Influence of the convective cooling and the thermal resistance on the temperature of the pad/disc tribosystem

The analytical solution of a boundary–value problem of heat conductivity for a tribosystem, consisting of the plane–parallel strip (pad) sliding with a velocity linearly decreasing in time, on a surface of a semi-infinity foundation (disc) is obtained. It is assumed, that the thermal contact of bodies is imperfect and the convective heat exchange with the surrounding occurs on an upper surface of the strip. For materials of frictional pair, i.e. the ceramic–metal strip and the cast-iron foundation, the influence of the coefficients (of both heat exchange and heat transfer through a surface of contact) on the distribution of temperature has been investigated.     

Numerical investigation of the effectiveness of effusion cooling for plane multi-layer systems with different base-materials

Within Collaborative Research Center (SFB) 561 “Thermally Highly Loaded, Porous and Cooled Multi-Layer Systems for Combined Cycle Power Plants” at RWTH Aachen University, an effusion-cooled multi-layer plate configuration is investigated numerically by the application of a three-dimensional in-house fluid flow and heat transfer solver, CHTflow. CHTflow is a conjugate code, which yields information on the temperature distribution in the solid body. This enables a detailed discussion of the effects of a change in materials. The geometrical set-up and the fluid flow conditions derive from modern gas turbine combustion chambers and bladings. Within the SFB, two different multi-layer systems, one consisting of substrate made of CMSX-4 (a singlecrystal super-alloy), anMCrAlY-bondoat and a ZrO₂ thermal barrier coating (TBC), and the other consisting of a NiAlalloy and a graded bondcoat/TBC, have been investigated. The grading will increase the life-span of the TBC as it can better compensate the different thermal expansion coefficients of different materials. The main focus in this study is on the different substrate materials, because the thermal conductivity of the NiAl is considerably higher than that of CMSX-4, which leads to different temperature profiles in the components.     

Influence of thermal stresses on thermal diffusion of hydrogen

Thermal diffusion of hydrogen atoms in zirconium taking into account thermal stresses is investigated. As mathematical model the steady-state temperature in the hollow cylinder is considered. The first invariant of the tensor of thermal stresses in the hollow cylinder has a logarithmic dependence on the radial coordinate. Such dependence permits an exact analytical solution of diffusion kinetics problem in view of thermal stresses.     

Use of La2O3 with 8YSZ as thermal barrier coating and its effect on thermal cycle behavior,microstructure, mechanical properties and performance of diesel engine operated by hydrogen-algae biodiesel blend

In this present work, the effect of lanthanum oxides (La₂O₃) on the thermal cycle behavior of TBC coatings and mechanical properties such as adhesion strength and microhardness of 8% Yttria Stabilized Zirconia (8YSZ) TBCs were investigated. CoNiCrAlY and aluminium alloy (Al–13%Si) were used as bond coat and substrate materials. 8YSZ and different wt % of La₂O₃ (10, 20, and 30%) top coatings were applied using the atmospheric plasma spray (APS) method. The thermal cycling test for TBC coated samples were conducted at 800 °C in the electric furnace. The XRD pattern shows that the La₂O₃ doped 8YSZ material transformed to cubic pyrochloric structured La₂Zr₂O₇ during thermal cycling. Further, the Taguchi-based grey relation analysis (GRA) method was applied to optimize the TBC coating parameters to achieve better mechanical properties such as adhesion strength and microhardness. And the optimized La₂O₃/8YSZ TBC coating was coated on CRDI engine combustion chamber components. The engine was tested with microalgae biodiesel and hydrogen, and the results were promising for the TBC-coated engine. The engine performance increased while using La₂O₃/8YSZ coated components, and the emissions from engine exhaust gas such as CO, HC, and smoke reduced considerably. It was found that there was no separation crack and spallation of the coating layer in the microstructure. Ultimately, the microstructural analysis of the optimized TBC coated piston sample after 50 h of running in the diesel engine confirmed that the developed coating had a superior thermal insulation effect and longer life.     

Influence of thermal sensitivity of the pad and disk materials on the temperature during braking

The transient frictional heating of pad–disk tribosystem at single braking is under consideration. To determine the average friction surface temperature, the one-dimensional thermal problem of friction at braking has been formulated. The linear dependence of the thermophysical properties of the disk and pad materials on the temperature has been taken into account. Model of materials with a simple nonlinearity has been adopted, i.e. materials in which coefficients of heat conduction and specific heat depend on the temperature, and their ratio – coefficient of thermal diffusivity – is constant. Linearization of the corresponding boundary-value heat conduction problem by the Kirchhoff transformation and linearizing parameter method has been performed. The numerical–analytical solution to the problem has been found by using the integral Laplace transform and the Newton–Raphson methods. The influence of the thermosensitive materials of titanium pad, sliding over the surface of the disk made of steel, aluminum alloy or gray cast iron, on the temperature has been studied.     

