Hydraulic characterization of high temperature hydrocarbon liquid jets

An experimental study has been conducted to investigate the hydraulic characteristics of a plain orifice nozzle issuing pressurized high-temperature liquid hydrocarbon, in order to simulate injection of aviation fuel after being used as coolant in an active cooling system in a hypersonic flight vehicle. The fuel was heated to 553 K (280°C) using an induction heater, at an upstream pressure of up to 1.0 MPa, and injected to atmospheric pressure conditions through a sharp-edged orifice of diameter 0.7 mm and length 4.3 mm. It has been observed that the isothermal lines on the plane of the mass flow rate versus the square root of the pressure drop (ΔP) were clearly affected by increased fuel temperatures, and the discharge coefficient (C_d) decreased sharply with increasing fuel injection temperature (T_inj) above the fuel boiling point of 460 K. The Reynolds number (Re) for three ΔPs with respect to T_inj reached maxima and then began to decrease as T_inj increased for each ΔP case, and the fuel temperature of maximum Re at a given pressure condition increased as ΔP increased. The effects of cavitation on the hydraulic characteristics of the high temperature fuel were explored by representing C_d with respect to three cavitation numbers and dissipation efficiency. The behaviors of C_d showed a clear dependency on cavitation number, and all of the results collapsed to a single curve, regardless of ΔP. In addition, the curve indicated that the C_d characteristics was divided into non-cavitating and cavitating regions by the critical cavitation numbers near the fuel boiling point, and a sharp decrease in C_d was found to be typical in the cavitating region. The relationship between C_d and Re showed that when T_inj exceeded the boiling point the high temperature liquid jets experienced a sharp decrease in C_d at a determined Reynolds number, due to the collapse of the mass flow rate induced by the choked cavitaiton.     

Experimental study on the direct contact condensation of the steam jet in subcooled water flow in a rectangular channel: Flow patterns and flow field

Direct contact condensation (DCC) of steam jet in subcooled water flow in a channel was experimentally studied. The main inlet parameters, including steam mass flux, water mass flux and water temperature were tested in the ranges of 200–600 kg/(m² s), 7–18 × 10³ kg/(m² s), 288–333 K, respectively. Two unstable flow patterns and two stable flow patterns were observed via visualization window by a high speed camera. The flow patterns were determined by steam mass flux, water mass flux and water temperature, and the relationship between flow patterns and flow field parameters was discussed. The results indicated that whether pressure or temperature distributions on the bottom wall of channel could represent different flow patterns. And the position of pressure peak on the bottom wall could almost represent the condensation length. The upper wall pressure distributions were mainly dependent on steam and water mass flux; and the upper wall temperature distributions were affected by the three main inlet parameters. Moreover, the bottom wall pressure and temperature distributions of different unstable flow patterns had similar characteristics while those of stable flow patterns were affected by shock and expansion waves. The underlying cause of transition between different flow patterns under different inlet parameters was reflected and discussed based on pressure distributions.     

Transient heating effects in high pressure Diesel injector nozzles

The tendency of today’s fuel injection systems to reach injection pressures up to 3000 bar in order to meet forthcoming emission regulations may significantly increase liquid temperatures due to friction heating; this paper identifies numerically the importance of fuel pressurization, phase-change due to cavitation, wall heat transfer and needle valve motion on the fluid heating induced in high pressure Diesel fuel injectors. These parameters affect the nozzle discharge coefficient (C_d), fuel exit temperature, cavitation volume fraction and temperature distribution within the nozzle. Variable fuel properties, being a function of the local pressure and temperature are found necessary in order to simulate accurately the effects of depressurization and heating induced by friction forces. Comparison of CFD predictions against a 0-D thermodynamic model, indicates that although the mean exit temperature increase relative to the initial fuel temperature is proportional to (1 − C_d²) at fixed needle positions, it can significantly deviate from this value when the motion of the needle valve, controlling the opening and closing of the injection process, is taken into consideration. Increasing the inlet pressure from 2000 bar, which is the pressure utilized in today’s fuel systems to 3000 bar, results to significantly increased fluid temperatures above the boiling point of the Diesel fuel components and therefore regions of potential heterogeneous fuel boiling are identified.     

