those that have been observed experimentally.

Description: Forms of the nickel-base superalloy Rene95 produced by three processing methods were evaluated in tensile, low cycle fatigue and fatigue crack propagation tests at 540 and 650 C. Two powder-metallurgy (PM) forms, hot-isostatically-pressed and extruded-and-forged, and a conventionally cast-and-wrought form were all given the same heat treatment. The extruded-and-forged form showed superior fatigue life in low strain range tests though the two PM forms exhibited nearly identical mechanical behavior in all other respects. Further, this life difference could not be explained by significant differences in the types, sizes or shapes of the defects initiating failure. The cast-and-wrought Rene95, however, had lower strength, ductility and fatigue life, but higher fatigue crack propagation resistance because of a larger grain size. It did not exhibit the environmentally-assisted intergranular mode of propagation which occurs in PM Rene95 and other fine-grained superalloys at these test temperatures and frequencies.

Description: An implicit finite-difference method is presented for obtaining steady-state solutions to the time-dependent, conservative Euler equations for flows containing shocks. The method uses a two-point central-difference scheme for the flux derivatives with dissipation added at supersonic points via the retarded density concept. Application of the method to 1-dimensional nozzle flow equations for various combinations of subsonic and supersonic boundary conditions show the method to be very efficient. Residuals are typically reduced to machine zero in approximately 35 time steps for 50 mesh points. For 1-dimensional Euler calculations, it is shown that the scheme offers two advantages over the more widely-used three-point schemes. The first is in regard to application of boundary conditions, and the second relates to the fact that the two-point algorithm is well-conditioned for large time steps.

Description: This paper is concerned with small-amplitude, unsteady, vortical and entropic motion imposed on steady potential flows. It is restricted to the case where the spatial scale of the unsteady motion is small compared to that of the mean flow. Under such conditions, the unsteady motion may be influenced by viscosity even if the mean flow is not. An exact high-frequency (small-wavelength) solution is obtained for the small-amplitude viscous motion imposed on a steady potential flow. It generalizes the one obtained by Pearson (1959) for the homogeneous-strain case to the case of quasi-homogeneous strain. This result is used to study the effect of viscosity on rapidly distorted turbulent flows. Specific numerical results are given for a turbulent flow near a two-dimensional stagnation point.

Description: Past work on the influence of Mach number on the viscous and inviscid instability of flat-plate boundary layers is reviewed, and new spatial calculations are presented. These calculations support the previous view that viscosity is only stabilizing for both two- and three-dimensional first-mode waves above M1 = 3.0, and for second-mode waves at all Mach numbers. It is concluded that the calculations of Wazzan, Taghavi, and Keltner that show viscous instability at M1 = 6.0 for first-mode 50 deg waves, and at M1 = 3.0 for two-dimensional second-mode waves, are not correct.

Description: Previously cited in issue 05, p. 635, Accession no. A83-16649

Description: The results of a study to determine the recovery rates and work-hardening coefficients for creep from constant cross-head speed compressive tests are presented. Stressing and straining rates are computed from measured time-load curves obtained from compression testing between 1200 and 1400 K of several B2 crystal structure Fe-39.8 Al intermetallic materials and the directionally solidified eutectic alloy gamma/gamma prime alpha. These quantities are then fitted to the universal form of the Bailey-Orowan equation for creep. The recovery rates were found to be functions of nominal strain rate, stress, and temperature, while the hardening coefficients were dependent only on temperature. While the work-hardening coefficient for gamma/gamma prime - alpha was about 0.05 of the elastic modulus, the work-hardening coefficients for Fe-39.8 at. pct Al were less than 0.002 of the modulus.

Description: A theory is developed for the stagnation point boundary layer with injection under the hypothesis that turbulence is produced at the wall by injection. From the existing experimental heat transfer rate data obtained in wind tunnels, the wall mixing length is deduced to be a product of a time constant and an injection velocity. The theory reproduces the observed increase in heat transfer rates at high injection rates. For graphite and carbon-carbon composite, the time constant is determined to be 0.0002 sec from the existing ablation data taken in an arc-jet tunnel and a balistic range.

Description: Many of the gas turbine combustors in operation use multiple rows of dilution jets, and some have geometries that are different from circular holes. The data base available in literature is generally applicable to a single row of circular holes. Tests were performed with uniform mainstream conditions for several orifice plate configurations. Temperature and pressure measurements were made in the test section at 4 axial and 11 transverse stations. These measurements were made with a 60-element rake probe. Test results for some of these cases are discussed.

