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- All Subjects: Mechanical Engineering
Description
Dissimilar metal joints such as aluminum-steel joints are extensively used in automobile, naval and aerospace applications and these are subjected to corrosive environmental and mechanical loading resulting in eventual failure of the structural joints. In the case of aluminum alloys under aggressive environment, the damage accumulation is predominantly due to corrosion and is accelerated in presence of other metals. During recent years several approaches have been employed to develop models to assess the metal removal rate in the case of galvanic corrosion. Some of these models are based on empirical methods such as regression analysis while others are based on quantification of the ongoing electrochemical processes. Here, a numerical model for solving the Nernst- Planck equation, which captures the electrochemical process, is implemented to predict the galvanic current distribution and, hence, the corrosion rate of a galvanic couple. An experimentally validated numerical model for an AE44 (Magnesium alloy) and mild steel galvanic couple, available in the literature, is extended to simulate the mechano- electrochemical process in order to study the effect of mechanical loading on the galvanic current density distribution and corrosion rate in AE44-mild steel galvanic couple through a multiphysics field coupling technique in COMSOL Multiphysics®. The model is capable of tracking moving boundariesy of the corroding constituent of the couple by employing Arbitrary Langrangian Eulerian (ALE) method.Results show that, when an anode is under a purely elastic deformation, there is no apparent effect of mechanical loading on the electrochemical galvanic process. However, when the applied tensile load is sufficient to cause a plastic deformation, the local galvanic corrosion activity at the vicinity of the interface is increased remarkably. The effect of other factors, such as electrode area ratios, electrical conductivity of the electrolyte and depth of the electrolyte, are studied. It is observed that the conductivity of the electrolyte significantly influences the surface profile of the anode, especially near the junction. Although variations in electrolyte depth for a given galvanic couple noticeably affect the overall corrosion, the change in the localized corrosion rate at the interface is minimal. Finally, we use the model to predict the current density distribution, rate of corrosion and depth profile of aluminum alloy 7075-stainless steel 316 galvanic joints, which are extensively used in maritime structures.
ContributorsMuthegowda, Nitin Chandra (Author) / Solanki, Kiran N (Thesis advisor) / Rykaczewski, Konrad (Committee member) / Jiao, Yang (Committee member) / Arizona State University (Publisher)
Created2015
Description
The subject of this thesis is concerned with the amount of cooling air assigned to seal high pressure turbine rim cavities which is critical for performance as well as component life. Insufficient air leads to excessive hot annulus gas ingestion and its penetration deep into the cavity compromising disc life. Excessive purge air, adversely affects performance. Experiments on a rotating turbine stage rig which included a rotor-stator forward disc cavity were performed at Arizona State University. The turbine rig has 22 vanes and 28 blades, while the rim cavity is composed of a single-tooth rim lab seal and a rim platform overlap seal. Time-averaged static pressures were measured in the gas path and the cavity, while mainstream gas ingestion into the cavity was determined by measuring the concentration distribution of tracer gas (carbon dioxide). Additionally, particle image velocimetry (PIV) was used to measure fluid velocity inside the rim cavity between the lab seal and the overlap. The data from the experiments were compared to an 360-degree unsteady RANS (URANS) CFD simulations. Although not able to match the time-averaged test data satisfactorily, the CFD simulations brought to light the unsteadiness present in the flow during the experiment which the slower response data did not fully capture. To interrogate the validity of URANS simulations in capturing complex rotating flow physics, the scope of this work also included to validating the CFD tool by comparing its predictions against experimental LDV data in a closed rotor-stator cavity. The enclosed cavity has a stationary shroud, a rotating hub, and mass flow does not enter or exit the system. A full 360 degree numerical simulation was performed comparing Fluent LES, with URANS turbulence models. Results from these investigations point to URANS state of art under-predicting closed cavity tangential velocity by 32% to 43%, and open rim cavity effectiveness by 50% compared to test data. The goal of this thesis is to assess the validity of URANS turbulence models in more complex rotating flows, compare accuracy with LES simulations, suggest CFD settings to better simulate turbine stage mainstream/disc cavity interaction with ingestion, and recommend experimentation techniques.
