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DOE OSTI2021

SURFACE FINISHING AND ELECTROLESS NICKEL PLATING OF ADDITIVELY MANUFACTURED (AM) METAL COMPONENTS

This study investigates the application of electroless nickel deposition on additively manufactured stainless steel samples. Current additive manufacturing (AM) technologies produce metal components with a rough surface. Rough surfaces generally exhibit fatigue characteristics, increasing the probability of initiating a crack or fracture to the printed part. For this reason, the direct use of as-produced parts in a finished product cannot be actualized, which presents a challenge. Post-processing of the AM parts is therefore required to smoothen the surface. This study analyzes chempolish (CP) and electropolish (EP) surface finishing techniques for post-processing AM stainless steel components CP has a great advantage in creating uniform, smooth surfaces regardless of size or part geometry EP creates an extremely smooth surface, which reduces the surface roughness to the sub-micrometer level. In this study, we also investigate nickel deposition on EP, CP, and as-built AM components using electroless nickel solutions. Electroless nickel plating is a method of alloy treatment designed to increase manufactured component's hardness and surface resistance to the unrelenting environment. The electroless nickel plating process is more straightforward than its counterpart electroplating.. We use low-phosphorus (2-5% P), medium-phosphorus (6-9% P), and high-phosphorus (10-13% P). These Ni deposition experiments were optimized using the L9 Taguchi design of experiments (TDOE), which compromises the prosperous content in the solution, surface finish, plane of the geometry, and bath temperature. The pre-and post-processed surface of the AM parts was characterized by KEYENCE Digital MicroscopeVHX-7000 and Phenom XL Desktop SEM. The experimental results show that electroless nickel deposition produces uniform Ni coating on the additively manufactured components up to 20 μm per hour. Mechanical properties of as-built and Ni coated AM samples were analyzed by applying a standard 10 N scratch test. Nickel coated AM samples were up to two times scratch resistant compared to the as-built samples. This study suggests electroless nickel plating is a robust viable option for surface hardening and finishing AM components for various applications and operating conditions.

Keywords: additive manufacturing, fatigue, chempol↗

DOE OSTI2022

Surface Water Mass Transformation in the Southern Ocean: The Role of Eddies Revisited

The water mass transformation (WMT) framework describes how water of one class, such as a discrete interval of density, is converted into another class via air–sea fluxes or interior mixing processes. Here, this paper investigates how this process is modified at the surface when mesoscale ocean eddies are present, using a state-of-the-art high-resolution climate model with reasonable fidelity in the Southern Ocean. The method employed is to coarse-grain the high-resolution model fields to remove eddy signatures, and compare the results with those from the full model fields. This method shows that eddies reduced the WMT by 2–4 Sv (10%–20%; 1 Sv ≡ 10 6 m 3 s −1 ) over a wide range of densities, from typical values of 20 Sv in the smoothed case. The corresponding water mass formation was reduced by 40% at one particular density increment, namely, between 1026.4 and 1026.5 kg m −3 , which corresponds to the lighter end of the range of Indian Ocean Mode Water in the model. The effect of eddies on surface WMT is decomposed into three terms: direct modulation of the density outcrops, then indirectly, by modifying the air–sea density flux, and the combined effect of the two, akin to a covariance. It is found that the first and third terms dominate, i.e., smoothing the outcrops alone has a significant effect, as does the combination of smoothing both outcrops and density flux distributions, but smoothing density flux fields alone has little effect. Results from the coarse-graining method are compared to an alternative approach of temporally averaging the data. Implications for climate model resolution are also discussed.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2026

Extracting the Breakout Distance from the ECOT Trajectories: Gaussian Process Regression Approach

Enhanced Corner Turning (ECOT) experiments provide an important metric of performance of high explosive (HE) formulations. The breakout distance is a single scalar value that characterizes the corner turning efficiency of an HE. Extracting the breakout distance from the raw ECOT results, whether experimental or simulated, is a conceptually straightforward procedure which, however, is non-unique, especially in the presence of noise. More specifically, this procedure involves numerical smoothing and selecting particular values for parameters of this smoothing introduces human bias. In this work, we propose to use the Gaussian process regression to analyze ECOT results. This analysis involves the effective smoothing of the data, thus allowing for accurate extraction of the breakout distance. Most importantly, the parameters of this smoothing can be inferred from the ECOT data itself, rendering the approach effectively parameter-free and thus diminishing the human bias. An additional benefit of the Gaussian process regression, being a statistical inference method, is that not just the value of the breakout distance, but also its confidence interval can be extracted from the data. This report introduces the Gaussian process regression, as applied to ECOT, and demonstrates its usefulness by extracting the breakout distances for a selection of experimental and simulated data.