Description: The surface protection subproject consists of three major thrusts: airfoil deposition model; metallic coating life prediction; and thermal barrier coating (TBC) life prediction. The time frame for each of these thrusts and the expected outputs are presented. Further details are given for each thrust such as specific element schedules and the status of performance; in-house, via grant, or via contract.

Description: Improved methods of predicting airfoil local metal temperatures require advances in the understanding of the physics and methods of analytically predicting the following four aerothermal loads: hot gas flow over airfoils, heat transfer rates on the gas-side of airfoils, cooling air flow inside airfoils, and heat transfer rates on the coolant-side of airfoils. A systematic building block research approach is being pursued to investigate these four areas of concern from both the experimental and analytical sides. Experimental approaches being pursued start with fundamental experiments using simple shapes and flat plates in wind tunnels, progress to more realistic cold and hot cascade tests using airfoils, continue to progress in large low-speed rigs and turbines and warm turbines, and finally, combine all the interactive effects in tests using real engines or real engine type turbine rigs. Analytical approaches being pursued also build from relatively simple steady two dimensional inviscid flow and boundary layer heat transfer codes to more advanced steady two and three dimensional viscous flow and heat transfer codes. These advanced codes provide more physics to model better the interactive effects and the true real-engine environment.

Description: The objective of this 36-month experimental and analytical program is to develop a heat transfer and pressure drop database, computational fluid dynamic techniques, and correlations for multipass rotating coolant passages with and without flow turbulators. The experimental effort will be focused on the simulation of configurations and conditions expected in the blades of advanced aircraft high pressure turbines so that the effects of Coriolis and buoyancy forces on the coolant side flow can be rationally included in the design of turbine blades.

Description: The effects of high-intensity, large-scale turbulence on turbulent boundary-layer heat transfer are studied. Flow fields were produced with turbulence intensities up to 40% and length scales up to several times the boundary layer thickness. In addition, three different types of turbulence will be compared to see whether they have the same effect on the boundary layer. The three are: the far field of a free jet, flow downstream of a grid, and flow downstream of a simulated gas turbine combustor. Each turbulence field will be characterized by several measures: intensity (by component), scale, and spectrum. Heat transfer will be measured on a 2.5 m long, 0.5 m wide flat plate using the energy-balance technique. The same plate will be used in each of the four flow fields; a low-turbulence tunnel for baseline data, and the three flow situations mentioned.

Description: The primary basis for heat transfer analysis of turbine airfoils is experimental data obtained in linear cascades. A detailed set of heat transfer coefficients was obtained along the midspan of a stator and a rotor in a rotating turbine stage. The data are to be compared to standard analyses of blade boundary layer heat transfer. A detailed set of heat transfer coefficients was obtained along the midspan of a stator located in the wake of a full upstream turbine stage. Two levels of inlet turbulence (1 and 10 percent) were used. The analytical capability will be examined to improve prediction of the experimental data.

Description: Advanced 3-D inelastic structural/stress analysis methods and solution strategies for more accurate and yet more cost-effective analysis of combustors, turbine blades, and vanes are being developed. The approach is to develop four different theories, one linear and three higher order with increasing complexities including embedded singularities. Progress in each area is reported.

Description: Two types of analyses relating to cast iron solidification were conducted. A theoretical analysis using a computer to predict the cooling versus time relationship throughout the test specimen was performed. Tests were also conducted in a ground-based laboratory to generate a cooling time curve for cast iron. In addition, cast iron was cooled through the solidification period on a KC-135 and an F-104 aircraft while these aircraft were going through a period of low gravity. Future subjects for low gravity tests are enumerated.

Description: The objectives of this work are: (1) to extend the technique of direct numerical simulations to turbulent, chemically reacting flows, (2) to test the validity of the method by comparing computational results with laboratory data, and (3) to use the simulations to gain a better understanding of the effects of turbulence on chemical reactions. The effects of both the large scale structure and the smaller scale turbulence on the overall reaction rates are addressed. The relationship between infinite reaction rate and finite reaction rate chemistry is compared with some of the results of calculations with existing theories and laboratory data. The direct numerical simulation method involves the numerical solution of the detailed evolution of the complex turbulent velocity and concentration fields. Using very efficient numerical methods (e.g., pseudospectral methods), the fully nonlinear (possibly low pass filtered) equations of motion are solved and no closure assumptions or turbulence models are used. Statistical data are obtained by performing spatial, temporal, and/or ensemble averages over the computed flow fields.