Three-dimensional FE model for calculation of temperature of a thermosensitive disc

An effect of variations of the temperature-dependent thermophysical properties of materials of a pad and a disc on the temperature generated due to friction was studied. A three-dimensional boundary-value problem of heat conduction of the disc heated locally within the contact area by the moving with the constant deceleration heat flux and the intensity proportional to the specific capacity of friction was formulated. An issue was solved numerically using the finite element method (FEM). The experimental dependences curves of the thermal conductivity and the thermal diffusivity on the temperature ranging from 20 to 500 °C indispensable for the calculations were approximated using Chichinadze's methodology. The comparative analysis of temperature values on the contact surface of the disc obtained with and without influence of temperature dependence of the four different pad and the same quantity of the disc materials was carried out. It was demonstrated that apparent temperature differences arose for each friction couple combining temperature-dependent and constant properties of materials, however, the largest observed discrepancy (13.7%) occurred for the disc made of aluminium alloy series Al MMC. Other disc materials i.e. iron alloy series FCD50, cast iron ChNMKh and steel EI-696 revealed relatively equal temperature differences of order of 6.4%. Furthermore incorporated in the formula for the heat partition temperature variability of the thermophysical properties of materials affected the resulting contact temperature of the disc for friction couple combined exclusively with the titanium pad VT-14 (3.1%).     

Temperature and thermal stresses in a pad/disc during braking

A two-element model of braking process for a tribosystem consisting of the pad (the strip) sliding with the time-dependent velocity (braking at uniform retardation) on a surface of the disc (the semi-space) is studied. The dependences of temperature and thermal stresses on the boundary conditions on upper surface of the ceramic–metal strip were investigated. It was proved that there is a possibility of applying the obtained results to modelling of a thermal cracking of the frictional elements during braking.     

Temperature in thermally nonlinear pad–disk brake system

The influence of the thermal sensitivity of pad and disk materials on temperature at braking is under investigation. A mathematical model of process of frictional heating in a pad–disk brake system, which takes into account the temperature-sensitive materials, is proposed. The basic element of this model is the thermal problem of friction—a one-dimensional boundary-value heat conduction problem with temperature-dependent thermal conductivity and specific heat. Contrary to the prior studies of authors, where a simple nonlinearity was considered, in this article the arbitrary nonlinearity of the thermophysical properties of materials is studied. The solution of a nonlinear boundary-value heat conduction problem is obtained by the method of successive approximations. The numerical analysis of temperature is executed for some materials of a pad and a disk with and without taking into account their thermal sensitivity.     

High-chain fatty acid esters of myristyl alcohol with even carbon number: Novel organic phase change materials for thermal energy storage—1

High-chain fatty acid esters have not been investigated for their thermal properties as phase change materials (PCMs) in thermal energy storage. A series of high-chain fatty acid esters of myristyl alcohol (1-tetradecanol) were synthesized via esterification of lauric, myristic, palmitic, stearic and arachidic acids under vacuum and in the absence of any catalyst. The esterification reactions were studied by FT-IR spectroscopy. A differential scanning calorimeter (DSC) and a thermo-gravimetric analyzer (TGA) were intensively used to determine the thermal properties of the introduced thermal storage materials. The thermal properties were given in terms of phase change temperature, enthalpy, specific heat (C_p) and thermal decomposition temperature with related statistical data. The thermal reliability of the novel organic PCMs was investigated by thermal cycling with 1000 thermal cycles with respect to the thermal properties of the original synthesized PCMs. In addition to the synthesized esters, one commercial product was also investigated. The DSC analyses indicated that the melting points of the novel organic PCMs were between 38 and 53 °C with phase change enthalpy above 200 kJ/kg. The effect of chemical structure of the materials on thermal properties was also discussed. The results showed that these materials were favorable for low temperature heat transfer applications with superior thermal properties and reliability.     

不同方法制备的TBC涂层特性的研究

众所周知,热障涂层（TBC）主要包括粘接层和面层两部分。该文采用空气助燃超音速火焰喷涂（HVAF）和氧气助燃超音速火焰喷涂（HVOF）两种方法制备粘接层,大气等离子喷涂（APS）方法制备面层,来研究不同制备方法对TBC涂层微观结构和性能的影响。试验结果表明,HVAF和APS制备的TBC涂层,粘接层中氧化现象较少,热生长氧化物（TGO）生长相对致密均匀,以α-Al2O3为主,其它复合氧化物（NiO、CrNi、CoNi等）较少,表现出较好的高温性能。YSZ陶瓷面层隔热效果良好,是一种成本低廉的新型制备TBC涂层技术。     

Influence of the pressure fluctuations on the temperature in pad/disc tribosystem

The influence of the duration of increase in pressure from zero (at the initial moment of time) to nominal value (at the moment of a stop) on the temperature for a friction pair metal–ceramic pad/cast iron disc is studied. Fluctuations of pressure are taken into account, too. The analytical solution to a thermal problem of friction during braking is obtained for a plane-parallel strip/semi-space tribosystem with a time-dependence friction power and the heat transfer through a contact surface.     

