Two-phase structure above hot surfaces in jet impingement boiling

Jet impingement boiling is very efficient in cooling of hot surfaces as a part of the impinging liquid evaporates. Several studies have been carried out to measure and correlate the heat transfer to impinging jets as a function of global parameters such as jet subcooling, jet velocity, nozzle size and distance to the surface, etc. If physically based mechanistic models are to be developed, studies on the fundamentals of two-phase dynamics near the hot surface are required. In the present study the vapor–liquid structures underneath a subcooled (20 K) planar (1 mm × 9 mm) water jet, impinging the heated plate vertically with a velocity of 0.4 m/s, were analyzed by means of a miniaturized optical probe. It has a tip diameter of app. 1.5 μm and is moved toward the plate by a micrometer device. The temperature controlled experimental technique enabled steady-state experiments in all boiling regimes. The optical probe data provides information about the void fraction, the contact frequencies and the distribution of the vapor and liquid contact times as a function of the distance to the surface. The measured contact frequencies range from 40 Hz at the onset of nucleate boiling to nearly 20,000 Hz at the end of the transition boiling regime. Due to condensation in the subcooled jet vapor disappears at a distance to the surface of app. 1.2 mm in nucleate boiling. This vapor layer becomes smaller with increasing wall superheat. In film boiling a vapor film thickness of 8 ± 2 μm was found.     

Experimental study on influence of microscale effects on liquid flow characteristic in microtubes

Using deioned water as a working fluid, the influence of the microscale effects on liquid flow resistance in microtubes with inner diameters of 19.6 and 44.2 μm, respectively, is experimentally studied. The temperature rise resulted from the microscale effects, such as viscous dissipation, electric double layer, wall rough on the wall surface, etc., is obtained by an IR camera with a special magnified lens adopting micro-area thermal image technology and the corresponding pressure drop and the flux are also measured, so the relationship among friction factor, temperature rise and Reynolds number is obtained. Investigation shows that experimental data are almost equal to those of Hagen–Poiseuille when Reynolds number is low. With the increase of Reynolds number, the values of the friction factor depart from that of classical theory due to the microscale effects. Moreover, the values of the experimental friction factor considering various microscale effects is the maximal 10–15% deviation from that of friction factor without considering various microscale effects with further increase of Reynolds number.     

Near-wall imaging using toluene-based planar laser-induced fluorescence in shock tube flow

A quantitative thermometry technique, based on planar laser-induced fluorescence (PLIF), was applied to image temperature fields immediately next to walls in shock tube flows. Two types of near-wall flows were considered: the side wall thermal boundary layer behind an incident shock wave, and the end wall thermal layer behind a reflected shock wave. These thin layers are imaged with high spatial resolution (15μm/pixel) in conjunction with fused silica walls and near-UV bandpass filters to accurately measure fluorescence signal levels with minimal interferences from scatter and reflection at the wall surface. Nitrogen, hydrogen or argon gas were premixed with 1–12% toluene, the LIF tracer, and tested under various shock flow conditions. The measured pressures and temperatures ranged between 0.01 and 0.8 bar and 293 and 600 K, respectively. Temperature field measurements were found to be in good agreement with theoretical values calculated using 2-D laminar boundary layer and 1-D heat diffusion equations, respectively. In addition, PLIF images were taken at various time delays behind incident and reflected shock waves to observe the development of the side wall and end wall layers, respectively. The demonstrated diagnostic strategy can be used to accurately measure temperature to about 60 μm from the wall.     