Numerical and experimental studies of temperature field characteristic inside an irregularly-shaped cavity of a space environment simulator system

Numerical and experimental methods were used to explore temperature and pressure distributions inside an irregularly-shaped cavity of a novel three-dimensional space environment simulator (SES) system. In order to obtain better temperature and pressure distributions, a plenum chamber and airflow diffusion perforated plate were adopted. Three-dimensional heat and mass transfer characteristics were analyzed using the Standard k–ε turbulence model. Simulation results revealed that the temperature and pressure distributions were greatly improved with improved diffusion configuration design, the temperature gradient decreased from 5 K to 1 K, and the pressure gradient decreased to 0.5% of the former value. Based on the simulation results, an improved experimental system for simulating space environment was set up. This experiment system could supply airflow with temperature ranging from 193 K to 353 K for simulating the real space environment. Experimental results showed that the temperature and pressure fields had smaller gradients across the surface and the inner cavity, which agreed considerably with the numerical results. The results of this study present useful information for the design of similar cavity structure.     

Gas temperature in the trace of water droplets streamlined by hot air flow

In order to obtain the knowledge necessary for developing new effective fire extinguishing technologies, we determined experimentally the gas temperature in the trace of water droplets streamlined by hot air flow. It was important to establish how much the temperature in the droplet trace decreases and how fast it recovery to the initial temperature field after the droplet evaporation. The following parameters were varied: droplet size from 1.3 mm to 1.7 mm, velocity from 1 m/s to 5 m/s, initial airflow temperature from 473 K to 773 K, number of droplets (one or two), and the arrangement of droplets relative to the hot inflow (serial or parallel). The study proves the theoretical hypothesis about a significant influence of evaporation on the temperature in the water droplet trace. When a temperature trace of water droplets is formed, irrespective of their arrangement, the role of the evaporation process strengthens with the gas flow temperature rising. Furthermore, the study specifies typical longitudinal dimensions of the aerodynamic and temperature traces of water droplets. It has been established that when droplets are located in series and in parallel, their combined impact on the temperature and velocity of the gas flow in the medium differs rather considerably.     

Atomistic simulation of crystallization of a polyethylene melt in steady uniaxial extension

We present simulation results of flow-induced crystallization of a dense polymeric liquid subjected to a strong uniaxial elongational flow using a rigorous nonequilibrium Monte Carlo method. A distinct transition between the liquid and the crystalline phases occurred at critical values of flow strength, with an abrupt, discontinuous transition of the overall chain conformation. The flow-induced crystalline phase matched quantitatively the experimental X-ray diffraction data of the real crystals remarkably well, including the sharp Bragg peaks at small wavenumbers, k < 1.5 Å^?1, indicating the existence of a global long-range ordering. We also found that the enthalpy change (ΔH = 225 J/g) during the phase transition was quantitatively very similar to the experimental heat of fusion (276 J/g) of polyethylene crystals under quiescent conditions. Furthermore, a detailed analysis of the configuration-based temperature provided a sound microscopic physical origin for the effective enhancement of the crystallization (or melting) temperature that has been observed in experiments. Simulation results also allow for the deduction of potential nonequilibrium expressions for thermodynamic quantities, such as temperature and heat capacity.     

On air-chemistry reduction for hypersonic external flow applications

In external hypersonic flows, viscous and compressibility effects generate very high temperatures leading to significant chemical reactions among air constituents. Therefore, hypersonic flow computations require coupled calculations of flow and chemistry. Accurate and efficient computations of air-chemistry kinetics are of much importance for many practical applications but calculations accounting for detailed chemical kinetics can be prohibitively expensive. In this paper, we investigate the possibility of applying chemical kinetics reduction schemes for hypersonic air-chemistry. We consider two chemical kinetics sets appropriate for three different temperature ranges: 2500 K to 4500 K; 4500 K to 9000 K; and above 9000 K. By demonstrating the existence of the so-called the slow manifold in each of the chemistry sets, we show that judicious chemical kinetics reduction leading to significant computational savings is possible without much loss in accuracy.     

Effect of temperature on the effective thermal conductivity of n-tetradecane-based nanofluids containing copper nanoparticles

Nanofluids were prepared by dispersing Cu nanoparticles (∼20 nm) in n-tetradecane by a two-step method. The effective thermal conductivity was measured for various nanoparticle volume fractions (0.0001–0.02) and temperatures (306.22–452.66 K). The experimental data compares well with the Jang and Choi model. The thermal conductivity enhancement was lower above 391.06 K than for that between 306.22 and 360.77 K. The interfacial thermal resistance increased with increasing temperature. The effective thermal conductivity enhancement was greater than that obtained with a more viscous fluid as the base media at 452.66 K because of nanoconvection induced by nanoparticle Brownian motion at high temperature.     