45 MILITARY TECHNOLOGY, WEAPONRY, AND NATIONAL DEF↗

DOE OSTI2023

Universal Passive Synchronization Method for Grid-Forming Inverters Without Mode Transition

Power systems are transforming with increasing levels of inverter-based resources (IBRs). This transformation requires critical roles of grid-forming (GFM) inverters replacing synchronous generators for bulk power system stabilization and ancillary services, also allowing flexible power system operation, such as microgrid that is operated by multiple GFM IBRs to achieve system resilience against contingencies. To realize the resilient power systems allowing flexible in-and-out operation of GFM IBRs potentially programmed with different primary controls, a synchronization method universally applicable, i.e., independent of control types, would be beneficial to ease the integration process, but it has not been actively studied. To fill the gap, this paper proposes a universal synchronization method that achieves a passive synchronization to enable a smooth transition in a grid with off-nominal system parameters, i.e., voltage and frequency. The logic proposed requires no modification on the primary control, thus applicable to any type of GFMs with a voltage reference input. To validate the concept, a simulation of an IEEE 13-bus benchmark system modified with 3 GFM inverters is presented. It simulates an inverter-driven black start scenario in which GFM inverters autonomously turn on and connect to the grid under heavy loading, using the synchronization logic. The case study demonstrates that GFM inverters can tune their voltage reference to smoothly synchronize without severe transients, and contribute to a seamless black start of the grid under unbalanced load conditions. Two GFM methods - Droop and dispatchable virtual oscillator control - are used for the demo to validate feasibility and interoperability of the passive synchronization.

black start↗

DOE OSTI2020

A new form of the Saint-Venant equations for variable topography

The solution stability of river models using the one-dimensional (1D) Saint-Venant equations can be easily undermined when source terms in the discrete equations do not satisfy the Lipschitz smoothness condition for partial differential equations. Although instability issues have been previously noted, they are typically treated as model implementation issues rather than as underlying problems associated with the form of the governing equations. This study proposes a new reference slope form of the Saint-Venant equations to ensure smooth slope source terms and eliminate one source of potential numerical oscillations. It is shown that a simple algebraic transformation of channel geometry provides a smooth reference slope while preserving the correct cross-section flow area and the total Piezometric pressure gradient that drives the flow. The reference slope method ensures the slope source term in the governing equations is Lipschitz continuous while maintaining all the underlying complexity of the real-world geometry. The validity of the mathematical concept is demonstrated with the open-source Simulation Program for River Networks (SPRNT) model in a series of artificial test cases and a simulation of a small urban creek. Validation comparisons are made with analytical solutions and the Hydrologic Engineering Center's River Analysis System (HEC-RAS) model. The new method reduces numerical oscillations and instabilities without requiring ad hoc smoothing algorithms.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2024

Microchannel Geometries for Improved Heat Transfer with Low-GWP refrigerants

Due to efforts aimed at decarbonizing industries, the use of refrigerants with low global warming potential (GWP) is highly recommended in the air-conditioning and refrigeration sectors. Despite possessing low-GWP values of less than 150, hydrofluoroolefins (HFO) exhibit relatively lower heat transfer performance compared to conventional hydrofluorocarbons (HFC) under certain operating conditions. In contrast to HFCs, there is a high demand for enhanced surfaces to meet the needs of heat transfer systems utilizing low GWP refrigerants. Accordingly, this study analyzes the pool boiling performance of low-GWP refrigerants in microchannel geometries. The experiments were carried out at various heat flux levels on both smooth and enhanced surfaces. The pool boiling behavior of low-GWP refrigerant R1234yf was compared to that of R-134a refrigerant in terms of heat transfer coefficient and wall superheat. The results indicate that the heat transfer coefficients of the enhanced surface are significantly higher than those of the smooth surface. Furthermore, the microchannel geometry demonstrated a lower wall superheat compared to the smooth surface. Additionally, a visualization study was performed using a high-speed camera to understand the pool boiling mechanism of low-GWP refrigerants on both smooth and enhanced surfaces.

