Engineering Papers⌕ Search

SEARCH · Engineering Papers

Results for “3D temperature modeling”

Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 235 records · Page 13
All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

Validation of 3D MHD simulations of Ne/D 2 mixed shattered pellet injection in JET

Nonlinear 3D magnetohydrodynamic (MHD) modeling of shattered pellet injection (SPI) in JET tokamak plasmas is performed with the JOREK code. The study focuses on the validation of simulation result with respect to experimental observations, addressing in particular figures of merit for the efficiency of the SPI, as a technique to mitigate thermal loads by injecting radiative impurities like neon during the thermal quench (TQ) phase of disruptions. A set of JET pulses with neon/deuterium atomic mixture ratio in the shattered pellet varying from 10% to 100% provides the experimental data to be compared with. Simulations using different models for the ablation of solid fragments and the radiation of neon impurities are considered. Synthetic diagnostics are employed for a direct quantitative comparison with key JET diagnostic systems providing in particular radiation, electron temperature and density, and magnetic measurements. 3D radiation structures from MHD simulations are analyzed to estimate the toroidal asymmetry of radiation, which is difficult to measure in JET due to the presence of only two toroidally displaced multi-channel bolometry systems. JOREK simulations show that, before the TQ, the bulk of the radiation is concentrated in a toroidal region enclosing the radiating fragments that is missed by both multi-channel bolometers, suggesting a possible underestimation of the total radiation by such diagnostic systems in the pre-TQ phase. On the other hand, JOREK predicts that during the TQ the radiation becomes more toroidally symmetric, with positive implications for the heat load to plasma facing components.

JOREK↗
DOE OSTI2022

Design optimization of an additively manufactured prototype recuperator for supercritical CO 2 power cycles

Supercritical CO 2 (sCO 2 ) power cycles are being developed due to their potential for high efficiency and reduced capital cost. It is necessary that these recuperators operate at high pressures and temperatures, up to 30 MPa and 900 K, with effectiveness values > 95% and pressure drops <1% to achieve high cycle efficiencies. Moreover, it is also necessary to have reasonable cost recuperators to control the capital costs of the sCO 2 power cycles. In this study, a Plate Pin-Fin (PPF) heat exchanger has been proposed as an sCO 2 recuperator. This preliminary recuperator design leverages capabilities enabled by additive manufacturing. Although the PPF design has characteristics similar to those of a plate heat exchanger, small diameter and relatively long fins are used to increase surface area, enhance heat transfer, and provide structural support for the partition plates that separate the fluid streams. Existing correlations for heat transfer and pressure drop were adapted for the PPF heat exchanger. These correlations were implemented in a 1D analytical model and used for the optimization of a 5-kW th high temperature recuperator for an indirect sCO 2 cycle by varying the design parameters to minimize the quantity of material required. A 3D conjugate heat transfer numerical simulations were conducted to validate the heat transfer and pressure loss correlations. A steepest descent method was used to minimize heat exchanger mass for a 5-kW prototype recuperator subject to a maximum specified pressure drop. Additionally, the design analysis indicated that an optimum PPF recuperator would be attained for the minimum allowable pin transverse spacing, minimum pin width, minimum pin height and near maximum cell aspect ratio. Moreover, at a low material requirement of 0.216 kg/kW and a pressure drop, which is almost five times lower than the allowable pressure drop design target, the optimized PPF heat exchanger has the high potential to be an alternative to a printed circuit heat exchanger, which is a conservative design basis for the current state-of-the-art sCO 2 recuperators.

42 ENGINEERING↗
DOE OSTI2025

Quenching through the QCD chiral phase transition

We present a detailed numerical and analytical study of the out-of-equilibrium dynamics of Model G, the dynamical universality class relevant to the chiral phase transition. We perform numerical 3D stochastic (Langevin) simulations of the 𝑂⁡(4) critical point for large lattices in the chiral limit. We quench the system from the high-temperature unbroken phase to the broken phase and study the nonequilibrium dynamics of pion fields. Strikingly, the nonequilibrium evolution of the two-point functions exhibits a regime of growth, a parametrically large enhancement, and a subsequent slow relaxation to equilibrium. We analyze our numerical results using dynamic critical scaling and mean-field theory. The growth of the two-point functions is determined by the nonlinear dynamics of an ideal non-Abelian superfluid, which is a limit of Model G that reflects the broken chiral symmetry. We also relate the nonequilibrium two-point functions to a long-lived parametric enhancement of soft pion yields relative to thermal equilibrium following a quench.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗
DOE OSTI2024