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.     

Wavelet decomposition method decoupled boiling/evaporation oscillation mechanisms over two to three timescales: A study for a microchannel with pin fin structure

Boiling/evaporation heat transfer in a microchannel with pin fin structure was performed with water as the working fluid. Simultaneous measurements of various parameters were performed. The chip wall temperatures were measured by a high spatial-time resolution IR image system, having a sensitivity of 0.02 °C. The flow pattern variations synchronously changed wall temperatures due to ultra-small Bi number. The wavelet decomposition method successfully identified the noise signal and decoupled various temperature oscillations with different amplitudes and frequencies. Three types of temperature oscillations were identified according to heat flux q and mass flux G. The first type of oscillation occurred at q/G < 0.62 kJ/kg. The approximation coefficient of wavelet decomposition decided the dominant cycle period which was ∼3 times of the fluid residence time in the microchannel, behaving the density wave oscillation characteristic. The detail coefficients of wavelet decomposition decided the dominant cycle period, which matched the flow pattern transition determined value well, representing the flow pattern transition induced oscillation. For the second type of oscillation, the wavelet decomposition decoupled the three oscillation mechanisms. The pressure drop oscillation caused the temperature oscillation amplitudes of 5–10 °C and cycle periods of 10–15 s. The density wave oscillation and flow pattern transition induced oscillation are embedded with both the pressure rise and decrease stages of the pressure drop oscillation. The third type of oscillation happened at q/G > 1.13 kJ/kg, having the density wave oscillation coupled with the varied liquid film evaporation induced oscillation. The liquid island, retention bubble induced nucleation sites and cone-shape two-phase developing region are unique features of microchannel boiling with pin fin structure. This study illustrated that pressure drop oscillation and density wave oscillation, usually happened in large size channels, also take place in microchannels. The flow pattern transition and varied liquid film evaporation induced oscillations are specific to microchannel boiling/evaporation flow.     

Saturated critical heat flux in a multi-microchannel heat sink fed by a split flow system

An extensive experimental campaign has been carried out for the measurement of saturated critical heat flux in a multi-microchannel copper heat sink. The heat sink was formed by 29 parallel channels that were 199 μm wide and 756 μm deep. In order to increase the critical heat flux and reduce the two-phase pressure drop, a split flow system was implemented with one central inlet at the middle of the channels and two outlets at either end. The base critical heat flux was measured using three HFC Refrigerants (R134a, R236fa and R245fa) for mass fluxes ranging from 250 to 1500 kg/m² s, inlet subcoolings from ?25 to ?5 K and saturation temperatures from 20 to 50 °C. The parametric effects of mass velocity, saturation temperature and inlet subcooling were investigated. The analysis showed that significantly higher CHF was obtainable with the split flow system (one inlet–two outlets) compared to the single inlet–single outlet system, providing also a much lower pressure drop. Notably several existing predictive methods matched the experimental data quite well and quantitatively predicted the benefit of higher CHF of the split flow.     

CFD–DEM simulation of the pneumatic conveying of fine particles through a horizontal slit

Fine particles play a significant role in many industrial processes. To study the dynamic behavior of fine particle and their deposition in rock fractures, the pneumatic conveying of fine particles (approximately 100 μm in diameter) through a small-scale horizontal slit (0.41 m × 0.025 m) was studied, which is useful for the sealing technology of underground gas drainage in coal mining production. The CFD–DEM method was adopted to model the gas-particle two-phase flow; the gas phase was treated as a continuum and modeled using computational fluid dynamics (CFD), particle motion and collisions were simulated using the DEM code. Then, the bulk movement of fine particles through a small-scale horizontal slit was explored numerically, and the flow patterns were further investigated by visual inspection. The simulation results indicated that stratified flow or dune flow can be observed at low gas velocities. For intermediate gas velocities, the flow patterns showed pulsation phenomena, and dune flow reappeared in the tail section. Moreover, periodic flow regimes with alternating thick and sparse stream structures were observed at a high gas velocity. The simulation results of the bulk movement of fine particles were in good agreement with the experimental findings, which were obtained by video-imaging experiments. Furthermore, the calculated pressure drop versus gas velocity profile was investigated and compared with relative experimental findings, and the results showed good agreement. Furthermore, the particle velocity vectors and voidage distribution were numerically simulated. Selected stimulation results are presented and provide a reference for the further study of fine particles.     

