Moisture recovery is important in the operation of many fuel cell systems, especially proton exchange membrane (PEM) fuel cells. The exhaust of a PEM fuel cell is a moderate temperature, pressurized humid air stream. A system that recovers liquid water condensate from the pressurized humid exhaust stream of a PEM fuel cell would markedly increase the effectiveness of such a system. The recovered water could be used to hydrate the fuel cell membrane, and it could supply a hydrocarbon reformer used for generating hydrogen. This project investigated and documented moisture recovery from the simulated humid exhaust stream of a 25 kW fuel cell with an improved axial flow separator. An axial flow centrifugal separator design was chosen as the best candidate due to its high efficiency and low pressure drop and a prototype was designed and constructed. The separator was then integrated into an experimental test system. First, the stream was simulated by heating compressed air and then humidifying it with superheated steam. Then, after expanding through the turbine section of an automotive turbocharger, the humid stream was passed through the moisture separator where liquid water condensate was removed from the flow. Results are presented for varying turbine inlet conditions at three separate separation lengths. It is shown that the separation efficiency for the improved design was 40% higher and the pressure drop was only 1/3 that of the conventional separator.

In this study, the effects of design parameters on the fan noise level are investigated both theoretically and experimentally. For the theoretical study, a computational aero- acoustic method is used to predict the flow induced noise of a fan. This method involves the coupling of a flow solver and a wave equation solver. Unsteady flow analysis is performed with URANS using FLUENT. Then the time dependent data are processed with LMS Sysnoise to compute the acoustic radiation. Experimental studies are performed to verify the theoretical results and additionally to investigate the effects of different design alternatives on noise level of the fan. The sound pressure and intensity level measurements are performed in the full anechoic room of Ar&ccedil / elik A.S. Research and Development Laboratories. The validation experiments indicate that there is a good agreement between numerical and experimental results. The experimental study with different fan designs gives information about the noise reduction possibilities.

In this study, the aim is to investigate the stiffness, longitudinal tensile strength and circumferential tensile strength of short fiber reinforced polyester composite pipes produced by centrifugal casting production method. To achieve this aim, theoretical calculation of modulus of elasticity of pipes was done and then test program was carried out on pipe samples produced with three different resin types which were orthophthalic, isophthalic and vinyl ester resin and three different fiber types which were E glass fiber, ECR glass fiber and basalt fiber. The tests were performed according to ISO (International Organization for Standardization) standards. When resin type and fiber type effect on the fiber reinforced polyester pipe samples were evaluated, calculated elastic modulus values were in accordance with the test results. According to the experimental test data, which were used to evaluate the effect of resin type on fiber reinforced polyester pipe properties, there is not a significant difference was observed in the stiffness, longitudinal and circumferential tensile strength test results of pipes having different resin types. In other words, there was not a significant effect of resin type on the stiffness, longitudinal tensile strength and circumferential tensile strength of short fiber reinforced pipes produced by centrifugal casting method. According to the experimental test data, which were used to evaluate the effect of fiber type on the properties of fiber reinforced polyester pipe, basalt fiber reinforced pipe samples showed higher mechanical performance over E glass fiber and ECR glass fiber reinforced pipes. However, the test results of basalt reinforced polyester pipe were not as good as the individual properties of basalt fiber. Finally, by comparing the basalt fiber reinforced pipe samples having almost the same stiffness and tensile test results as E glass fiber reinforced pipe samples, the gain in fiber and resin amount were investigated. Basalt fiber reinforced pipes were slightly lighter and thinner than E glass fiber reinforced pipes. However, the decrease in the amount of the fiber and resin in basalt reinforced pipe did not result in an overall cost reduction.

Centrifugal compressors are widely used in propulsion technology. As an important part of turbo-engines, centrifugal compressors increase the pressure of the air and let the pressurized air flow into the combustion chamber. The developed pressure and the flow characteristics mainly affect the thrust generated by the engine. The design of centrifugal compressors is a challenging and time consuming process including several tests, computational fluid dynamics (CFD) analyses and optimization studies. In this study, a methodology on the geometry optimization and CFD analyses of the centrifugal compressor of an existing small turbojet engine are introduced as increased pressure ratio being the objective. The purpose is to optimize the impeller geometry of a centrifugal compressor such that the pressure ratio at the maximum speed of the engine is maximized. The methodology introduced provides a guidance on the geometry optimization of centrifugal impellers supported with CFD analysis outputs. The original geometry of the centrifugal compressor is obtained by means of optical scanning. Then, the parametric model of the 3-D geometry is created by using a CAD software. A design of experiments (DOE) procedure is applied through geometrical parameters in order to decrease the computation effort and guide through the optimization process. All the designs gathered through DOE study are modelled in the CAD software and meshed for CFD analyses. CFD analyses are carried out to investigate the resulting pressure ratio and flow characteristics. The results of the CFD studies are used within the Artificial Neural Network methodology to create a fit between geometric parameters (inputs) and the pressure ratio (output). Then, the resulting fit is used in the optimization study and a centrifugal compressor with higher pressure ratio is obtained by following a single objective optimization process supported by design of experiments methodology.

