Experimental and numerical analyses on the effect of increasing inflow temperatures on the flow mixing behavior in a T-junction

Thermal degradation of piping induced by high cycle thermal fatigue (HCTF) is of significant importance as operating Nuclear Power Plants (NPP) become older and lifetime extension activities are initiated. In particular, HCTF incidents related to turbulent thermal mixing of fluids in a T-junction piping system are not well understood and could not be adequately monitored using common thermocouple instrumentation. To investigate this phenomenon, an experimental T-junction test facility was commissioned at the University of Stuttgart, known as the Fluid Structure Interaction (FSI) test facility. The paper presents the experimental investigation and the corresponding numerical validation using the large eddy simulation (LES) method to study T-junction flow mixing. Three experimental test cases are investigated with temperature differences (∆T) of 51.5 K (Case 1), 76 K (Case 2) and 97 K (Case 3) between the mixing fluids. A constant mass flow rate ratio (main/branch) of 4:1 is maintained in all the investigated cases. Flow mixing is observed to be incomplete in all the cases, resulting in a thermally stratified flow with an oscillating stratification layer downstream of the T-junction. Mean temperature and root mean square (RMS) temperature fluctuations predicted by LES in the mixing region are found to be in good agreement with measurement data, with the exception of few positions. Amplitudes of temperature fluctuations are observed to be higher near the stratification layer, ranging from 6.3–9.9% of ∆T. Power spectral density (PSD) analyses of temperature fluctuations indicate no dominant frequency (spectral peak) under prevailing flow conditions, an important factor in thermal fatigue analysis, and the energy of these fluctuations are mainly contained in the frequency range of 0.1–2 Hz for all the investigated cases. LES is performed using the CFD software ANSYS CFX 14.0.     

Influence of wall proximity on characteristics of wake behind a square cylinder: PIV measurements and POD analysis

Influence of wall proximity on characteristics of the wake behind a two-dimensional square cylinder was experimentally studied in the present work. A low-speed recirculation water channel was established for the experiment; the Reynolds number based on the free-stream velocity and cylinder width (D) was kept at Re_D = 2250. Four cases with different gap width, e.g., G/D = 0.1, 0.2, 0.4 and 0.8, were chosen for comparison. Two experimental techniques, e.g., the standard PIV with high image-density CCD camera and TR-PIV with a high-speed camera were employed in measuring the wake field, enabling a comprehensive view of the time-averaged wake pattern at high spatial resolution and the instantaneous flow field at high temporal resolution, respectively. For the four cases, the difference in spatial characteristics of the wake in the vicinity of the plane wall was analyzed in terms of the time-averaged quantities measured by the standard PIV, e.g., the streamline pattern, the vector field, the streamwise velocity fluctuation intensity and the reverse-flow intermittency. The proper orthogonal decomposition (POD) method was extensively used to decompose the TR-PIV measurements, giving a close-up view of the energetic POD modes buried in the wake. The low-order flow model of the wake at G/D = 0.8 and 0.4 was constructed by using the linear combination of the first two POD modes and the time-mean flow field, which reflected well the vortex shedding process in the sense of the phase-dependent patterns. The intermittent appearance of the weakly separated region near the wall was found at G/D = 0.4. On going from G/D = 0.8 to 0.4, the remarkable variation of the instantaneous wake in the longitudinal direction confirmed that the wall constraint stretches the vortices in the plane of the wall and transfers the energy to the longitudinal component at the expense of the lateral one.     

Study on the radial jet velocity distribution of two closely spaced opposed jets

The experimental and theoretical researches on the radial jet of two opposed jets have been carried out in this paper. The radial velocities of opposed jets with various exit velocities, nozzle diameters and nozzle separations were measured experimentally by a hot-wire anemometer (HWA). The results show that, the normalized radial velocities are self-similar across various radial sections at r ? 1.5D and the radial velocity profiles can be described by a Gaussian distribution function. The half-width increases linearly with increasing radial distance at r ? 1.5D, and spreading rates of radial jet are about 0.121. The normalized radial velocity at impingement plane increases firstly, and then decreases with the increasing normalized radial distance. The normalized radial velocity is independent on nozzle diameter, nozzle separation and exit velocity. The maximum radial velocity at impingement plane is proportional to the exit velocity, and it is inversely proportional to the 0.551th power of the normalized nozzle separation. The position of the maximum radial velocity increases with the nozzle separation at L/D < 1, and keeps invariant at L/D ? 1.     