Experimental investigation of the effects of blowing conditions and Mach number on the unsteady behavior of coolant ejection through a trailing edge cutback

The present paper shows the results of an experimental investigation into the unsteadiness of coolant ejection at the trailing edge of a highly loaded nozzle vane cascade. The trailing edge cooling scheme features a pressure side cutback with film cooling slots, stiffened by evenly spaced ribs in an inline configuration. Cooling air is also ejected through two rows of cylindrical holes placed upstream of the cutback. Tests were performed with a low inlet turbulence intensity level (Tu₁ = 1.6%), changing the cascade operating conditions from low speed (M_2is = 0.2) up to high subsonic regime (M_2is = 0.6), and with coolant to main stream mass flow ratio varied within the 0.5–2.0% range. Particle Image Velocimetry (PIV) and flow visualizations were used to investigate the unsteady mixing process taking place between coolant and main flow downstream of the cutback, up to the trailing edge. For all the tested conditions, the results show the presence of large coherent structures, which presence is still evident up to the trailing edge. Their shape and direction of rotation change with injection conditions, as a function of coolant to mainstream velocity ratio, strongly influencing the thermal protection capability of the injected coolant flow. The Mach number increase is only responsible for a positioning of such vortical structures closer to the wall, while the Strouhal number almost remains unchanged.     

Resolving the stratification discrepancy of turbulent natural convection in differentially heated air-filled cavities. Part III: A full convection–conduction–surface radiation coupling

The present study concerns an air-filled differentially heated cavity of 1 m × 0.32 m × 1 m (width × depth × height) subject to a temperature difference of 15 K and is motivated by the need to understand the persistent discrepancy observed between numerical and experimental results on thermal stratification in the cavity core. An improved experiment with enhanced metrology was set up and experimental data have been obtained along with the characteristics of the surfaces and materials used. Experimental temperature distributions on the passive walls have been introduced in numerical simulations in order to provide a faithful prediction of experimental data. By means of DNS using spectral methods, heat conduction in the insulating material is first coupled with natural convection in the cavity. As heat conduction influences only the temperature distribution on the top and bottom surfaces and in the near wall regions, surface radiation is added to the coupling of natural convection with heat conduction. The temperature distribution in the cavity is strongly affected by the polycarbonate front and rear walls of the cavity, which are almost black surfaces for low temperature radiation, and also other low emissivity walls. The thermal stratification is considerably weakened by surface radiation. Good agreement between numerical simulations and experiments is observed on both time-averaged fields and turbulent statistics. Treating the full conduction–convection–radiation coupling allowed to confirm that experimental wall temperatures resulted from the coupled phenomena and this is another way to predict correctly the experimental results in the cavity.     

An experimental and numerical study of the localization behavior of tantalum and stainless steel

In general, the shear localization process involves initiation and growth. Initiation is expected to be a stochastic process in material space where anisotropy in the elastic–plastic behavior of single crystals and inter-crystalline interactions serve to form natural perturbations to the material’s local stability. A hat-shaped sample geometry was used to study shear localization growth. It is an axi-symmetric sample with an upper “hat” portion and a lower “brim” portion with the shear zone located between the hat and brim. The shear zone length is 870–890 μm with deformation imposed through a split-Hopkinson pressure bar system at maximum top-to-bottom velocity in the range of 8–25 m/s. We present experimental results of the deformation response of tantalum and 316L stainless steel samples. The tantalum samples did not form shear bands but the stainless steel sample formed a late stage shear band. We have also modeled these experiments using both conductive and adiabatic continuum models. An anisotropic elasto-viscoplastic constitutive model with damage evolution was used within the finite element code EPIC. A Mie-Gruneisen equation of state and the rate and temperature sensitive MTS flow stress model together with a Gurson flow surface were employed. The models performed well in predicting the experimental data. The numerical results for tantalum suggested a maximum equivalent strain rate on the order of 7 × 10⁴ s⁻¹ in the gage section for an imposed top surface displacement rate of 17.5 m/s. The models also suggested that for an initial temperature of 298 K a temperature in the neighborhood of 900 K was reached within the shear section. The numerical results for stainless steel suggest that melting temperature was reached throughout the shear band shortly after peak load. Due to sample geometry, the stress state in the shear zone was not pure shear; a significant normal stress relative to the shear zone basis line was developed.     