Pattern evaluation for in-plane displacement measurement of thin films

Ultra-lightweight spacecraft incorporating “gossamer” structures are extremely compliant, which complicates control, design, and ground testing in full scale. One approach to model the behavior of a full-scale gossamer structure is to construct a small-scale model test article that can be used to verify a corresponding small-scale computer model. Once the predictions of the computer model have been verified by measurement of the physical test article, it can be scaled up to allow computation of the full-scale structure behavior. As model verification requires accurate deflection measurements at multiple points along the surface of the structure, a sensing system that provides full-field data without changing the dynamic response of the structure must be developed. Hence, an optical approach is taken. Since the thin films used in gossamer space structures are typically smooth and featureless, targets must be incorporated into the film surface to enable tracking of both in-plane and out-of-plane displacements. A krypton fluoride excimer laser system was used to etch 35 μm wide linear features approximately 0.1 μm into the surface metallization of both 50.8 μm polyester and 127 μm polyimide films. These optically diffuse surface features, designed mainly to investigate the precision of the laser etching method, were used as targets for ultra-close-range photogrammetry, the method chosen for displacement tracking. A force applied to the surface of the etched mirror (test article) produced in-plane and out-of-plane deformations that were resolved via ultra-close-range photogrammetry. To measure the in-plane tracking resolution, 1.5 and 3.0 mm circular dots were added (using ink) to the surface of the thin film, and some of these targets were tracked as the test article was translated on a precision linear stage. In-plane tracking resolution using ultra-close-range photogrammetry was related to the ground sample distance of the camera, which in this case was 51.25 μm pixel⁻¹ (equal to the ratio of sample dimension to number of pixels in the field of view). Using a manual technique to identify features of the etched pattern for tracking, the mean tracking error was about 13 μm (σ=43 μm). Using an automated, subpixel marking technique to identify the 1.5 mm circular targets, the mean tracking error was 22 μm (σ=13 μm). Neither of these methods achieved the desired 10 μm tracking resolution.     

Heat transfer in pool boiling of binary and ternary non-azeotropic mixtures

Heat transfer coefficients in nucleate pool boiling of binary and ternary non-azeotropic hydrocarbon mixtures were obtained experimentally using a vertical electrically heated cylindrical carbon steel surface at atmospheric pressure with several surface roughness. The fluids used were Methanol/1-Pentanol and Methanol/1-Pentanol/1,2-Propandiol at constant 1,2-Propandiol mole fraction of 30%. Heat fluxes were varied in the range 25–235 kW/m². The cylindrical heater surface was polished to an average surface roughness of 0.2 μm, and sandblasted yielding surface roughness of 2.98 and 4.35 μm, respectively. The experimental results were compared to available prediction correlations, indicating that the correlations based on the boiling range are in better qualitative agreement than correlations based on the phase envelope. Increasing surface roughness resulted in an increase in the heat transfer coefficient, and the effect was observed to be dependent on the heat flux and fluid composition.     

Scanning Electron Microscopy for Quantitative Small and Large Deformation Measurements Part II: Experimental Validation for Magnifications from 200 to 10,000

A combination of drift distortion removal and spatial distortion removal are performed to correct Scanning Electron Microscope (SEM) images at both ×200 and ×10,000 magnification. Using multiple, time-spaced images and in-plane rigid body motions to extract the relative displacement field throughout the imaging process, results from numerical simulations clearly demonstrate that the correction procedures successfully remove both drift and spatial distortions with errors on the order of ±0.02 pixels. A series of 2D translation and tensile loading experiments are performed in an SEM for magnifications at ×200 and ×10,000, where both the drift and spatial distortion removal methods described above are applied to correct the digital images and improve the accuracy of measurements obtained using 2D-DIC. Results from translation and loading experiments indicate that (a) the fully corrected displacement components have nearly random variability with standard deviation of 0.02 pixels (≈25 nm at ×200 and ≈0.5 nm at ×10,000) in each displacement component and (b) the measured strain fields are unbiased and in excellent agreement with expected results, with a spatial resolution of 43 pixels (≈54 μm at ×200 and ≈1.1 μm at ×10,000) and a standard deviation on the order of 6 × 10⁻⁵ for each component.

Steady and transient liquid sphere heating in a convective gas stream

 A finite-difference scheme has been developed to solve the equations governing the laminar forced convection heat transfer around and inside a spherical fluid droplet moving steadily in another immiscible fluid for both steady and transient thermal conditions. For large values of the external flow Reynolds number (Re), results not available in the literature have been obtained for circulating droplets at intermediate and high interior-to-exterior viscosity ratios (μ^*). Detailed results over a wide range of viscosity ratio (μ^*) and for 200≤Re≤1000 are presented for the temperature profiles outside and inside the sphere, Nusselt number, the time required to attain a uniform surface temperature and the time required to reach the steady-state temperature. Results show that convective heating is dependent on the external flow Reynolds number (Re) and the interior-to-exterior viscosity ratio (μ^*) where increasing Re or decreasing μ^* result in increasing heat transfer rate convected to the liquid sphere. Received on 1 March 1999     

Spatiotemporal Thermal Inhomogeneities During Compression of Highly Textured Zirconium