This thesis describes the analysis, fabrication and testing of a rotor with extremely flexible blades, focusing on application to a micro-helicopter. The flexibility of the rotor blades is such that they can be rolled into a compact volume and stowed inside the rotor hub. Stiffening and stabilization of the rotor is enabled by centrifugal forces acting on a tip mass. Centrifugal effects such as bifilar and propeller moments are investigated and the torsional equation of motion for a blade with low torsional stiffness is derived. Criteria for the design of the tip mass are also derived and it is chosen that the center of gravity of each blade section must be located ahead of the aerodynamic center. This thesis presents the design of 18-inch diameter two-bladed rotors having untwisted circular arc airfoil profile with constant chord. A systematic experimental investigation of the effect of various blade parameters on the stability of the rotor is conducted in hover and forward flight. These parameters include blade flexibility in bending and torsion, blade planform and mass distribution. Accordingly, several sets of blades varying these parameters are constructed and tested. It is observed that rotational speed and collective pitch angles have a significant effect on rotor stability. In addition, forward flight velocity is found to increase the blade stability. Next, the performance of flexible rotors is measured. In particular, they are compared to the performance of a rotor with rigid blades having an identical planform and airfoil section. It is found that the flexible blades are highly twisted during operation, resulting in a decreased efficiency compared to the rigid rotor blades. This induced twist is attributed to an unfavorable combination of tip body design and the propeller moment acting on it. Consequently, the blade design is modified and three different approaches to passively tailor the spanwise twist distribution for improved efficiency are investigated. In a first approach, extension-torsion composite material coupling is analyzed and it is shown that the centrifugal force acting on the tip mass is not large enough to balance the nose-down twist due to the propeller moment. The second concept makes use of the propeller moment acting on the tip mass located at an index angle to produce an untwisted blade in hover. It is constructed and tested. The result is an untwisted 18-inch diameter rotor whose maximum Figure of Merit is equal to 0.51 at a blade loading of 0.14. Moreover, this rotor is found to be stable for any collective pitch angle greater than 11 degrees. Finally, in a third approach, addition of a trailing-edge flap at the tip of the flexible rotor blade is investigated. This design is found to have a lower maximum Figure of Merit than that of an identical flexible rotor without a flap. However, addition of this control surface resulted in a stable rotor for any value of collective pitch angle. Future plans for increasing the efficiency of the flexible rotor blades and for developing an analytical model are described. / text

A wind turbine needs to be controlled to ensure its safe and optimal operation, especially during high wind speeds. The most common control objectives are to limit the power and rotational speed of the wind turbine by using pitch control. Aero Energy is a company based in Potchefstroom, South Africa, that has been developing and manufacturing wind turbine blades since 2000. Their most popular product is the AE1kW blades. The blades have a tendency to over-speed in high wind speeds and the cut-in wind speed must be improved. The objective of this study was to develop an active pitch control system for wind turbines. A prototype active pitch control system had to be developed for the AE1kW blades. The objectives of the control system are to protect the wind turbine from over-speeding and to improve start-up performance. An accurate model was firstly developed to predict a wind turbine’s performance with active pitch control. The active pitch control was implemented by means of a two-stage centrifugal governor. The governor uses negative or stalling pitch control. The first linear stage uses a soft spring to provide improved start-up performance. The second non-linear stage uses a hard spring to provide over-speed protection. The governor was manufactured and then tested with the AE1kW blades. The governor achieved both the control objectives of over-speed protection and improved start-up performance. The models were validated by the results. It was established that the two-stage centrifugal governor concept can be implemented on any wind turbine, provided the blades and tower are strong enough to handle the thrust forces associated with negative pitch control. It was recommended that an active pitch control system be developed that uses positive pitching for the over-speed protection, which will eliminate the large thrust forces. Keywords: pitch control, wind turbine, centrifugal governor, over-speed protection, cut-in wind speed, blade element-momentum theory, rotor, generator, stall, feathering. / Thesis (M.Ing. (Mechanical Engineering))--North-West University, Potchefstroom Campus, 2009.

A wind turbine needs to be controlled to ensure its safe and optimal operation, especially during high wind speeds. The most common control objectives are to limit the power and rotational speed of the wind turbine by using pitch control. Aero Energy is a company based in Potchefstroom, South Africa, that has been developing and manufacturing wind turbine blades since 2000. Their most popular product is the AE1kW blades. The blades have a tendency to over-speed in high wind speeds and the cut-in wind speed must be improved. The objective of this study was to develop an active pitch control system for wind turbines. A prototype active pitch control system had to be developed for the AE1kW blades. The objectives of the control system are to protect the wind turbine from over-speeding and to improve start-up performance. An accurate model was firstly developed to predict a wind turbine’s performance with active pitch control. The active pitch control was implemented by means of a two-stage centrifugal governor. The governor uses negative or stalling pitch control. The first linear stage uses a soft spring to provide improved start-up performance. The second non-linear stage uses a hard spring to provide over-speed protection. The governor was manufactured and then tested with the AE1kW blades. The governor achieved both the control objectives of over-speed protection and improved start-up performance. The models were validated by the results. It was established that the two-stage centrifugal governor concept can be implemented on any wind turbine, provided the blades and tower are strong enough to handle the thrust forces associated with negative pitch control. It was recommended that an active pitch control system be developed that uses positive pitching for the over-speed protection, which will eliminate the large thrust forces. Keywords: pitch control, wind turbine, centrifugal governor, over-speed protection, cut-in wind speed, blade element-momentum theory, rotor, generator, stall, feathering. / Thesis (M.Ing. (Mechanical Engineering))--North-West University, Potchefstroom Campus, 2009.