Study on premixed combustion in cylindrical micro combustors: Transient flame behavior and wall heat flux

The micro combustor is a key component of the micro thermophotovoltaic (TPV) system. Improving the wall temperature of the micro combustor is an effective way to elevate the system efficiency. An experimental study on the wall temperature and radiation heat flux of a series of cylindrical micro combustors (with a backward-facing step) was carried out. For the micro combustors with d = 2 mm, the regime of successful ignition (under the cold wall condition) was identified for different combustor lengths. Acoustic emission was detected for some cases and the emitted sound was recorded and analyzed. Under the steady-state condition, the effects of the combustor diameter (d), combustor length (L), flow velocity (u₀) and fuel–air equivalence ratio (Ф) on the wall temperature distribution were investigated by measuring the detailed wall temperature profiles. In the case that the micro combustor is working as an emitter, the optimum efficiency was found at Ф ≈ 0.8, independent of the combustor dimensions (d and L) and the flow velocity. Under the experimental conditions employed in the present study, the positions of the peak wall temperature were found to be about 8–11 mm and 4–6 mm from the step for the d = 3 mm and d = 2 mm micro combustors, respectively, which are 8–11 and 8–12 times of their respective step heights. This result suggests that the backward-facing step employed in the combustor design is effective in stabilizing the flame position.     

Large-eddy simulation in a mixing tee junction: High-order turbulent statistics analysis

This study analyses the mixing and thermal fluctuations induced in a mixing tee junction with circular cross-sections when cold water flowing in a pipe is joined by hot water from a branch pipe. This configuration is representative of industrial piping systems in which temperature fluctuations in the fluid may cause thermal fatigue damage on the walls. Implicit large-eddy simulations (LES) are performed for equal inflow rates corresponding to a bulk Reynolds number Re = 39,080. Two different thermal boundary conditions are studied for the pipe walls; an insulating adiabatic boundary and a conducting steel wall boundary. The predicted flow structures show a satisfactory agreement with the literature. The velocity and thermal fields (including high-order statistics) are not affected by the heat transfer with the steel walls. However, predicted thermal fluctuations at the boundary are not the same between the flow and the solid, showing that solid thermal fluctuations cannot be predicted by the knowledge of the fluid thermal fluctuations alone. The analysis of high-order turbulent statistics provides a better understanding of the turbulence features. In particular, the budgets of the turbulent kinetic energy and temperature variance allows a comparative analysis of dissipation, production and transport terms. It is found that the turbulent transport term is an important term that acts to balance the production. We therefore use a priori tests to evaluate three different models for the triple correlation.     

Flow evolution of a turbulent submerged two-dimensional rectangular free jet of air. Average Particle Image Velocimetry (PIV) visualizations and measurements

The paper presents average flow visualizations and measurements, obtained with the Particle Image Velocimetry (PIV) technique, of a submerged rectangular free jet of air in the range of Reynolds numbers from Re = 35,300 to Re = 2200, where the Reynolds number is defined according to the hydraulic diameter of a rectangular slot of height H. According to the literature, just after the exit of the jet there is a zone of flow, called zone of flow establishment, containing the region of mixing fluid, at the border with the stagnant fluid, and the potential core, where velocity on the centerline maintains a value almost equal to the exit one. After this zone is present the zone of established flow or fully developed region. The goal of the paper is to show, with average PIV visualizations and measurements, that, before the zone of flow establishment is present a region of flow, never mentioned by the literature and called undisturbed region of flow, with a length, L_U, which decreases with the increase of the Reynolds number. The main characteristics of the undisturbed region is the fact that the velocity profile maintains almost equal to the exit one, and can also be identified by a constant height of the average PIV visualizations, with length, L_CH, or by a constant turbulence on the centerline, with length L_CT. The average PIV velocity and turbulence measurements are compared to those performed with the Hot Film Anemometry (HFA) technique. The average PIV visualizations show that the region of constant height has a length L_CH which increases from L_CH = H at Re = 35,300 to L_CH = 4–5H at Re = 2200. The PIV measurements on the centerline of the jet show that turbulence remains constant at the level of the exit for a length, L_CT, which increases from L_CT = H at Re = 35,300 to L_CT = 4–5H at Re = 2200. The PIV measurements show that velocity remains constant at the exit level for a length, L_U, which increases from L_U = H at Re = 35,300 to L_U = 6H at Re = 2200 and is called undisturbed region of flow. In turbulent flow the length L_U is almost equal to the lengths of the regions of constant height, L_CH, and constant turbulence, L_CT. In laminar flow, Re = 2200, the length of the undisturbed region of flow, L_U, is greater than the lengths of the regions of constant height and turbulence, L_CT = L_CH = 4–5H. The average PIV and HFA velocity measurements confirm that the length of potential core, L_P, increases from L_P = 4–5H at Re = 35,300 to L_P = 7–8H at Re = 2200, and are compared to the previous experimental and theoretical results of the literature in the zone of mixing fluid and in the fully developed region with a good agreement.     