The contact heat transfer between the plane-parallel strip and the semi-infinite foundation

The analytical solution of a boundary-value problem of heat conduction for tribosystem, consisting of a plane-parallel strip sliding with a constant velocity on a surface of semi-infinite foundation, is obtained. It is assumed that the thermal contact between strip and foundation is imperfect. The asymptotic formulae of temperature for small and large time values were found, too. The influence of the contact heat transfer on temperature distribution in materials of frictional pair such as FMK-11 metal–ceramic strip–ChNMKh cast iron foundation, was investigated.     

The effect of start-up cycle in ceramic coating used as thermal barrier for a gas turbine bucket

The unsteady aerodynamic and aero-thermal performance of a first stage gas turbine bucket with thermal barrier coating (TBC) and internal cooling configuration were investigated by application of a three dimensional Navier–Stokes commercial turbomachinery oriented CFD-code. Convection and conduction were modeled for a super alloy blade with TBC.The CFD simulations were configured with a mesh domain including the nozzle and bucket interstage in order to accurately predict the fluid parameters at inlet and outlet of bucket. Comparisons to the gas turbine manufacturer data have permitted validation of the flow conditions at the inlet of the rotor.The effects of blade TBC surface temperature changes during a start-up cycle were simulated by means of an unsteady simulation, with unsteady inlet/outlet boundary conditions specified according to test data. The calculations include not only the fluid but also the solving of conduction within the blade, allowing for a correct modeling of the large difference of thermal inertia between the fluid and solid.The role of thermal barrier coatings (TBC) is, as their name suggests, to provide thermal insulation of the blade. A coating of about 100–400 μm can reduce the temperature by up to 200 °C. A TBC can be used either to reduce the need for blade cooling (by about 36%) increasing the turbine efficiency, while maintaining identical creep life of the substrate; or to increase considerably the creep life of the blade while maintaining level of blade cooling (and therefore allowing the blade to operate at a lower temperature for an identical turbine inlet temperature).     

3D investigation of thermal stresses in a locomotive ventilated brake disc based on a conjugate thermo-fluid coupling boundary conditions

The frictional heat generated during braking application can cause several negative effects on the brake system such as brake fade, premature wear, thermal cracks and disk thickness variation. It is then important to determine with precision, the temperature field and thermal stresses of the brake disc. In this study, thermal stress analyses on a ventilated locomotive wheel-mounted brake disc R920K with a three-dimensional model for two cases (the first case considers braking to a standstill; the second case considers braking on a hill and maintaining a constant speed) were investigated. The rate of braking heat generation is calculated using the assumption of uniform pressure distribution at the contact area. Then, thermal stress analyses for each case were performed. Finally, we have found that the maximum thermal stresses occur in the case with an emergency braking in the beginning of the braking process.     

Modeling of thermal stresses in low alloy steels

Abstract

Computing the evolution of thermal stresses accurately requires appropriate constitutive relations. This includes both the thermal and mechanical aspects, as temperature is the driver to thermal stresses. The paradigm of Integrated Computational Materials Engineering (ICME) aims at being able to quantitatively relate process-structure-property of a material. The article describes physics based models, denoted bridging elements, which are one step towards the vision of ICME. They couple material structure with heat capacity, heat conductivity, thermal and transformation strains and elastic properties for hypo-eutectoid steels. The models can account for the chemical composition of the steel and its processing, i.e. thermomechanical history, giving the evolution of the microstructure and the corresponding properties.     

Numerical investigation of the effectiveness of effusion cooling for plane multi-layer systems with different base-materials

Within Collaborative Research Center (SFB) 561 “Thermally Highly Loaded, Porous and Cooled Multi-Layer Systems for Combined Cycle Power Plants” at RWTH Aachen University, an effusion-cooled multi-layer plate configuration is investigated numerically by the application of a three-dimensional in-house fluid flow and heat transfer solver, CHTflow. CHTflow is a conjugate code, which yields information on the temperature distribution in the solid body. This enables a detailed discussion of the effects of a change in materials. The geometrical set-up and the fluid flow conditions derive from modern gas turbine combustion chambers and bladings. Within the SFB, two different multi-layer systems, one consisting of substrate made of CMSX-4 (a single-crystal super-alloy), an MCrAlY-bondoat and a ZrO₂ thermal barrier coating (TBC), and the other consisting of a NiAl-alloy and a graded bondcoat/TBC, have been investigated. The grading will increase the life-span of the TBC as it can better compensate the different thermal expansion coefficients of different materials. The main focus in this study is on the different substrate materials, because the thermal conductivity of the NiAl is considerably higher than that of CMSX-4, which leads to different temperature profiles in the components. The numerical grid for the simulations contains the coolant supply (plenum), the solid body for the conjugate calculations, and the main flow area on the plate. The effusion-cooling is realized by finest drilled shaped holes with a diameter of 0.2mm. The investigation is concentrated on a cooling hole geometry with a laterally widened fan-shaped outlet, contoured throughout, and one without lateral widening that is only shaped in the TBC-region of the system. Two blowing ratios, M=0.28 and M=0.48, are investigated, both for a hot gas Mach number of 0.25. The results for the lower blowing ratio and the fully contoured hole are discussed as well as those of the higher blowing ratio and the non-laterally widened hole. These represent two characteristic cases.     