Murugan, Muneeshwaran↗

DOE OSTI2023

Study of Seamless Microgrid Transition Operation Using Grid-Forming Inverters

This paper investigates operational techniques to achieve seamless (smooth) microgrid (MG) transitions by dispatching a grid-forming (GFM) inverter. In traditional approaches, the GFM inverter must switch between grid-following (GFL) and GFM control modes during MG transition operation. Today's inverter technology allows GFM inverters to always operate in GFM control mode, so it is worth exploring how to use them to achieve smooth MG transition operation. This paper proposes three operational techniques: a traditional scheme of switching between GFL and GFM control; a new scheme of consistent GFM control and shifting the droop intercept up before islanding operation; and a new scheme of consistent GFM control and shifting the droop intercept up before synchronization operation. A full hardware setup is established to compare the three techniques and showcase their implementations in real-world applications. The results show that the third technique outperforms the others and exhibits the best transition performance because the GFM inverter maintains the same operating points during the transition operation. Therefore, we conclude that ensuring smooth MG transition operation requires that the GFM inverter(s) maintain the same operating points (v, f, P, Q, and phase angle) during the transition operation in addition to minimizes the point of common coupling power flow.

grid-forming control↗

DOE OSTI2024

Modeling and simulations of hydrodynamic shocks in a plasma flowing across randomized ICF scale laser beams

High-energy laser beams interacting with flowing plasmas can produce a plasma response that leads to deflection of the beam, beam bending. Such beams have usually a speckle structure generated by optical smoothing techniques that reduce the spatial and temporal coherence in the laser field pattern. The cumulative plasma response from laser speckles slows down the velocity of the incoming flow by momentum conservation. For slightly super-sonic flow the cumulative plasma response to the ponderomotive force exerted by the beam speckle ensemble is the strongest, such that slowing down the flow to subsonic velocities leads eventually to the generation of a shock around the cross section of the beam. This scenario has been predicted theoretically and is confirmed here by our hydrodynamic simulations in two dimensions with speckled beams and in one dimension with a reduced model. The conditions of shock generation are given in terms of the ponderomotive pressure, speckle size and the flow velocity. The nonlinear properties of the shocks are analyzed using Rankine–Hugoniot relations. According to linear theory, temporally smoothed laser beams exhibit a higher threshold for shock generation. Numerical simulations with beams that are smoothed by spectral dispersion compare well with the linear theory results, diverging from those produced by beams with only a random phase plates in the nonlinear regime. The conditions necessary for shock generation and their effects on the laser plasma coupling in inertial confinement fusion (ICF) experiments are also discussed.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗

DOE OSTI2023

Study of Seamless Microgrid Transition Operation Using Grid-Forming Inverters

grid-forming↗

DOE OSTI2022

Formation of Point Shocks for 3D Compressible Euler

We consider the 3D isentropic compressible Euler equations with the ideal gas law. We provide a constructive proof of the formation of the first point shock from smooth initial datum of finite energy, with no vacuum regions, with nontrivial vorticity present at the shock, and under no symmetry assumptions . We prove that for an open set of Sobolev‐class initial data that are a small L ∞ perturbation of a constant state, there exist smooth solutions to the Euler equations which form a generic stable shock in finite time. The blowup time and location can be explicitly computed, and solutions at the blowup time are smooth except for a single point , where they are of cusp‐type with Hölder C 1/3 regularity. Our proof is based on the use of modulated self‐similar variables that are used to enforce a number of constraints on the blowup profile, necessary to establish global existence and asymptotic stability in self‐similar variables. © 2022 Wiley Periodicals LLC.