ContributorsKanjiyani, Shezan (Author) / Lee, Taewoo (Thesis advisor) / Mirzamoghadam, Alexander (Committee member) / Huang, Huei-Ping (Committee member) / Arizona State University (Publisher)
Created2016
Description
In this thesis, we focus on some of the NP-hard problems in control theory. Thanks to the converse Lyapunov theory, these problems can often be modeled as optimization over polynomials. To avoid the problem of intractability, we establish a trade off between accuracy and complexity. In particular, we develop a sequence of tractable optimization problems - in the form of Linear Programs (LPs) and/or Semi-Definite Programs (SDPs) - whose solutions converge to the exact solution of the NP-hard problem. However, the computational and memory complexity of these LPs and SDPs grow exponentially with the progress of the sequence - meaning that improving the accuracy of the solutions requires solving SDPs with tens of thousands of decision variables and constraints. Setting up and solving such problems is a significant challenge. The existing optimization algorithms and software are only designed to use desktop computers or small cluster computers - machines which do not have sufficient memory for solving such large SDPs. Moreover, the speed-up of these algorithms does not scale beyond dozens of processors. This in fact is the reason we seek parallel algorithms for setting-up and solving large SDPs on large cluster- and/or super-computers.
We propose parallel algorithms for stability analysis of two classes of systems: 1) Linear systems with a large number of uncertain parameters; 2) Nonlinear systems defined by polynomial vector fields. First, we develop a distributed parallel algorithm which applies Polya's and/or Handelman's theorems to some variants of parameter-dependent Lyapunov inequalities with parameters defined over the standard simplex. The result is a sequence of SDPs which possess a block-diagonal structure. We then develop a parallel SDP solver which exploits this structure in order to map the computation, memory and communication to a distributed parallel environment. Numerical tests on a supercomputer demonstrate the ability of the algorithm to efficiently utilize hundreds and potentially thousands of processors, and analyze systems with 100+ dimensional state-space. Furthermore, we extend our algorithms to analyze robust stability over more complicated geometries such as hypercubes and arbitrary convex polytopes. Our algorithms can be readily extended to address a wide variety of problems in control such as Hinfinity synthesis for systems with parametric uncertainty and computing control Lyapunov functions.
We propose parallel algorithms for stability analysis of two classes of systems: 1) Linear systems with a large number of uncertain parameters; 2) Nonlinear systems defined by polynomial vector fields. First, we develop a distributed parallel algorithm which applies Polya's and/or Handelman's theorems to some variants of parameter-dependent Lyapunov inequalities with parameters defined over the standard simplex. The result is a sequence of SDPs which possess a block-diagonal structure. We then develop a parallel SDP solver which exploits this structure in order to map the computation, memory and communication to a distributed parallel environment. Numerical tests on a supercomputer demonstrate the ability of the algorithm to efficiently utilize hundreds and potentially thousands of processors, and analyze systems with 100+ dimensional state-space. Furthermore, we extend our algorithms to analyze robust stability over more complicated geometries such as hypercubes and arbitrary convex polytopes. Our algorithms can be readily extended to address a wide variety of problems in control such as Hinfinity synthesis for systems with parametric uncertainty and computing control Lyapunov functions.
ContributorsKamyar, Reza (Author) / Peet, Matthew (Thesis advisor) / Berman, Spring (Committee member) / Rivera, Daniel (Committee member) / Artemiadis, Panagiotis (Committee member) / Fainekos, Georgios (Committee member) / Arizona State University (Publisher)
Created2016
Description
Gas turbine efficiency has improved over the years due to increases in compressor
pressure ratio and turbine entry temperature (TET) of main combustion gas, made viable
through advancements in material science and cooling techniques. Ingestion of main
combustion gas into the turbine rotor-stator disk cavities can cause major damage to the
gas turbine. To counter this ingestion, rim seals are installed at the periphery of turbine
disks, and purge air extracted from the compressor discharge is supplied to the disk
cavities. Optimum usage of purge air is essential as purge air extraction imparts a penalty on turbine efficiency and specific fuel consumption.
In the present work, experiments were conducted in a newly constructed 1.5-stage
axial flow air turbine featuring vanes and blades to study main gas ingestion. The disk
cavity upstream of the rotor, the 'front cavity', features a double seal with radial clearance
and axial overlap at its rim. The disk cavity downstream of the rotor, the 'aft cavity', features a double seal at its rim but with axial gap. Both cavities contain a labyrinth seal radially inboard; this divides each disk cavity into an 'inner cavity' and a 'rim cavity'.
Time-averaged static pressure at various locations in the main gas path and disk
cavities, and tracer gas (CO2) concentration at different locations in the cavities were
measured. Three sets of experiments were carried out; each set is defined by the main air flow rate and rotor speed. Each of the three sets comprises of four different purge air flow rates, low to high.