The influence of pipe length on thermal statistics computed from DNS of turbulent heat transfer

We present results from direct numerical simulation of turbulent heat transfer in pipe flow at a bulk flow Reynolds number of 5000 and Prandtl numbers ranging from 0.025 to 2.0 in order to examine the effect of streamwise pipe length (πδ ≡ πD/2 ⩽ L ⩽ 12πδ) on the convergence of thermal turbulence statistics. Various lower and higher order thermal statistics such as mean temperature, rms of fluctuating temperature, turbulent heat fluxes, two-point auto and cross-correlations, skewness and flatness were computed and it is found that the value of L required for convergence of the statistics depends on the Prandtl number: larger Prandtl numbers requires comparatively shorter pipe length for convergence of most of the thermal statistics.     

The influence of pipe length on thermal statistics computed from DNS of turbulent heat transfer

We present results from direct numerical simulation of turbulent heat transfer in pipe flow at a bulk flow Reynolds number of 5000 and Prandtl numbers ranging from 0.025 to 2.0 in order to examine the effect of streamwise pipe length (πδ ≡ πD/2 ? L ? 12πδ) on the convergence of thermal turbulence statistics. Various lower and higher order thermal statistics such as mean temperature, rms of fluctuating temperature, turbulent heat fluxes, two-point auto and cross-correlations, skewness and flatness were computed and it is found that the value of L required for convergence of the statistics depends on the Prandtl number: larger Prandtl numbers requires comparatively shorter pipe length for convergence of most of the thermal statistics.     

Flow structures and heat transfer on dimples in a staggered arrangement

Vortex structures and heat transfer enhancement mechanism of turbulent flow over a staggered array of dimples in a narrow channel have been investigated using Large Eddy Simulation (LES), Laser Doppler Velocimetry (LDV) and pressure measurements for Reynolds numbers Re_H = 6521 and Re_H = 13,042.The flow and temperature fields are calculated by LES using dynamic mixed model applied both for the velocity and temperature. Simulations have been validated with experimental data obtained for smooth and dimpled channels and empiric correlations. The flow structures determined by LES inside the dimple are chaotic and consist of small eddies with a broad range of scales where coherent structures are hardly to detect. Proper Orthogonal Decomposition (POD) method is applied on resolved LES fields of pressure and velocity to identify spatial–temporal structures hidden in the random fluctuations. For both Reynolds numbers it was found that the dimple package with a depth h to diameter D ratio of h/D = 0.26 provides the maximum thermo-hydraulic performance. The heat transfer rate could be enhanced up to 201% compared to a smooth channel.     

Flow structures around an equilateral triangle arrangement of three spheres

This paper represents the results of an experimental study on the flow structure around a single sphere and three spheres in an equilateral-triangular arrangement. Flow field measurements were performed using a Particle Image Velocimetry (PIV) technique and dye visualization in an open water channel for a Reynolds number of Re = 5 × 10³ based on the sphere diameter. The distributions and flow features at the critical locations of the contours of the velocity fluctuations, the patterns of sectional streamlines, the vorticity contours, the turbulent kinetic energy, the Reynolds stress correlations and shedding frequency are discussed. The gap ratios (G/D) of the three spheres were varied in the range of 1.0 ⩽ G/D ⩽ 2.5 where G was the distance between the sphere centers, and D was the sphere diameter which was taken as 30 mm. Due to the interference of the shedding shear layers and the wakes, more complex features of the flow patterns can be found in the wake region of the two downstream spheres behind the leading sphere. For G/D = 1.25, a jet-like flow around the leading sphere through the gap between the two downstream spheres occurred, which significantly enhanced the wake region. It was observed that a continuous flow development involving shearing phenomena and the interactions of shedding vortices caused a high rate of fluctuations over the whole flow field although most of the time-averaged flow patterns were almost symmetric about the two downstream spheres.     

