High performance hydraulic design techniques of mixed-flow pump impeller and diffuser

In this paper, we describe a numerical study about the performance improvement of a mixed-flow pump by optimizing the design of the impeller and diffuser using a commercial computational fluid dynamics (CFD) code and design-of-experiments (DOE). The design variables of impeller and diffuser in the vane plane development were defined with a fixed meridional plane. The design variables were defined by the vane plane development, which indicates the blade-angle distributions and length of the impeller and diffuser. The vane plane development was controlled using the blade-angle in a fixed meridional plane. The blade shape of the impeller and diffuser were designed using a traditional method in which the inlet and exit angles are connected smoothly. First, the impeller optimum design was performed with impeller design variables. The diffuser optimum design was performed with diffuser design variables while the optimally designed impeller shape was fixed. The importance of the impeller and diffuser design variables was analyzed using 2^k factorial designs, and the design optimization of the impeller and diffuser design variables was determined using the response surface method (RSM). The objective functions were defined as the total head (Ht) and the total efficiency (?t) at the design flow rate. The optimally designed model was verified using numerical analysis, and the numerical analysis results for both the optimum model and the reference model were compared to determine the reasons for the improved pump performance. A pump performance test was carried out for the optimum model, and its reliability was proved by a comparative analysis of the results of the numerical analysis and an experiment using the optimum model.     

Multi-objective optimization for mixed-flow pump with blade angle of impeller exit and diffuser inlet

During design optimization, the impeller and diffuser of a mixed-flow pump are generally optimized separately. In such cases, the total head can be overdesigned. In this study, the designs of the impeller and diffuser were optimized simultaneously by using computational fluid dynamics and the Response surface method (RSM). Design variables were defined according to the vane plane development of the impeller and diffuser. Three-dimensional Reynolds-averaged Navier–Stokes equations for the shear stress transport turbulence model were discretized by finite volume approximations and solved on hexahedral grids to analyze the flow in the pump. The total head and total efficiency were selected as objective functions, with four design variables related to the impeller outlet angles and diffuser inlet angles used for optimization. The RSM was constructed based on the objective functions with design points generated from the central composite method. The hydraulic performance of the optimum model was analyzed.     

Numerical study on the range enhancement of a centrifugal compressor with a ring groove system

A numerical study of casing treatments on a centrifugal compressor to improve stability and stall margin is presented. High efficiency, high pressure ratio, and a wide operating range are required for a high-performance centrifugal compressor. A ring groove casing treatment is effective for flow range enhancement in centrifugal compressors. Compressor performance was analyzed according to the ring groove location, and the results were compared with the case without a ring groove. The effect of guide vanes in the ring groove was also investigated. Four variants of grooves were modeled and simulated using computational fluid dynamics to optimize the groove location. Numerical analysis was performed using a commercial code ANSYS-CFX program. The simulation results showed that the ring groove increased the operating range of the compressor. The ring groove with guide vanes improved both performance of the compressor at low flow rates and the stall margin of the compressor.     

The effects of Co γ-ray on poly(ethylene-co-vinyl acetate)/carbon black composites

Cables used in a nuclear power plant are irradiation suppressing ones. Until now, researches on the irradiation suppressing cables have mainly been focused on insulation materials. Therefore, in this paper, the non-isothermal crystallization behaviors and degradation characteristics of ethylene vinyl acetate-carbon black (EVA-CB), used as a shielding material, were investigated by means of the Differential scanning calorimetry (DSC) and chemiluminescence analyzer (CL). The specimens were cooled after removing thermal history at 150 °C for 5 min by changing the cooling rates to 5, 7.5, 10, 15 and 20 °C/min with DSC. In addition, after maintaining a thermal equilibrium at each temperature of 25, 50, 75, 100, 125, 150 and 175 °C, their thermoluminescence was measured for 20 min with CL equipment. The ⁶⁰Co γ-ray was used for irradiation. T_c, T₀, T_∞ and t_1/2 in the DSC experiments are found to decrease gradually as radiation dose increases. Secondly, with the CL experiment, the 0.1, 0.25 and 0.5 MGy EVA-CB composites were found to show a much smaller thermoluminescence than the intact EVA-CB composites, while the 0.75 and 1 MGy EVA-CB composites were found to show a much higher thermoluminescence than ones.     

Nitrogen doping effects on the structure behavior and the field emission performance of double-walled carbon nanotubes

The nitrogen (N) doping effect and field emission properties of double-walled carbon nanotubes (DWCNTs) were investigated. Diameter transformation and defect generation in the N-doped DWCNTs mainly depend on the amount of nitrogen employed. By applying N-doping into DWCNTs (1.5 N at.%), the average diameters of the DWCNTs were increased from 1.7 to 2.4 nm, and the crystallinity (I_G/I_D) was decreased from 13.5 to 5. Field emission properties were enhanced by the N doping into DWCNTs. The turn-on field, corresponding to a current density of 0.1 μA/cm², was about 0.9 V/μm for the N-doped DWCNTs (1.5 N at.%). The field enhancement factor of the N-doped DWCNTs was higher than that of the undoped DWCNTs. It was found that the field emission properties were controlled by pyridine-like N in the graphite due to N-doping.     