Using a focal plane array infrared camera, the heat generated during large strain compression (at a rate of 1 s⁻¹) is used to study the characteristics of plastic flow for hcp zirconium. Heat generation during plastic flow in a reference material, copper, was seen to develop uniformly both at the lower (40 μm/pixel) and higher (8 μm/pixel) magnifications used in this study. The thermomechanical response of Zr, however, was seen to depend on the loading direction with respect to the specimen texture. Highly textured zirconium compressed along nonbasal oriented grains results in a homogeneous thermal response at both scales. However, compression along basal (0001) oriented grains shows evidence of inhomogeneous deformation at small strains that lead to macroscale localization and failure at large strains. The conversion of plastic work into heat is observed to be a dynamic process, both in the time-dependent nature of the energy conversion, but also in the passage of waves and ‘bursts’ of plastic heating. Basal compression also showed evidence of small scale localization at strains far below macroscale localization, even below 10%. These localizations at the lower strain levels eventually dominate the response, and form the shear band that is responsible for the softening of the macroscopic stress–strain curve.     

Determination of Stresses and Retained Austenite in Carbon Steels by X-rays - A Round Robin Study

Residual stresses and retained austenite are two important process-related parameters which need to be controlled and monitored carefully during production and heat treatment of products. X-ray diffraction techniques are normally used in this context, and the purpose of the present study was to investigate the reproducibility and accuracy of these methods for medium and high carbon steels. The work was carried out as a round robin study including nine different laboratories in Sweden and Finland. Stress measurements were carried out on three specimens etched to three different depths, 0 μm, 230 μm and 515 μm. Retained austenite measurements were carried out on three specimens containing approximately 11, 17 and 30 vol.-% of this phase. The stress measurements showed good reproducibility with standard deviations of typically 4% on flat and smooth surfaces and not more than about 8% on etched surfaces. Estimations revealed that specimen misalignment and improper X-ray spot location were the main sources behind the variation in the stress recordings. The determination of retained austenite showed a standard deviation of typically 15% between the different contributors. However, by using identical evaluation methods for all raw data, the data spread could be narrowed by a factor of 3 to 4 despite the fact that different experimental settings were used in the individual laboratories.     

An Investigation of Fatigue Characteristics of Copper Film

Tensile and fatigue behaviors of the copper film coated by tin (Sn) were investigated considering S-N relationships and scanning electron microscope (SEM) observation of fracture surfaces. The fatigue behavior was investigated considering the effect of load ratio, R. The specimen of 2000 μm width, 8000 μm length and 15.26 μm thickness was fabricated by etching process. Tensile properties were measured using the micro-tensile testing system and in-plane electronic speckle pattern interferometric (ESPI) system for measuring the tensile strain during the test. The fatigue tests of the film were carried out in load-control mode with 40 Hz at three different stress ratios of 0.05, 0.3 and 0.5. The S-N curves, including the slope of the curve and fatigue limit, at the respective stress ratios were obtained. These curves were dependent on the load ratio. Empirical relationships indicating the dependency of the fatigue limit and S-N curve on the load ratio were suggested in this study. SEM observation of the tensile fracture surface showed that the cross-sectional area of the testing section was necked in the direction of the film thickness (i.e. parallel to the substrate surface normal) and some ductile dimples in the fracture surface were present. The fracture of the copper film under cyclic loading was progressed in the transgranular fracture mode.     

Tailoring Beam Mechanics Towards Enhancing Detection of Hazardous Biological Species

Microcantilever based sensors have been widely employed for measuring or detecting various hazardous chemical agents and biological agents. Although they have been successful in detecting agents of interest, researchers desire to improve their performance by enhancing their mass sensitivity towards developing “detect to warn” detection capabilities. Moreover, there has been little work aimed at tailoring beam mechanics as a means to enhance mass sensitivity. In this paper, a numerical study is performed to assess the influence of microcantilever geometry on mass sensitivity in order to improve these devices for better detection of hazardous biological agents in liquid environments. Modal analysis was performed on microcantilevers of different geometries and shapes using ANSYS software and compared to the basic rectangular shaped microcantilever structures employed by most researchers. These structures all possessed a 50 μm length, 0.5 μm thickness and 25 μm width where the cantilever is clamped to the substrate, and were analyzed for their basic resonance frequency as well as the frequency shift for the attachment of a 0.285 pg of mass attached on their surfaces. These numerical results indicated that two parameters dominate their behavior, (1) the effective mass of the cantilever at the free end and (2) the clamping width at the fixed end. The ideal geometry was a triangular shape, which minimized effective mass and maximized clamping width, resulting in an order of magnitude increase in mass sensitivity (1,775 Hz/pg) over rectangular shaped cantilevers (172 Hz/pg) of identical length and clamping width. The most practical geometry was triangular shaped cantilever with a square pad at the free end for capturing the agent of interest. This geometry resulted in a mass sensitivity of 628 Hz/pg or nearly a 4-fold increase in performance over their rectangular counterparts.     