The thermal problem of friction during braking for a three-element tribosystem with a composite pad

The analytical solution to a thermal problem of friction during braking with constant retardation for a three-element system (a foundation/strip/semi-space) is obtained. The solution allows to find the evolution and distribution of transient temperature in the caliper/pad/disk tribosystem. Unlike known solutions for three-element tribosystem, this one is obtained on the assumption that material of the pad (strip) is the periodic composite. The every unit cell of the composite contains four sub-cells with rectangular cross-section and with different thermo-physical properties. It is assumed, that intensity of the heat generation on the contact surface is equal to power of friction and through this surface the heat transfer takes place. The influence of the geometrical dimensions and thermo-physical properties of composite sub-cells on the maximum temperature in the system has been investigated.     

Effect of nanofluids on the thermal performance of a flat micro heat pipe with a rectangular grooved wick

In this paper, the effect of water-based Al₂O₃ nanofluids as working fluid on the thermal performance of a flat micro-heat pipe with a rectangular grooved wick is investigated. For the purpose, the axial variations of the wall temperature, the evaporation and condensation rates are considered by solving the one-dimensional conduction equation for the wall and the augmented Young–Laplace equation for the phase change process. In particular, the thermophysical properties of nanofluids as well as the surface characteristics formed by nanoparticles such as a thin porous coating are considered. From the comparison of the thermal performance using both DI water and nanofluids, it is found that the thin porous coating layer formed by nanoparticles suspended in nanofluids is a key effect of the heat transfer enhancement for the heat pipe using nanofluids. Also, the effects of the volume fraction and the size of nanoparticles on the thermal performance are studied. The results shows the feasibility of enhancing the thermal performance up to 100% although water-based Al₂O₃ nanofluids with the concentration less than 1.0% is used as working fluid. Finally, it is shown that the thermal resistance of the nanofluid heat pipe tends to decrease with increasing the nanoparticle size, which corresponds to the previous experimental results.     

Aging and Thermal Conditioning of Modified Heat Exchanger Surfaces—Impact on Crystallization Fouling

ABSTRACT

In many research studies diamond-like-carbon coatings are used to change the wetting behavior by varying the solids´ surface free energy of heat exchanger surfaces to mitigate crystallization fouling. For future industrial application, the stability of their specific surface properties, exposed to fluidic, thermal, and chemical stresses, determines their efficiency. Therefore, fluidic thermal and cleaning stresses applied to the coating are investigated. Cleaning procedures with acid, base, and heat treatment over multiple cycles were conducted in order to investigate the solids´ surface free energy over time and thereby the stability of the coating. From this information an optimal conditioning to set constant surface properties was derived. Furthermore, the fouling behavior of CaSO₄ on new and conditioned coatings was investigated in order to identify repeatable and favorable surface properties for fouling reduction. For all coatings the cleaning treatments and fouling experiments provided changes in the energetic surface properties, dominated by the change of polar/γ^? content. Most probably these changes originate from varying elementary composition and structure of the coating.     

Thermal deflection and thermal stresses in a thin circular plate under an axisymmetric heat source

Motivated by the need to investigate thermal effects on the deflection and stresses in a thin-wall workpiece during machining, the thermal problem is modeled with an axisymmetric input to emulate the heat generated at the tool-workpiece interface in a turning process. Using a compressor disk as an illustrative example, the boundary value problem is formulated with a plate model where the perimetric edge is clamped and insulated, and the upper and lower surfaces are subjected to heat convection. The closed form solution of temperature distribution is obtained via Green’s function method, based on which the thermal deflection/stresses are obtained in serial forms from the plate constitutive relations. The obtained solutions have been numerically verified with finite-element analysis (FEA), where simulations have been performed for three different materials with discrepant thermomechanical properties to study the thermal effects on the induced deflection and stresses. The analytical result is justified by its good agreement with FEA and its time efficiency in computation offers advantages in potential real-time application to manufacturing process monitoring.