Highly dispersed multi-walled carbon nanotubes in ethanol using potassium doping

We demonstrated the production of an effective dispersion of multi-walled carbon nanotubes (MWCNTs) in ethanol using potassium doping (π-stacking interaction). The homogeneous dispersion of individual MWCNTs was achieved without any contamination or severe disruption at the end caps or periphery of the tubes. Potassium as a doping material, phenanthrene as a nonpolar molecule, and 1,2-dimethoxyethane as a dipole solvent were used for our experiment. From UV-visible spectroscopy and visual observation, it was found that the dispersibility of the MWCNTs in ethanol was about 14 mg/dm³. High resolution transmission electron microscopy and Raman spectroscopy showed that disruption of the end caps of the tubes and severance along the tube axis were rarely found. The scanning electron microscopy and corresponding EDX results indicated that the key to the dispersion mechanism was the potassium doping, which is driven by π-stacking complex formation. We suggest that the dispersion of the MWCNTs was influenced by the potassium doping, which caused the enlargement and separation of the entangled-MWCNT networks, and was not affected by defects or modification of the surface morphology.     

Highly conductive, printable and stretchable composite films of carbon nanotubes and silver

Conductive films that are both stretchable and flexible could have applications in electronic devices, sensors, actuators and speakers. A substantial amount of research has been carried out on conductive polymer composites, metal electrode-integrated rubber substrates and materials based on carbon nanotubes and graphene. Here we present highly conductive, printable and stretchable hybrid composites composed of micrometre-sized silver flakes and multiwalled carbon nanotubes decorated with self-assembled silver nanoparticles. The nanotubes were used as one-dimensional, flexible and conductive scaffolds to construct effective electrical networks among the silver flakes. The nanocomposites, which included polyvinylidenefluoride copolymer, were created with a hot-rolling technique, and the maximum conductivities of the hybrid silver-nanotube composites were 5,710 S cm?1 at 0% strain and 20 S cm?1 at 140% strain, at which point the film ruptured. Three-dimensional percolation theory reveals that Poisson's ratio for the composite is a key parameter in determining how the conductivity changes upon stretching.     

Numerical study on the effect of the tip clearance of a 100 HP axial fan on the aerodynamic performance and unsteady stall characteristics

In this study, a numerical analysis was conducted to investigate the effect of the tip clearance on the aerodynamic performance, internal flow characteristics, and stall region characteristics of an axial fan. Three-dimensional steady and unsteady Reynolds-averaged Navier-Stokes (RANS) calculations were conducted with a shear stress transport (SST) turbulence model. Tip clearance ratios of 0, 0.01, and 0.02 were applied to the impeller. As the tip clearance ratio increased, the aerodynamic performance of the axial fan decreased at both the design and the off-design conditions. The correlation between the tip leakage vortex (TLV) and the flow angle of the velocity triangle was presented for the difference in the tip clearance and flow rate. As the flow rate increased, the differences in the aerodynamic performance induced by the tip clearance ratio decreased. As the tip clearance ratio increased, the size of the TLV increased and gradually moved in the circumferential direction to interfere with the main flow at the low flow rate. Meanwhile, the size of the TLV was similar and gradually moved in the axial direction even if the tip clearance ratio increased at the high flow rate. The pressure fluctuations were observed by the fast Fourier transformation (FFT) analysis to compare and analyze internal flow characteristics at the stall region and design point. The static pressure was converted to the appropriate magnitude. The locations of the highest magnitude were shown to be different at the stall region and the design point, respectively.

     

Flow-dependent directional growth of carbon nanotube forests by chemical vapor deposition

We demonstrated that the structural formation of vertically aligned carbon nanotube (CNT) forests is primarily affected by the geometry-related gas flow, leading to the change of growth directions during the chemical vapor deposition (CVD) process. By varying the growing time, flow rate, and direction of the carrier gas, the structures and the formation mechanisms of the vertically aligned CNT forests were carefully investigated. The growth directions of CNTs are found to be highly dependent on the nonlinear local gas flows induced by microchannels. The angle of growth significantly changes with increasing gas flows perpendicular to the microchannel, while the parallel gas flow shows almost no effect. A computational fluid dynamics (CFD) model was employed to explain the flow-dependent growth of CNT forests, revealing that the variation of the local pressure induced by microchannels is an important parameter determining the directionality of the CNT growth. We expect that the present method and analyses would provide useful information to control the micro- and macrostructures of vertically aligned CNTs for various structural/electrical applications.     

Design of axial fan using inverse design method

The axial fans for cooling condensers were designed by inverse design code TURBOdesign-1. The parameters of the inverse design were set by DOE (design of experiments). By changing the design parameters, such as the distribution of the blade loading, spanwise circulation distribution and stacking, 32 different fan designs were created for the screening of parameters. The overall performance and the local flow field of these fans were computed using a commercial CFD code. The results of the CFD computations were analyzed by DOE. The pressure rise and efficiency were selected as the main responses, and the main effects of the design parameters on the responses were discussed. The main design parameters for the optimum design of the fan were decided from the results of the screening procedure. We designed the optimum axial fan by RSM (response surface method). The design center fan was made by RP (rapid prototype) and the performance was tested using a fan tester based on AMCA standards. These procedures ensured proper screening of parameters and optimum design of the axial fan. This paper was presented at the 9^th Asian International Conference on Fluid Machinery (AICFM9), Jeju, Korea, October 16–19, 2007.