Characterization of wettability effects on pressure drop of two-phase flow in microchannel

The Characterization of the effects of surface wettability and geometry on pressure drop of slug flow in isothermal horizontal microchannels is investigated for circular and square channels with hydraulic diameter (D _h ) of 700 μm. Flow visualization is employed to characterize the bubble in slug flow established in microchannels of various surface wettabilities. Pressure drop increases with decrease in surface wettability, while the channel geometry influences slug frequency. It is observed that the gas–liquid contact line in advancing and receding interfaces of bubble change with surface wettability in slug flows. Flow resistance, where capillary force is important, is estimated using Laplace–Young equation considering the change of dynamic contact angles of bubble. The experimental study also demonstrates that the liquid film presence elucidates the pressure drop variation of slug flows at various surface wettabilities due to diminishing capillary effect.     

Impact of liquid drops on a rough surface comprising microgrooves

Impact of water drops on a stainless steel surface comprising rectangular shaped parallel grooves is studied experimentally. Geometric parameters of the surface groove structure such as groove depth, groove width and solid pillar width separating any two successive grooves were kept at 7.5, 136 and 66 μm, respectively. The study was confined to the impact of drops in inertia dominated flow regime with Weber number in the range 15–257. Experimental results of drop impact process obtained for the grooved surface were compared with those obtained for a smooth surface to elucidate the influence of surface grooves on the impact process. The grooves definitely influence both spreading and receding processes of impacting liquid drops. A more striking observation from this study is that the receding process of impacting liquid drops is dramatically changed by the groove structure for all droplet Weber number.     

An Innovative Method for 3-D Shape,Strain and Temperature Full-Field Measurement Using a Single Type of Camera: Principle and Preliminary Results

An innovative technique for measuring both the shape, the displacement, the strain and the temperature fields at the surface of an object using a single stereovision sensor is proposed. The sensor is based on two off-the-shelf low-cost high-resolution uncooled CCD cameras. To allow both dimensional and thermal measurements, the sensor operates in the visible and near infrared (NIR) spectral band (0.7–1.1 μm), and a radiometric and geometric calibration of the sensor is required. This technique leads to a low-cost camera-based simplified instrumentation that gives simultaneously dimensional/kinematical and thermal field measurements.     

Detection of liquid–metal, free-surface flow using the DLP measurement technique

Novel accelerator applications favor free-surface liquid–metal flows, in which the liquid acts both as a target producing secondary particles but also to remove efficiently the heat deposited. A crucial aspect for the operation is the continuous monitoring of both shape and position of the liquid’s surface. This demands, in a nuclear environment, a non-intrusive measurement technique with high temporal and spatial resolution. In this context, the double-layer projection (DLP) technique based on geometric optics has been developed, allowing one to detect either point-wise or area-wise the shape and position of the nearly totally reflecting liquid–metal surface. The DLP technique employs a laser beam projected through a coplanar glass plate to the surface from which it is reflected to the plate again. Beam locations captured by means of a camera permit the position and shape of the surface to be reconstructed. The parameters affecting the resolution and performance of the DLP technique are discussed. Additionally, validation studies using static and moving objects of pre-defined shape are conducted, exhibiting spatial and temporal resolutions of 300 μm and 100 Hz, respectively. Finally, the DLP system is applied to perform measurements of a circular hydraulic jump (CHJ) in a liquid metal. The DLP system has proved the capability to measure the jump both qualitatively and quantitatively. Additionally, the experiments identified, at high Reynolds numbers, the existence of a two-step jump. The analysis of spectral data of the DLP surface measurements shows clearly that, at the outer radius, gravity waves occur. Also, contributions from the pump oscillations were found, demonstrating the high performance of the DLP system.     