The mass flow rate of ingested main gas into the front and aft rim cavities is
reported at the different purge air flow rates, for the three experiment sets. For the present stage configuration, it appears that some ingestion persisted into both the front and aft rim cavities even at high purge air flow rates. On the other hand, the front and aft inner cavity were completely sealed at all purge flows.
pressure ratio and turbine entry temperature (TET) of main combustion gas, made viable
through advancements in material science and cooling techniques. Ingestion of main
combustion gas into the turbine rotor-stator disk cavities can cause major damage to the
gas turbine. To counter this ingestion, rim seals are installed at the periphery of turbine
disks, and purge air extracted from the compressor discharge is supplied to the disk
cavities. Optimum usage of purge air is essential as purge air extraction imparts a penalty on turbine efficiency and specific fuel consumption.
In the present work, experiments were conducted in a newly constructed 1.5-stage
axial flow air turbine featuring vanes and blades to study main gas ingestion. The disk
cavity upstream of the rotor, the 'front cavity', features a double seal with radial clearance
and axial overlap at its rim. The disk cavity downstream of the rotor, the 'aft cavity', features a double seal at its rim but with axial gap. Both cavities contain a labyrinth seal radially inboard; this divides each disk cavity into an 'inner cavity' and a 'rim cavity'.
Time-averaged static pressure at various locations in the main gas path and disk
cavities, and tracer gas (CO2) concentration at different locations in the cavities were
measured. Three sets of experiments were carried out; each set is defined by the main air flow rate and rotor speed. Each of the three sets comprises of four different purge air flow rates, low to high.
The mass flow rate of ingested main gas into the front and aft rim cavities is
reported at the different purge air flow rates, for the three experiment sets. For the present stage configuration, it appears that some ingestion persisted into both the front and aft rim cavities even at high purge air flow rates. On the other hand, the front and aft inner cavity were completely sealed at all purge flows.
ContributorsMichael, Mukilan Sebastiraj (Author) / Roy, Ramendra P (Thesis advisor) / Mignolet, Marc P (Thesis advisor) / Phelan, Patrick (Committee member) / Arizona State University (Publisher)
Created2015
Description
Contact angle goniometer is one of the most common tools in surfaces science. Since the introduction of this instrument by Fox and Zisman1 in 1950, dispensing the liquid using a syringe has generated pendant drops. However, using such approach at conditions significantly deviating from standard pressure and temperature would require an elaborate and costly fluidic system. To this end, this thesis work introduces alternative design of a goniometer capable of contact angle measurement at wide pressure and temperature range. In this design, pendant droplets are not dispensed through a pipette but are generated through localized condensation on a tip of a preferentially cooled small metal wire encapsulated within a thick thermal insulator layer. This thesis work covers experimental study of the relation between the geometry of the condensation-based pendant drop generator geometry and subcooling, and growth rate of drops of representative high (water) and low (pentane) surface tension liquids. Several routes that the generated pendant drops can be used to measure static and dynamic contact angles of the two liquids on common substrates well as nanoengineered superhydrophobic and omniphobic surfaces are demonstrated.
ContributorsMohan, Ajay Roopesh (Author) / Rykaczewski, Konrad (Thesis advisor) / Herrmann, Marcus (Committee member) / Wang, Robert (Committee member) / Arizona State University (Publisher)
Created2015
Description
CubeSats offer a compelling pathway towards lowering the cost of interplanetary exploration missions thanks to their low mass and volume. This has been possible due to miniaturization of electronics and sensors and increased efficiency of photovoltaics. Interplanetary communication using radio signals requires large parabolic antennas on the spacecraft and this often exceeds the total volume of CubeSat spacecraft. Mechanical deployable antennas have been proposed that would unfurl to form a large parabolic dish. These antennas much like an umbrella has many mechanical moving parts, are complex and are prone to jamming. An alternative are inflatables, due to their tenfold savings in mass, large surface area and very high packing efficiency of 20:1. The present work describes the process of designing and building inflatable parabolic reflectors for small satellite radio communications in the X band.
Tests show these inflatable reflectors to provide significantly higher gain characteristics as compared to conventional antennas. This would lead to much higher data rates from low earth orbits and would provide enabling communication capabilities for small satellites in deeper space. This technology is critical to lowering costs of small satellites while enhancing their capabilities.
Principle design challenges with inflatable membranes are maintaining accurate desired shape, reliable deployment mechanism and outer space environment protection. The present work tackles each of the mentioned challenges and provides an
understanding towards future work. In the course of our experimentation we have been able to address these challenges using building techniques that evolved out of a matured understanding of the inflation process.