Validation of a Hybrid Domain Overlapping Coupling Between SAM and CFD Against the TALL-3D Transients

The System Thermal Hydraulics (STH) code SAM has been coupled to the Computational Fluid Dynamics (CFD) code Simcenter STAR-CCM+ utilizing a hybrid domain overlapping method with an explicit coupling in time. The coupling aims to extend the STH code’s applicability to scenarios where local momentum and energy transfers are important yet difficult for STH codes to capture, such as three-dimensional (3D) mixing. The coupling method’s numerical stability was verified in the past against two closed-loop configurations, and it was validated against a double T-junction experiment with 3D scalar mixing. In the present work, the coupling method is validated against the TALL-3D STH/CFD coupling benchmark facility. TALL-3D is a three-legged, liquid-metal facility with a large, pool-type enclosure (test section) that exhibits 3D flow effects to be modeled by a CFD code. The rest of the system exhibits approximately 1D behavior well-predicted by an STH code. First, the present STAR-CCM+ CFD model of the 3D test section is validated against experimental data. Then, the SAM-STARCCM+ coupled model is validated against six different TALL-3D steady states, including SAM standalone model results for comparison. Lastly, the SAM-STARCCM+ coupled model is validated against two TALL-3D transients, one exhibiting flow reversal in the test section and one exhibiting nonlinear, Limit Cycle Oscillations (LCO). For the first transient, the SAM-STARCCM+ coupled model properly predicts an increase in the test section’s inlet temperature during flow reversal, and this is not predicted by the SAM standalone model. Following flow reversal, the SAM-STARCCM+ coupled model better-predicts the initial flow recovery and following oscillations as the system approaches a final natural circulation state. For the second transient, no true final steady state is observed due to LCO. Neither the SAM-STARCCM+ coupled model nor the SAM standalone model can perfectly capture the experiment’s changing oscillation frequency during the transient. However, the SAM-STARCCM+ coupled model does reproduce the oscillatory feedback observed in the system. This is a significant achievement as the SAM-STARCCM+ coupled model only uses an explicit coupling in time, as opposed to a semi-implicit coupling. In comparison, previous STH/CFD coupling efforts of the TALL-3D facility required semi-implicit coupling to obtain similar results.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2024

Modeling of Sagging for 3D Printed Layers During the Curing Process

Here, a printed layer of silica-enforced poly(dimethylsiloxane)-co-(diphenylsiloxane) is modeled as a two-phase system consisting of air and polymer with an interface set up during the printing process. The structural geometry changes mostly due to the action of surface tension, while all material properties are strongly temperature dependent. Polymer flow is described using equations of the extended Herschel–Bulkley model, with parameters strongly dependent on temperature and degree of curing. Parameters of the model are determined using flow sweep measurements and separate experiments with vertical structure sagging at different temperatures. The curing process is modeled using dependencies between the curing rate, degree of curing, and temperature obtained in studies by differential scanning calorimetry. The developed model is used for simulations of printed structure deformations with different initial and boundary conditions.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Quantifying Drivers of Methane Hydrobiogeochemistry in a Tidal River Floodplain System

The influence of coastal ecosystems on global greenhouse gas (GHG) budgets and their response to increasing inundation and salinization remains poorly constrained. In this study, we have integrated an uncertainty quantification (UQ) and ensemble machine learning (ML) framework to identify and rank the most influential processes, properties, and conditions controlling methane behavior in a freshwater floodplain responding to recently restored seawater inundation. Our unique multivariate, multiyear, and multi-site dataset comprises tidal creek and floodplain porewater observations encompassing water level, salinity, pH, temperature, dissolved oxygen (DO), dissolved organic carbon (DOC), total dissolved nitrogen (TDN), partial pressure of carbon dioxide (pCO 2 ), nitrous oxide (pN 2 O), methane (pCH 4 ), and the stable isotopic composition of methane (δ 13 CH 4 ). Additionally, we incorporated topographical data, soil porosity, hydraulic conductivity, and water retention parameters for UQ analysis using a previously developed 3D variably saturated flow and transport floodplain model for a physical mechanistic understanding of factors influencing groundwater levels and salinity and, therefore, CH 4 . Principal component analysis revealed that groundwater level and salinity are the most significant predictors of overall biogeochemical variability. The ensemble ML models and UQ analyses identified DO, water level, salinity, and temperature as the most influential factors for porewater methane levels and indicated that approximately 80% of the total variability in hourly water levels and around 60% of the total variability in hourly salinity can be explained by permeability, creek water level, and two van Genuchten water retention function parameters: the air-entry suction parameter α and the pore size distribution parameter m. These findings provide insights on the physicochemical factors in methane behavior in coastal ecosystems and their representation in local- to global-scale Earth system models.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2024