Mathematics↗

DOE OSTI2022

Adaptive clipping‐and‐redistribution algorithms for bounded and conservative high‐order interpolations applied to discontinuous and reactive flows

Abstract A new adaptive clipping‐and‐redistribution method is presented which provides bounds‐preservation for multidimensional interpolation in the context of high‐order finite‐volume discretizations with adaptive mesh refinement (AMR). The underlying finite‐volume method (FVM) for the computational fluid dynamics applications is fourth‐order accurate for smooth solutions and utilizes AMR for computational efficiency in solving multiscale problems involving turbulence and combustion. High‐order interpolation between different AMR levels is required. However, this operation often leads to numerical issues because combustion species must have physical bounds preserved. The present study overcomes two major challenges in the development of the high‐order interpolation method. First, the method needs to be bound‐preserving near extrema or discontinuities to prevent the emergence of unphysical oscillations while maintaining fourth‐order accuracy in smooth flows. Second, the method needs to satisfy the conservation requirement in multiple dimensions, particularly in the context of curvilinear coordinate transformations. Additionally, the method is designed to be localized and computationally inexpensive. The new interpolation scheme is demonstrated by solving reacting flows, which are extremely sensitive to unphysical overshoots in conserved quantities. The test problems are shock‐induced ‐ combustion and a ‐air flame in a practical bluff‐body combustor. Results show the method prevents new extrema near discontinuities while maintaining high‐order accuracy in smooth regions. In particular, the method is extremely beneficial for combustion with stiff chemistry. With the proposed new method, even if flame fronts cross AMR interfaces or new grids are created in the vicinity of the flame, solution stability is retained.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2023

Local element operations for curved simplex meshes

Summary Mesh optimization procedures are generally a combination of node smoothing and discrete operations which affect a small number of elements to improve the quality of the overall mesh. These procedures are useful as a post‐processing step in mesh generation procedures and in applications such as fluid simulations with severely deforming domains. In order to perform high‐order mesh optimization, these ingredients must also be extended to high‐order (curved) meshes. In this work, we present a method to perform local element operations on curved meshes. The mesh operations discussed in this work are edge/face swaps, edge collapses, and edge splitting (more generally refinement) for triangular and tetrahedral meshes. These local operations are performed by first identifying the patch of elements which contain the edge/face being acted on, performing the operation as a “straight‐sided one" by placing the high‐order nodes via an isoparametric mapping from the master element, and smoothing the high‐order nodes on the elements in the patch by minimizing a Jacobian‐based high‐order mesh distortion measure. Since the initial “straight‐sided guess” from the placement of the nodes via the isoparametric mapping frequently results in invalid elements, the distortion measure must be regularized which allows for mesh untangling for the optimization to succeed. We present several examples in 2D and 3D to demonstrate these local operations and how they can be combined with a high‐order node smoothing procedure to maintain mesh quality when faced with severe deformations.

Shi, A.↗

DOE OSTI2022

New superstrata from three-dimensional supergravity

We find a two-parameter family of generalized superstrata that emerge as smooth, supersymmetric solutions in three-dimensional gauged supergravity coupled to additional scalar fields. This new family of generalized superstrata are smooth microstate geometries and may be thought of as supersymmetric Coulomb-branch extensions of the original superstrata in which the underlying supertube undergoes an elliptical deformation. These solutions had already been obtained numerically, and as series solutions, to the equations of motion, and some of them were conjectured to be supersymmetric. Here we prove the supersymmetry of an entire two-parameter family and we obtain a highly non-trivial analytic and smooth solution for a one-parameter limit in which the global symmetry of the metric is enhanced to SO(3). We also confirm that the other known families of microstrata are not supersymmetric. We conclude with a cursory analysis of some of the singular brane distributions that can be accessed from three-dimensional gauged supergravity while preserving the same supersymmetries as the superstratum, and therefore of the three-charge black hole.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗

DOE OSTI2024

An Empirical Quantile Estimation Approach for Chance-Constrained Nonlinear Optimization Problems

We investigate an empirical quantile estimation approach to solve chance-constrained nonlinear optimization problems. Our approach is based on the reformulation of the chance constraint as an equivalent quantile constraint to provide stronger signals on the gradient. In this approach, the value of the quantile function is estimated empirically from samples drawn from the random parameters, and the gradient of the quantile function is estimated via a finite-difference approximation on top of the quantile-function-value estimation. We establish a convergence theory of this approach within the framework of an augmented Lagrangian method for solving general nonlinear constrained optimization problems. The foundation of the convergence analysis is a concentration property of the empirical quantile process, and the analysis is divided based on whether or not the quantile function is differentiable. In contrast to the sampling-and-smoothing approach used in the literature, the method developed in this paper does not involve any smoothing function and hence the quantile-function gradient approximation is easier to implement and there are less accuracy-control parameters to tune. Furthermore, we demonstrate the effectiveness of this approach and compare it with a smoothing method for the quantile-gradient estimation. Numerical investigation shows that the two approaches are competitive for certain problem instances.