Our design is based on low cost chemical sublimates as inflation substances that use a simple mechanism for inflation. To improve the reliability of the inflated shape, we use UV radiation hardened polymer support structures. The novelty of the design lies in its simplicity, low cost and high reliability. The design and development work provides an understanding towards extending these concepts to much larger deployable structures such as solar sails, inflatable truss structures for orbit servicing and large surface area inflatables for deceleration from hypersonic speeds when re-entering the atmosphere.
Tests show these inflatable reflectors to provide significantly higher gain characteristics as compared to conventional antennas. This would lead to much higher data rates from low earth orbits and would provide enabling communication capabilities for small satellites in deeper space. This technology is critical to lowering costs of small satellites while enhancing their capabilities.
Principle design challenges with inflatable membranes are maintaining accurate desired shape, reliable deployment mechanism and outer space environment protection. The present work tackles each of the mentioned challenges and provides an
understanding towards future work. In the course of our experimentation we have been able to address these challenges using building techniques that evolved out of a matured understanding of the inflation process.
Our design is based on low cost chemical sublimates as inflation substances that use a simple mechanism for inflation. To improve the reliability of the inflated shape, we use UV radiation hardened polymer support structures. The novelty of the design lies in its simplicity, low cost and high reliability. The design and development work provides an understanding towards extending these concepts to much larger deployable structures such as solar sails, inflatable truss structures for orbit servicing and large surface area inflatables for deceleration from hypersonic speeds when re-entering the atmosphere.
ContributorsChandra, Aman (Author) / Thangavelautham, Jekanthan (Thesis advisor) / Huang, Huei Ping (Thesis advisor) / Oswald, Jay (Committee member) / Arizona State University (Publisher)
Created2015
Description
Additive manufacturing, also known as 3-dimensional (3-d) printing, is now a rapidly growing manufacturing technique. Innovative and complex designs in various aspects of engineering have called for more efficient manufacturing techniques and 3-d printing has been a perfect choice in that direction. This research investigates the use of additive manufacturing in fabricating polymer heat exchangers and estimate their effectiveness as a heat transfer device. Fused Deposition Modeling (FDM), Selective Laser Sintering (SLS) and Stereolithography (SLA) are the three 3-d printing techniques that are explored for their feasibility in manufacturing heat exchangers. The research also explores a triply periodic minimal structure–the gyroid, as a heat exchanger design. The performance of the gyroid heat exchanger was studied using experiments. The main parameters considered for the experiments were heat transfer rate, effectiveness and pressure drop. From the results obtained it can be inferred that using polymers in heat exchangers helps reducing corrosion and fouling problems, but it affects the effectiveness of the heat exchangers. For our design, the maximum effectiveness achieved was 0.1. The pressure drop for the heat exchanger was observed to decrease with an increase in flow rate and the maximum pressure drop measured was 0.88 psi for a flow rate of 5 LPM.
ContributorsDanayat, Swapneel Shailesh (Author) / Phelan, Patrick (Thesis advisor) / Kwon, Beomjin (Committee member) / Azeredo, Bruno (Committee member) / Arizona State University (Publisher)
Created2019
Description
Near-field thermal radiation occurs when the distance between two surfaces at different temperatures is less than the characteristic wavelength of thermal radiation. While theoretical studies predict that the near-field radiative heat transfer could exceed Planck’s blackbody limit in the far-field by orders of magnitudes depending on the materials and gap distance, experimental measurement of super-Planckian near-field radiative heat flux is extremely challenging in particular at sub-100-nm vacuum gaps and few has been demonstrated. The objective of this thesis is to develop a novel thermal metrology based on AFM bi-material cantilever and experimentally measure near-field thermal radiation.
The experiment setup is completed and validated by measuring the near-field radiative heat transfer between a silica microsphere and a silica substrate and comparing with theoretical calculations. The bi-material AFM cantilever made of SiNi and Au bends with temperature changes, whose deflection is monitored by the position-sensitive diode. After careful calibration, the bi-material cantilever works as a thermal sensor, from which the near-field radiative conductance and tip temperature can be deduced when the silica substrate approaches the silica sphere attached to the cantilever by a piezo stage with a resolution of 1 nm from a few micrometers away till physical contact. The developed novel near-field thermal metrology will be used to measure the near-field radiative heat transfer between the silica microsphere and planar SiC surface as well as nanostructured SiC metasurface. This research aims to enhance the fundamental understandings of radiative heat transfer in the near-field which could lead to advances in microelectronics, optical data storage and thermal systems for energy conversion and thermal management.