The flow field around a micropillar confined in a microchannel

The flow field over a low aspect ratio (AR) circular pillar (L/D = 1.5) in a microchannel was studied experimentally. Microparticle image velocimetry (μPIV) was employed to quantify flow parameters such as flow field, spanwise vorticity, and turbulent kinetic energy (TKE) in the microchannel. Flow regimes of cylinder-diameter-based Reynolds number at 100 ⩽ Re_D ⩽ 700 (i.e., steady, transition from quasi-steady to unsteady, and unsteady flow) were elucidated at the microscale. In addition, active flow control (AFC), via a steady control jet (issued from the pillar itself in the downstream direction), was implemented to induce favorable disturbances to the flow in order to alter the flow field, promote turbulence, and increase mixing. Together with passive flow control (i.e., a circular pillar), turbulent kinetic energy was significantly increased in a controllable manner throughout the flow field.     

Heat transfer enhancement in a tube with equilateral triangle cross sectioned coiled wire inserts

The heat transfer and pressure drop were experimentally investigated in a coiled wire inserted tube in turbulent flow regime. The coiled wire has equilateral triangular cross section and was inserted separately from the tube wall. The experiments were carried out with three different pitch ratios (P/D = 1, 2 and 3) and two different ratio of equilateral triangle length side to tube diameter (a/D = 0.0714 and 0.0892) at a distance (s) of 1 mm from the tube wall in the range of Reynolds number from 3500 to 27,000. Uniform heat flux was applied to the external surface of the tube and air was selected as fluid. The experimental results obtained from a smooth tube were compared with those from the studies in literature for validation of experimental set-up. The use of coiled wire inserts leads to a considerable increase in heat transfer and pressure drop over the smooth tube. The Nusselt number rises with the increase of Reynolds number and wire thickness and the decrease of pitch ratio. The highest overall enhancement efficiency of 36.5% is achieved for the wire with a/D = 0.0892 and P/D = 1 at Reynolds number of 3858. Consequently, the experimental results reveal that the best operating regime of all coiled wire inserts is detected at low Reynolds number, leading to more compact heat exchanger.     

Hydrodynamic forces on a rotating sphere

The wake dynamics of a rotating sphere with prescribed rotation axis angles are quantitatively analysed by carrying out numerical simulations at Reynolds numbers of Re = 100, 250 and 300, non-dimensional rotational rates Ω¹ = 0–1 and rotation axis angles α = 0, π/6, π/3 and π/2 measured from the free stream axis. These parameters are the same as those in an earlier study (Poon et al., 2010, Int. J. Heat Fluid Flow) where the instantaneous flow structures were discussed qualitatively. This study extends the findings of the earlier study by employing phase diagrams (C_Lx, C_Ly) and (C_D, C_L) to provide a quantitative analysis of the time-dependent behaviour of the flow structures. At Re = 300 and Ω¹ = 0.05, the phase diagrams (C_Lx, C_Ly) show ‘saw tooth’ patterns for both α = 0 and π/6. The ‘saw tooth’ pattern indicates that the flow structures comprise a higher frequency oscillation component at a Reynolds number of 300 which is not observed until Re ≈ 800 for a stationary sphere. This ‘saw tooth’ pattern disappears as Ω¹ increases. The employment of the phase diagrams also reveals that different flow structures induce different oscillation amplitudes on both lateral force coefficients. With the exception of the vortices formed from a shear layer instability, all other flow regimes show larger fluctuations in C_L than C_D.     