The Electrical Submersible Pump (ESP) manufactured by Baker Hughes, model no. WJE-1000 is designed for wells that are expected to have a high content of abrasive solids. It is a mixed flow, tandem compression type pump. Although the erosion of the pump diffuser and impeller stages are significant, the ESP study shows that the most sever failure is due to components that affect the pump’s rotor dynamics such as radial bearings and impeller seals when eroded with 100 mesh sand. Erosion of these seals will result in an internal leakage that can significantly affect stage pressure rise, efficiency, power consumption, vibration, pump life and running cost. The erosion study utilizing 100 mesh fracture sand at 0.2% concentration, with the pump operating at 3600 RPM, 40 PSI intake pressure, 1150 GPM for over 117 hours comparisons are made to the pump’s baseline performance. Measurements of the rotor bearings, impeller seals and their corresponding stators showed that the wear patterns generally increase with time and differ by location. Stage 1 bearings and seals suffered the least amount of erosion and stage 3 rotor components suffered the most erosion. The maximum change in stage 3 bearing clearances was 223% and the maximum change in stage 3 impeller seal clearances was 300%. Performance wise the total pump efficiency dropped by 6.77%, the total pressure rise dropped by 6.3%, the pump’s best efficiency point decreased by 0.78%, and the power consumption increased by 0.49%. Pump vibration patterns also changed with time and by location. The maximum shaft orbit diameter was at stage 3 and it grew 643% in diameter after 117 hours of erosion. The waterfall plots of the pump’s ramp up changed significantly with time. After 117 hours at 3600 RPM, sub-synchronous oscillations at 67% of the synchronous speed dominated the amplitude peaks showing that the rotor vibration locked with the rotor’s first natural frequency at around 2500 RPM. After 117 hours, another sub-synchronous started showing a peak at the rotor’s second natural frequency at 1500 RPM.

In this study molecular dynamics simulation program in NVT ensemble using Velocity Verlet integration was written in order to investigate the glass forming ability of two metallic systems. The Zn-Mg system, one of the frontiers of simple metal-metal metallic glasses and Fe-B, inquiring attention due to presence of many bulk glass forming alloy systems evolved from this binary with different alloying element additions. In addition to this, atomistic calculations on the basis of ordering were carried out for both Zn-Mg and Fe-B systems. Ordering energy values are calculated using electronic theory of alloys in pseudopotential approximation and elements which increase the ordering energy between atoms were determined. The elements which increase the ordering energy most were selected as candidate elements in order to design bulk amorphous alloy systems. In the experimental branch of the study centrifugal casting experiments were done in order to see the validity of atomistic calculations. Industrial low grade ferroboron was used as the master alloy and pure element additions were performed in order to constitute selected compositions. Fe62B21Mo5W2Zr6 alloy was successfully vitrified in bulk form using nearly conventional centrifugal casting processing. Specimens produced were characterized using SEM, XRD, and DSC in order to detect the amorphous structure and also the crystalline counterpart of the structure when the cooling rate is lower. Sequential peritectic and eutectic reaction pattern was found to be important for metallic glasses which can be vitrified in bulk forms with nearly conventional solidification methods.

Due to the increasing demand, nonclog type sewage pumps are designed and manufactured in large amounts all over the world. However, a methodology on the design of these special duty pumps is not encountered in the literature. Therefore, the manufacturers tend to develop their own empirical methodologies. In this thesis, a nonclog pump is designed and constructed on the basis of suitable approaches of known centrifugal pump design methods. In this frame, a nonclog type submersible pump that is capable of handling solids, up to a diameter of 80 mm is aimed to be designed. The designed pump delivers 100 l/s flow rate against a head of 24 m. The rotational speed of the pump is 1000 rpm. Design procedure and the important points that differ nonclog pump design from standard centrifugal pump designs are given. In addition, hydraulic characteristics of two nonclog pumps, one of which is the pump designed in this study, are investigated by means of computational fluid dynamics (CFD) code. The designed pump is manufactured and tested in Layne Bowler Pump Company Inc. The test result indicates that design point is reached with a deviation in the limits of the related standard. Wire to water total best efficiency obtained by the test is 60%. Close agreement between results of actual test and numerical experimentation performed by CFD code shows that CFD analysis is a quite useful tool in predicting the hydraulic characteristics of nonclog pumps. Moreover, the pump is tested at 750 rpm and the test results are found to be in good agreement with the similitude anaysis results.