Description: The present paper will compare temperature field measurements from selected cases in these investigations with distributions calculated with an empirical model based on assumed vertical profile similarity and superposition and with a 3-D elliptic code using a standard K-E turbulence model. The results will show the capability (or lack thereof) of the models to predict the effects of the principle flow and geometric variables.

Description: Fuel spray analyses which are a necessary input to the analytical modeling of the complex mixing and combustion processes which occur in advanced combustor systems are discussed. It is anticipated that by controlling fuel air reaction conditions, combustor temperatures can be better controlled, leading to improved combustion system durability. The capability to measure liquid droplet size, velocity, and number density throughout a fuel spray and to utilize this measurement technique in laboratory benchmark experiments was demonstrated. The experiment to characterize fuel sprays is described. The experiments and data are useful for application to and validation of turbulent flow modeling to improve the design systems of future advanced technology engines.

Description: Most fluid flows are turbulent rather than laminar and the reason for this was studied. One of the earliest explanations was that laminar flow is unstable, and the linear instability theory was first developed to explore this possibility. A series of early papers by Rayleigh produced many notable results concerning the instability of inviscid flows, such as the discovery of inflectional instability. Viscosity was commonly thought to act only to stabilize the flow, and flows with convex velocity profiles appeared to be stable. The investigations that led to a viscous theory of boundary layer instability was reported. The earliest application of linear stability theory to transition prediction calculated the amplitude ratio of the most amplified frequency as a function of Reynolds number for a Blasius boundary layer, and found that this quantity had values between five and nine at the observed Ret. The experiment of Schubauer and Skramstad (1947) completely reversed the prevailing option and fully vindicated the Gottingen proponents of the theory. This experiment demonstrated the existence of instability waves in a boundary layer, their connection with transition, and the quantitative description of their behavior by the theory of Tollmien and Schlichting. It is generally accepted that flow parameters such as pressure gradient, suction and heat transfer qualitatively affect transition in the manner predicted by the linear theory, and in particular that a flow predicted to be stable by the theory should remain laminar. The linear theory, in the form of the e9, or N-factor is today in routine use in engineering studies of laminar flow. The stability theory to boundary layers with pressure gradients and suction was applied. The only large body of numerical results for exact boundary layer solutions before the advent of the computer age by calculating the stability characteristics of the Falkner-Skan family of velocity profiles are given. When the digital computer reached a stage of development which permit the direct solution of the primary differential equations, numerical results were obtained from the linear theory during the next 10 years for many different boundary layer flows: three dimensional boundary layers; free convention boundary layers; compressible boundary layers; boundary layers on compliant walls; a recomputation of Falkner-Skan flows; unsteady boundary layers; and heated wall boundary layers.

Description: Research progress in understanding the effects of cobalt and some possible substitute on microstructure, mechanical properties, and environmental resistance of turbine alloys is discussed. The United States imports over 90 percent of its cobalt, chromium, tantalum and columbium, all key elements in high temperature nickel base superalloys for aircraft gas turbine disks and airfoils. NASA, through joint government/industry/university teams, undertook a long range research program aimed at reducing or eliminating these strategic elements by examining their basic roles in superalloys and identifying viable substitutes.

Description: The initiation and growth of small cracks (5-500 microns) from edge notches in 2024-T3 aluminum alloy sheets were studied under constant-amplitude loading. Two methods were used to measure crack shape and size. In the first method, striation marker bands were periodically formed along the crack front by interrupting the constant-amplitude loading by either an elevated R-ratio load sequence, or by an overload sequence. In each case the marker loading was selected so as to have minimal influence on the growth rate under the primary loading. In the second method, the surface crack length was monitored by taking surface replicas at regular intervals. The marker band techniques did not provide reliable crack length and crack shape information for cracks smaller than 2 mm. The replica technique provided accurate information for surface crack length at all crack lengths, and fracture tests on specimens with small cracks provided crack-shape information.