Coalescence of sessile droplets of varying viscosities for line printing

Coalescence of sessile droplets is studied experimentally with water–glycerin mixtures of different viscosities. Effects of viscosity on the dimensionless spreading length (Ψ) and the center-to-center distance (L) are investigated for two droplets; the first droplet (D_s) is stationary on a substrate and the second droplet (D₀) landing at a center-to-center distance L from the first droplet. For a low viscosity fluid, Ψ is maximum when L approaches zero (or λ → 1, where λ = 1 − L/D_s), which represents a head-on collision. For a high viscosity fluid, Ψ is minimum when λ → 0.6. The effect of λ on line printing for various viscosities is also examined by printing multiple droplets. We found that the larger the viscosity, the less the breakup between droplets; viscosities smaller than 60 wt% glycerin yielded line breakup. The overlap ratio of λ > 0.3 produced not a line, but a bigger droplet or puddle because of coalescence. Data obtained in this work can provide insights for the fabrication of conductive microtracks or microinterconnects in printed-electronics applications where a line breakup between droplets would lead to an electrical circuit short.     

Revisiting the perforation of ductile plates by sharp-nosed rigid projectiles

The process of ductile plate perforation by sharp-nosed rigid projectiles is further examined in this work through 2D numerical simulations. We highlight various features concerning the effective resisting stress (σ_r) which a finite thickness plate, with a flow stress of Y_t, exerts on the projectile during perforation. In particular, we show that the normalized resisting stress (σ_r/Y_t) can be represented as a unique function of the normalized thickness of the plate (H/D, where H is plate thickness and D is projectile diameter), for a large range of normalized thicknesses. Our simulations for very thin target plates show that the penetration process is achieved through the well-known dishing mechanism, where the target material is pushed forward by the projectile’s nose. An important observation, which emerges from our simulations, is that the transition between the dishing and the hole enlargement mechanisms takes place at a normalized thickness of about H/D = 1/3. We also find that the normalized resistive stress for intermediate plate thicknesses, 1/3 < H/D < 1.0, is relatively constant at a value of σ_r/Y_t = 2.0. This range of thicknesses conforms to a state of quasi plane stress in the plates. For thicker plates (H/D > 1) the σ_r/Y_t ratio increases monotonically to values which represent the resistance to penetration of semi-infinite targets, where the stress state is characterized by plane strain conditions. Using a simple model, which is based on energy conservation, we can predict the values of the ballistic limit velocities for many projectile/target combinations, provided the perforation is done through the ductile hole enlargement mechanism. Good agreement is demonstrated between predictions from our model and experimental data from different sources, strongly enhancing the confidence in both the validity and usefulness of our model.     

CFD based mini- vs. micro-system delineation in elongated bubble flow regime

Delineation of mini- and micro-scale channels with respect to two-phase flow has been the subject of many research papers. There is no consensus on when the small channel can be characterized as a mini-channel or micro-channel. The idea proposed by this paper is to use the normalized bubble nose radius, liquid film thickness top over bottom ratio, and bubble shape contour, which are found under normal gravity conditions in slug flow through a horizontal adiabatic channel, as the delineation criteria. The input parameters are bubble nose radius and bubble nose velocity as the characteristic length scale and characteristic velocity scale respectively. 3D numerical simulation with ANSYS FLUENT was used to obtain the necessary data. Following CFD practice, a mesh independence study and a numerical model validation against published experimental data were both conducted. Analysis of the numerical simulation results showed that channels with D ⩽ 100 μm can be characterized as a micro-system, while channels with D ⩾ 400 μm belong to mini-systems. The region 200 μm ⩽ D ⩽ 300 μm represents a transition from the micro-scale to mini-scale.     

Particle image velocimetry investigation on mixing enhancement of non-circular sharp edge nozzles

An experimental study using Particle Image Velocimetry (PIV) on free jets issuing from different orifice plate (OP) nozzles is reported. Mean velocity, turbulence intensity and higher order profiles relevant for large and small scale mixing are considered in the near field and interaction zone (0 < X/D < 20). This is done to determine mixing enhancement due to rectangular, squared, elliptic and triangular nozzles in comparison to circular nozzle results in two orthogonal planes. The effect of Reynolds number on the differences among the nozzle shapes is also considered by performing measurements just after laminar–turbulent transition (Re = 8000) and in the fully turbulent regime (Re = 35,000). The results at low Reynolds number show two classes of jets, i.e. at one side, those closer to axial-symmetric conditions, as circular, square and triangular jets, whereas on the other side those with elongated nozzles as rectangular and elliptic. The reason for the different behavior of the latter is connected to the phenomenon of axis-switching which allows a rearrangement of turbulence over the different velocity components and directions. However, for the highest Reynolds number investigated, all nozzles show similar behavior especially in the jet far field (X/D > 10), thus suggesting a significant Reynolds number dependence of the results.     