Applied Probability↗

DOE OSTI2023

Nucleation dependence of atomic layer deposition on diamond surface termination

Surface termination and interfacial interactions are critical for advanced solid-state quantum applications. Here, in this paper, we demonstrate that atomic layer deposition (ALD) can both provide valuable insight on the chemical environment of the surface, having sufficient sensitivity to distinguish between the common diamond (001) surface termination types and passivate these interfaces as desired. We selected diamond substrates exhibiting both smooth and anomalously rough surfaces to probe the effect of morphology on ALD nucleation. We use high resolution in situ spectroscopic ellipsometry to monitor the surface reaction with sub-angstrom resolution, to evaluate the nucleation of an ALD Al 2 O 3 process as a function of different ex and in situ treatments to the diamond surface. In situ water dosing and high vacuum annealing provided the most favorable environment for nucleation of dimethylaluminum isopropoxide and water ALD. Hydrogen termination passivated both smooth and rough surfaces while triacid cleaning passivated the smooth surface only, with striking effectiveness.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2025

A discontinuous Galerkin spectral element method for compressible reacting flows

High-order methods have recently been shown to be an effective tool for high-fidelity flow computations like direct numerical simulations and large-eddy simulations because of their strong balance between accuracy and computational cost. In this work, a high-order discontinuous Galerkin spectral element method (DGSEM) is developed to solve the chemically reacting Navier-Stokes equations. To handle the disparate length and time scales associated with these equations, we develop a novel method which combines the spectral accuracy of the SEM with the flexibility of the DG approach. The framework, implemented in the spectral element code Nek5000, is well suited to capture turbulence in smooth regions of the flow, while maintaining numerical stability in the presence of shocks. An entropy-residual based artificial viscosity is added to smooth shocked regions of flow, and a positivity-preserving limiter is implemented to suppress non-physical oscillations. These enhancements support the numerical stability of the hydrodynamic sub-step, which is decoupled from the chemistry integration through a second-order operator splitting method. Here, a series of smooth and discontinuous validation cases are presented in increasing physical and computational complexity for both inviscid and viscous flows. In particular, simulations of canonical one-dimensional and two-dimensional detonations are performed, and the high-order numerical results are validated against available literature data. Additional validation studies are carried out for classical three-dimensional numerical simulations of incompressible and compressible turbulent flows.

Compressible reacting flows↗

DOE OSTI2020

A new flow pattern map for flow boiling of R410A in horizontal micro-fin tubes considering the effect of the helix angle

This paper presents an improved flow pattern map for flow boiling in horizontal micro-fin tubes considering the effect of helix angle. The proposed map is modified from the one developed for horizontal smooth tubes by Wojtan et al. (2005) and takes the early transition to annular flow due to micro-fin geometry into account. Visualization of R410A flow boiling is carried out through the transparent smooth and micro-fin tubes with 0°, 10° and 18° helix angle and plotted on the proposed map for comparison. The result shows that the flow pattern map for micro-fin tube with 0° helix angle is generally similar to that for the smooth tube. For the tube with 10° and 18° helix angle, the annular flow occurs at lower vapor quality and lower mass flux. The proposed map shows good agreements when compared with the visualization and reflects the downward shift (to lower mass flux and vapor quality conditions) of the SW-WA transition with the increase of the helix angle. In order to further validate the proposed model, the flow pattern transitions calculated from the equations are also compared with the experimental data of the micro-fin tube in literature. The results show that the modified map increase the prediction accuracy of the flow patterns in the micro-fin tube.

42 ENGINEERING↗

DOE OSTI2022

Conservative high-order data transfer method on generalized polygonal meshes

A conservative data transfer (remap) between two meshes is an important step of arbitrary Lagrangian-Eulerian (ALE) hydrodynamics simulations. High-order numerical methods for ALE simulations require both high-order (curvilinear) meshes and high-order remap algorithms. Here we develop a conservative and bounds-preserving method for accurate remapping of discrete fields on generalized polygonal meshes with curvilinear edges. The properties of the proposed method are studied theoretically and numerically for various (smooth and non-smooth) mesh deformations and discrete fields that represent smooth and discontinuous functions.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