Description: An iterative collocation technique is described for modeling implicit viscosity in three-dimensional incompressible wall bounded shear flow. The viscosity can vary temporally and in the vertical direction. Channel flow is modeled with a Fourier-Legendre approximation and the mean streamwise advection is treated implicitly. Explicit terms are handled with an Adams-Bashforth method to increase the allowable time-step for calculation of the implicit terms. The algorithm is applied to low amplitude unstable waves in a plane Poiseuille flow at an Re of 7500. Comparisons are made between results using the Legendre method and with Chebyshev polynomials. Comparable accuracy is obtained for the perturbation kinetic energy predicted using both discretizations.

Description: The effect of shoulder radiusing and grooving (longitudinally or circumferentially) the afterbodies of bluff bodies of reduce the base drag at low speeds is discussed. Shoulder radii as large as 2.75 body diameters are examined. Reynolds number based on body diameter varied from 20,000 to 200,000. Results indicate that increasing the shoulder radius to 2.75 body diameters can reduce the drag levels to those of a streamline body having 67 percent greater fineness ratio. For the relatively sharp shoulder case, body drag reductions as large as 50% are obtained using circumferential or longitudinal grooves.

Description: A detailed computerized sensitivity analysis of the triple hot-wire equations has been performed in order to delineate the uncertainties associated with measurements of the velocity components. Absolute and relative uncertainties for the instantaneous hot-wire outputs are calculated as functions of roll and pitch angles, based on a constant probability combination of the uncertainties in the inputs. From the results, it is concluded that the small inherent difficulties associated with the triple hot-wire data do not reflect artifacts introduced by the data processing. Fixed errors present in the V and W channels of the output are due to the nonzero measuring volume of the triple wire probe, and are entirely predictable.

Description: A computationally efficient method is proposed for obtaining fine-mesh solutions of the Navier-Stokes equations for high-Re flow, including separation. The method involves implementing a multi-grid solution procedure with suitably chosen elements, such that the resulting overall solution technique is efficient as well as robust. The robustness and efficiency of the solution technique are demonstrated by applying it to three model problems: flow in a driven cavity, downstream asymptotic flow in curved ducts of square and polar sections, and Newmann boundary-value problem in clustered curvilinear orthogonal coordinates.

Description: The differential formulations and computational techniques currently used for the incompressible Navier-Stokes (NS) and parabolic Navier-Stokes (PNS) equations are reviewed. In particular, attention is given to problems associated with the choice of difference equations, the method of solution and the choice of algorithm, the coupling of dependent variables and discretized equations, the application of boundary conditions, and grid generation. A new composite velocity NS and PNS formulation in (u,v,p) variables is presented, and the applicability of a 'forward' difference global pressure iteration for the (u,v,p) PNS system is demonstrated.

Description: An attempt was made to model the so called leading edge vortex which forms over the leading edge of delta wings at high angles of attack. A simplified model was considered, namely that of a two-dimensional, inviscid, incompressible steady flow around a flat plate at an angle of attack with a stationary vortex detached on top, as well as a sink to simulate the strong spanwise flow. The results appear to agree qualitatively with experiments. A comparison was also made between the lift and the drag of this model and the corresponding results for two classical solutions: (1) that of totally attached flow over the plate with the Kutta condition satisfied at the trailing edge only: and (2) the Helmholtz solution of totally separated flow over the plate.

Description: Zonal concepts are utilized to delineate regions of application of three-dimensional boundary layer (DBL) theory. The zonal approach requires three distinct analyses. A modified version of the 3-DBL code named TABLET is used to analyze the boundary layer flow. This modified code solves the finite difference form of the compressible 3-DBL equations in a nonorthogonal surface coordinate system which includes coriolis forces produced by coordinate rotation. These equations are solved using an efficient, implicit, fully coupled finite difference procedure. The nonorthogonal surface coordinate system is calculated using a general analysis based on the transfinite mapping of Gordon which is valid for any arbitrary surface. Experimental data is used to determine the boundary layer edge conditions. The boundary layer edge conditions are determined by integrating the boundary layer edge equations, which are the Euler equations at the edge of the boundary layer, using the known experimental wall pressure distribution. Starting solutions along the inflow boundaries are estimated by solving the appropriate limiting form of the 3-DBL equations.

Description: The experimental contract objective is to provide a complete set of benchmark quality data for the flow within a large rectangular turning duct. The data are to be used to evaluate and verify three-dimensional internal viscous flow models and computational codes. The analytical contract objective is to select such a computational code and define the capabilities of this code to predict the experimental results. Details of the proper code operation will be defined and improvements to the code modeling capabilities will be formulated.