Publications

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

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

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

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

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

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In this report, we investigate how manufacturing conditions result in the warpage of moderate density PMDI polyurethane foam (12-50 lb/ft³) when they are released from a mold. We have developed a multiphysics modeling framework to simulate the manufacturing process including resin injection, foaming and mold filling, gelation of the matrix, elevated cure, vitrification, cool down, and demolding. We have implemented this framework within the Sierra Mechanics Finite Element Code Suite. We couple Aria for flow, energy conservation, and foaming/curing kinetics with Adagio for the nonlinear viscoelastic solid response in a multi-staged simulation process flow. We calibrate a model for the PMDI-10S (10 lb/ft³ free rise foam) through a suite of characterization data presented here to calibrate the solid cure behavior of the foam. The model is then used and compared to a benchmark experiment, the manufacturing and warpage over 1 year of a 10 cm by 10 cm by 2.5 cm foam "staple". This component features both slender and thick regions that warp considerably differently over time. Qualitative agreement between the model and the experiment is achieved but quantitative accuracy is not.

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Polyurethane foams are used widely for encapsulation and structural purposes because they are inexpensive, straightforward to process, amenable to a wide range of density variations (1 lb/ft3 - 50 lb/ft3), and able to fill complex molds quickly and effectively. Computational model of the filling and curing process are needed to reduce defects such as voids, out-of-specification density, density gradients, foam decomposition from high temperatures due to exotherms, and incomplete filling. This paper details the development of a computational fluid dynamics model of a moderate density PMDI structural foam, PMDI-10. PMDI is an isocyanate-based polyurethane foam, which is chemically blown with water. The polyol reacts with isocyanate to produces the polymer. PMDI- 10 is catalyzed giving it a short pot life: it foams and polymerizes to a solid within 5 minutes during normal processing. To achieve a higher density, the foam is over-packed to twice or more of its free rise density of 10 lb/ft3. The goal for modeling is to represent the expansion, filling of molds, and the polymerization of the foam. This will be used to reduce defects, optimize the mold design, troubleshoot the processed, and predict the final foam properties. A homogenized continuum model foaming and curing was developed based on reaction kinetics, documented in a recent paper; it uses a simplified mathematical formalism that decouples these two reactions. The chemo-rheology of PMDI is measured experimentally and fit to a generalized- Newtonian viscosity model that is dependent on the extent of cure, gas fraction, and temperature. The conservation equations, including the equations of motion, an energy balance, and three rate equations are solved via a stabilized finite element method. The equations are combined with a level set method to determine the location of the foam-gas interface as it evolves to fill the mold. Understanding the thermal history and loads on the foam due to exothermicity and oven curing is very important to the results, since the kinetics, viscosity, and other material properties are all sensitive to temperature. Results from the model are compared to experimental flow visualization data and post-test X-ray computed tomography (CT) data for the density. Several geometries are investigated including two configurations of a mock structural part and a bar geometry to specifically test the density model. We have found that the model predicts both average density and filling profiles well. However, it under predicts density gradients, especially in the gravity direction. Further model improvements are also discussed for future work.

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