Spatiotemporal representation of the dynamic modes in turbulent cavity flows

Proper orthogonal decomposition (POD) and dynamic mode decomposition (DMD) were used to extract the coherent structures in turbulent cavity flows. The spatiotemporal representation of the modes was achieved by performing the circular convolution of a change of basis on the data sequence, wherein the transformation function was extracted from the POD or DMD. The spatiotemporal representation of the modes provided significant insight into the evolutionary behavior of the structures. Self-sustained oscillations arise in turbulent cavity flows due to unsteady separation at the leading edge. The turbulent cavity flow at Re_D = 12,000 and a length to depth ratio L/D = 2 was analyzed. The dynamic modes extracted from the data clarified the presence of self-sustained oscillations. The spatiotemporal representation of the POD and DMD modes that caused self-sustained oscillations revealed the prevalent dynamics and evolutionary behavior of the coherent structures from their formation at the leading edge to their impingement at the trailing edge. A local minimum in the mode amplitude representing the energy contributions to the flow was observed upon the impingement of coherent structure at the trailing edge. The modal energy associated with the periodic formation of organized coherent structures followed by their dissipation upon impingement revealed the oscillatory behavior over time.     

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.     

Instantaneous flow field above the free end of finite-height cylinders and prisms

The flow above the free ends of surface-mounted finite-height circular cylinders and square prisms was studied experimentally using particle image velocimetry (PIV). Cylinders and prisms with aspect ratios of AR = 9, 7, 5, and 3 were tested at a Reynolds number of Re = 4.2 × 10⁴. The bodies were mounted normal to a ground plane and were partially immersed in a turbulent zero-pressure-gradient boundary layer, where the boundary layer thickness relative to the body width was δ/D = 1.6. PIV measurements were made above the free ends of the bodies in a vertical plane aligned with the flow centreline. The present PIV results provide insight into the effects of aspect ratio and body shape on the instantaneous flow field. The recirculation zone under the separated shear layer is larger for the square prism of AR = 3 compared to the more slender prism of AR = 9. Also, for a square prism with low aspect ratio (AR = 3), the influence of the reverse flow over the free end surface becomes more significant compared to that for a higher aspect ratio (AR = 9). For the circular cylinder, a cross-stream vortex forms within the recirculation zone. As the aspect ratio of the cylinder decreases, the reattachment point of the separated flow on the free end surface moves closer to the trailing edge. For both the square prism and circular cylinder cases, the instantaneous velocity vector field and associated in-plane vorticity field revealed small-scale structures mostly generated by the separated shear layer.     

Effects of the jet-to-crossflow momentum ratio on a sonic jet into a supersonic crossflow

Numerical investigation of a transverse sonic jet injected into a supersonic crossflow was carried out using large-eddy simulation for a free-stream Mach number M = 1.6 and a Reynolds number Re = 1.38 × 10⁵ based on the jet diameter. Effects of the jet-to-crossflow momentum ratio on various fundamental mechanisms dictating the intricate flow phenomena, including flow structures, turbulent characters and frequency behaviors, have been studied. The complex flow structures and the relevant flow features are discussed to exhibit the evolution of shock structures, vortical structures and jet shear layers. The strength of the bow shock increases and the sizes of the barrel shock and Mach disk also increase with increasing momentum ratio. Turbulent characters are clarified to be closely related to the flow structures. The jet penetration increases with the increase of the momentum ratio. Moreover, the dominant frequencies of the flow structures are obtained using spectral analysis. The results obtained in this letter provide physical insight in understanding the mechanisms relevant to this complex flow.     

Investigation of slip boundary conditions in the T-shaped microchannel

Flow regimes and mixing performance in a T-type micromixer at high Reynolds numbers were studied by numerical solution of the Navier–Stokes equations. The Reynolds number was varied from 1 to 1000. The cross section of the mixing channel was 100 μm × 200 μm, and its length was 1400 μm. The transverse inlet channels were symmetric about the mixing channel, and their cross-section was 100 μm × 100 μm, and the total length was 800 μm. Five different flow regimes were identified: (i) stationary vortex-free flow (Re < 5); (ii) stationary symmetric vortex flow with two horseshoe vortices (5 < Re < 150); (iii) stationary asymmetric vortex flow (150 < Re < 240); (iv) non-stationary periodic flow (240 < Re < 400); and (v) stochastic flow (Re > 400). Maximum mixing efficiency is obtained for nonstationary asymmetric vortex flow. In this case, an S-shaped vortex structure is formed in the flow field. The effect of the slip conditions on the flow pattern and mixing efficiency is studied. The slip length varied from 1 to 70 μm in the calculations. It was shown that the mixing can be controlled by hydrophobic coating.