Low Reynolds number flow over a square cylinder with a detached flat plate

A numerical study of the alteration of a square cylinder wake using a detached downstream thin flat plate is presented. The wake is generated by a uniform flow of Reynolds number 150 based on the side length of the cylinder, D. The sensitivity of the near wake structure to the downstream position of the plate is investigated by varying the gap distance (G) along the wake centerline in the range 0 ⩽ G ⩽ 7D for a constant plate length of L = D. A critical gap distance is observed to occur at G_c ≈ 2.3D that indicates the existence of two flow regimes. Regime I is characterised by vortex formation occurring downstream of the gap while for regime II, formation occurs within the gap. By varying the plate length and gap distance, a condition is found where significant unsteady total lift reduction can occur. The root mean square lift reduction is limited by an unsteady stall process on the plate.     

Extrudate swell of linear and branched polyethylenes: ALE simulations and comparison with experiments

Extrudate swell is a common phenomenon observed in the polymer extrusion industry. Accurate prediction of the dimensions of an extrudate is important for appropriate design of dies for profile extrusion applications. Prediction of extrudate swell has been challenging due to (i) difficulties associated with accurate representation of the constitutive behavior of polymer melts, and (ii) difficulties associated with the simulation of free surfaces, which requires special techniques in the traditionally used Eulerian framework. In a previous work we had argued that an Arbitrary Lagrangian Eulerian (ALE) based finite element formulation may have advantages in simulating free surface deformations such as in extrudate swell. In the present work we reinforce this argument by comparing our ALE simulations with experimental data on the extrudate swell of commercial grades of linear polyethylene (LLDPE) and branched polyethylene (LDPE). Rheological behavior of the polymers was characterized in shear and uniaxial extensional deformations, and the data was modeled using either the Phan–Thien Tanner (PTT) model or the eXtended Pom–Pom (XPP) model. Additionally, flow birefringence and pressure drop measurements were done using a 10:1 contraction–expansion (CE) slit geometry in a MultiPass Rheometer. Simulated pressure drop and contours of the principal stress difference were compared with experimental data and were found to match well. This provided an independent test for the accuracy of the ALE code and the constitutive equations for simulating a processing-like flow. The polymers were extruded from long (L/D = 30) and short (L/D = 10) capillaries dies at 190 °C. ALE simulations were performed for the same extrusion conditions and the simulated extrudate swell showed good agreement with the experimental data.     

Heat transfer due to impinging co-axial jets and the jets’ fluid flow characteristics

This investigation had multiple goals. One goal was to obtain definitive information about the heat transfer characteristics of co-axial impinging jets, and this was achieved by measurements of the stagnation-point, surface-distribution and average heat transfer coefficients. These results are parameterized by the Reynolds number Re which ranged from 5000 to 25,000, the dimensionless separation distance between the jet exit and the impingement plate H/D (4–12), and the ratio of the inner diameters of the inner and outer pipes d/D (0–0.55). The d/D = 0 case corresponds to a single circular jet. The other major goal of this work was to quantify the velocity field of co-axial free jets (impingement plate removed). The velocity-field study included both measurements of the mean velocity and the turbulence intensity.It was found that the variation of the stagnation-point heat transfer coefficient with d/D attained a maximum at d/D = 0.55. Furthermore, the variation of the local heat transfer coefficient across the impingement surface was more peaked for d/D = 0 and became flatter with decreasing d/D. This suggests that for cooling a broad expanse of surface, co-axial jets of high d/D are preferable. On the other hand, for localized cooling, the single jet (d/D = 0) performed the best. In general, for a given Reynolds number, a co-axial jet yields higher heat transfer coefficients than a single jet. Off-axis velocity peaks were encountered for the jets with d/D = 0.105. The measurements of turbulence intensity yielded values as high as 18%.