The effect of particles on fluid turbulence in a turbulent boundary layer over a cylinder

The turbulent fluid and particle interaction in the turbulent boundary layer for cross flow over a cylinder has been experimentally studied. A phase-Doppler anemometer was used to measure the mean and fluctuating velocities of both phases. Two size ranges of particles (30μm–60μm and 80μm–150μm) at certain concentrations were used for considering the effects of particle sizes on the mean velocity profiles and on the turbulent intensity levels. The measurements clearly demonstrated that the larger particles damped fluid turbulence. For the smaller particles, this damping effect was less noticeable. The measurements further showed a delay in the separation point for two phase turbulent cross flow over a cylinder. The project supported by the National Natural Science Foundation of China     

LIF measurements of concentration profiles in the aqueous mass boundary layer

 A laser-induced fluorescence (LIF) technique is described to measure vertical concentration profiles of gases in the aqueous mass boundary layer at a free water surface. The technique uses an acid-base reaction of the fluorescence indicator fluorescein at the water surface to visualize the concentration profiles. The technique is capable of measuring two-dimensional vertical concentration profiles at a rate of 200 frames/s and a spatial resolution of 16 μm. The mass boundary layer at a free surface is characterized by significant fluctuations. Direct surface renewal is observed. The mean profiles also support rather surface renewal models than turbulent diffusion models. Received: 21 May 1997/Accepted: 18 December 1997     

Equilibrium of a free nonisothermal liquid film

The equilibrium of a free weightless liquid film fixed over a planar contour and acted upon by thermocapillary forces is studied. Trends in the behavior of free liquid films are important for understanding the processes occurring in foams. The equilibrium equations for a nonisothermal weightless free film are derived for the two limiting cases: the temperature of the film is considered a known function of the coordinates; the free surface of the film is thermally insulated. For the plane and axisymmetric cases, the existence conditions for the solutions of the resulting nonlinear boundary-value problems are found and their properties are studied. For the general case, an approximate solution of the equilibrium problem is obtained provided that the analogue of the Marangoni number is small. __________ Translated from Prikladnaya Mekhanika i Tekhnicheskaya Fizika, Vol. 48, No. 3, pp. 16–29, May–June, 2007.     

An experimental analysis of accuracy and precision of a high-speed strain-gage system based on the direct-resistance method

An experimental study about the relative merits of using a high-speed digital-acquisition system to measure directly the strain-gage resistance rather than using a conventional Wheatstone bridge, is carried out. Both strain gages, with a nominal resistance of 120 Ω and 1 kΩ, are simulated with precision resistors and the output signals were acquired over a time of 48 and 144 hours; furthermore, the effects in metrological performances caused by a statistical filtering are evaluated. The results show that the implementation of the statistical filtering gains a considerable improvement in gathering straingage-resistance readings. On the other hand such a procedure causes, obviously, a loss of performance with regard to the acquisition rate, therefore to the dynamic data-collecting capabilities. In any case the intrinsic resolution of the 12-bit a/d converter, utilized in the present experimental analysis, causes a limitation for measurement accuracy in the range of hundreds μ m/m. Paper was originally presented at the 1991 SEM Spring Conference on Experimental Mechanics held in Milwaukee, WI on June 9–13.     

Investigation of liquid–liquid drop coalescence using tomographic PIV

High-speed tomographic PIV was used to investigate the coalescence of drops placed on a liquid/liquid interface; the coalescence of a single drop and of a drop in the presence of an adjacent drop (side-by-side drops) was investigated. The viscosity ratio between the drop and surrounding fluids was 0.14, the Ohnesorge number (Oh = μ_d/(ρ_dσD)^1/2) was 0.011, and Bond numbers (Bo = (ρ _d  − ρ _s )gD ²/σ) were 3.1–7.5. Evolving volumetric velocity fields of the full coalescence process allowed for quantification of the velocity scales occurring over different time scales. For both single and side-by-side drops, the coalescence initiates with an off-axis film rupture and film retraction speeds an order of magnitude larger than the collapse speed of the drop fluid. This is followed by the formation and propagation of an outward surface wave along the coalescing interface with wavelength of approximately 2D. For side-by-side drops, the collapse of the first drop is asymmetric due to the presence of the second drop and associated interface deformation. Overall, tomographic PIV provides insight into the flow physics and inherent three-dimensionalities in the coalescence process that would not be achievable with flow visualization or planar PIV only.