The experiment setup is completed and validated by measuring the near-field radiative heat transfer between a silica microsphere and a silica substrate and comparing with theoretical calculations. The bi-material AFM cantilever made of SiNi and Au bends with temperature changes, whose deflection is monitored by the position-sensitive diode. After careful calibration, the bi-material cantilever works as a thermal sensor, from which the near-field radiative conductance and tip temperature can be deduced when the silica substrate approaches the silica sphere attached to the cantilever by a piezo stage with a resolution of 1 nm from a few micrometers away till physical contact. The developed novel near-field thermal metrology will be used to measure the near-field radiative heat transfer between the silica microsphere and planar SiC surface as well as nanostructured SiC metasurface. This research aims to enhance the fundamental understandings of radiative heat transfer in the near-field which could lead to advances in microelectronics, optical data storage and thermal systems for energy conversion and thermal management.
ContributorsKondakindi, Ramteja Reddy (Author) / Wang, Liping (Thesis advisor) / Kwon, Beomjin (Committee member) / Wang, Qing Hua (Committee member) / Arizona State University (Publisher)
Created2019
Description
In nature, it is commonly observed that animals and birds perform movement-based thermoregulation activities to regulate their body temperatures. For example, flapping of elephant ears or plumage fluffing in birds. Taking inspiration from nature and to explore the possibilities of such heat transfer enhancements, augmentation of heat transfer rates induced by the vibration of solid and well as novel flexible pinned heatsinks were studied in this research project. Enhancement of natural convection has always been very important in improving the performance of the cooling mechanisms. In this research, flexible heatsinks were developed and they were characterized based on natural convection cooling with moderately vibrating conditions. The vibration of heated surfaces such as motor surfaces, condenser surfaces, robotic arms and exoskeletons led to the motivation of the development of heat sinks having flexible fins with an improved heat transfer capacity. The performance of an inflexible, solid copper pin fin heat sink was considered as the baseline, current industry standard for the thermal performance. It is expected to obtain maximum convective heat transfer at the resonance frequency of the flexible pin fins. Current experimental results with fixed input frequency and varying amplitudes indicate that the vibration provides a moderate improvement in convective heat transfer, however, the flexibility of fins had negligible effects.
ContributorsPrabhu, Saurabh (Author) / Rykaczewski, Konrad (Thesis advisor) / Phelan, Patrick (Committee member) / Wang, Robert (Committee member) / Arizona State University (Publisher)
Created2019
Description
Non-Destructive Testing (NDT) is a branch of scientific methods and techniques
used to evaluate the defects and irregularities in engineering materials. These methods
conduct testing without destroying or altering material’s structure and functionality. Most
of these defects are subsurface making them difficult to detect and access.
SONIC INFRARED (IR) is a relatively new and emerging vibrothermography
method under the category of NDT methods. This is a fast NDT inspection method that
uses an ultrasonic generator to pass an ultrasonic pulse through the test specimen which
results in a temperature variation in the test specimen. The temperature increase around
the area of the defect is more because of frictional heating due to the vibration of the
specimen. This temperature variation can be observed using a thermal camera.
In this research study, the temperature variation in the composite laminate during
the SONIC IR experimentation using an infrared thermal camera. These recorded data are
used to determine the location, dimension and depth of defects through SONIC IR NDT
method using existing defect detection algorithms. Probability of detection analysis is
used to determine the probability of detection under specific experimental conditions for
two different types of composite laminates. Lastly, the effect of the process parameters
such as number of pulses, pulse duration and time delay between pulses of this technique
on the detectability and probability of detection is studied in detail.
used to evaluate the defects and irregularities in engineering materials. These methods
conduct testing without destroying or altering material’s structure and functionality. Most
of these defects are subsurface making them difficult to detect and access.
SONIC INFRARED (IR) is a relatively new and emerging vibrothermography
method under the category of NDT methods. This is a fast NDT inspection method that
uses an ultrasonic generator to pass an ultrasonic pulse through the test specimen which
results in a temperature variation in the test specimen. The temperature increase around
the area of the defect is more because of frictional heating due to the vibration of the
specimen. This temperature variation can be observed using a thermal camera.
In this research study, the temperature variation in the composite laminate during
the SONIC IR experimentation using an infrared thermal camera. These recorded data are
used to determine the location, dimension and depth of defects through SONIC IR NDT
method using existing defect detection algorithms. Probability of detection analysis is
used to determine the probability of detection under specific experimental conditions for
two different types of composite laminates. Lastly, the effect of the process parameters
such as number of pulses, pulse duration and time delay between pulses of this technique
on the detectability and probability of detection is studied in detail.
ContributorsDarnal, Aryabhat (Author) / Liu, Yongming (Thesis advisor) / Zhuang, Houlong (Committee member) / Nian, Qiong (Committee member) / Arizona State University (Publisher)
Created2019