Ensemble Manufacturing Techniques for Steam Turbine Components Across Length Scales

Faster design to manufacturing requirements were sought for steam turbine components to meet the changing demands of today’s power grid of improved efficiency through operating temperature increases and enhanced operational flexibility from baseload to cyclic operations. Advances in multiple advanced manufacturing (AM) process enabled redesign of turbine components for extreme environments with the potential to reduce cost. AM is of particular interest to improve component functionality, higher temperature capability, and superior durability in large scale steam turbine applications. AM methods have an immense potential to open-up the design space by working directly with the 3D model to produce near-net shapes, enable fast design-manufacturing iterations, thereby significantly reducing product cost and lead-time up to 25 % from current baseline. However, these benefits cannot be fully realized due to the potential for unknown AM processing defects and their resultant effect upon component performance in service. Siemens is partnering with Oak Ridge National Laboratory (ORNL), Electric Power Research Institute (EPRI), and Connecticut Center for Advanced Technology (CCAT) to advance the knowledge of complex process-material interactions for desired microstructures and properties that are closely interlinked to component geometries across different length scales. The proposed program utilized an ensemble of multidisciplinary technologies to accelerate the development of materials, high-throughput experiments for their qualification, and design flexibility/topology optimization for repair/redesign of components to address critical failure mechanisms for improved performance and increased reliability of existing power plant components. The proposed activities, if successfully demonstrated for identified components, will enable paradigm shift in customized manufacturing and accelerated qualification/certification towards increased steam turbine component durability, increased turbine efficiency, and reduced CO 2 emissions in load-following environments compared to today’s technology. Technology maturation is built into the project as successful research will include customized process-component down-selection enabling AM methodologies to be incorporated directly into the existing supply chain. The specific activities of the proposed effort are: 1. Topology optimization of down-selected steam turbine parts that are amenable to additive and hybrid manufacturing for cost/performance improvement. 2. Process-structure-property relationships for five AM processes for steam turbine materials of interest to compare with conventional materials. 3. Perform part/assembly build process using advanced additive/hybrid machine tools followed by quality inspection of the built components for insight into qualification for production scale-up. Steam turbine rig testing of printed components under targeted, well monitored and characterized environmental conditions of for performance comparison of baseline and redesigned components.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Numerical simulations of membrane distillation systems with actively heated membranes

Membrane distillation (MD) is a thermal desalination process that is gaining attention for treating hypersaline brines. One recent approach uses composite membranes with a thermally conductive layer that delivers heat to the membrane–feed interface, where it drives evaporation. Though this increases single-pass recovery, it comes with the challenge of promoting lateral heat conduction through the thin membrane. Herein, we develop a 3D, computational fluid dynamics (CFD) model that simulates conjugate heat, mass, and momentum transport in the feed channel and composite membrane. We then use the CFD to verify a simpler numerical model that approximates the feed velocity field analytically. We validate the numerical model experimentally, and use it to investigate the impacts of the conductive layer thickness, feed channel geometry, and operating conditions on temperature and concentration polarization, permeate production, and specific energy consumption. Overall, we find that lateral heating increases permeate production at the expense of increased concentration polarization. In extreme cases, the concentration increases more than four-fold along the membrane surface. Furthermore, we show however, that the feed flow rate and conductive layer thickness can be tailored to mitigate concentration polarization, for only a small reduction in permeate production.

42 ENGINEERING↗
DOE OSTI2022

Improved Representation of Horizontal Variability and Turbulence in Mesoscale Simulations of an Extended Cold-Air Pool Event

Abstract Cold-air pools (CAPs), or stable atmospheric boundary layers that form within topographic basins, are associated with poor air quality, hazardous weather, and low wind energy output. Accurate prediction of CAP dynamics presents a challenge for mesoscale forecast models in part because CAPs occur in regions of complex terrain, where traditional turbulence parameterizations may not be appropriate. This study examines the effects of the planetary boundary layer (PBL) scheme and horizontal diffusion treatment on CAP prediction in the Weather Research and Forecasting (WRF) Model. Model runs with a one-dimensional (1D) PBL scheme and Smagorinsky-like horizontal diffusion are compared with runs that use a new three-dimensional (3D) PBL scheme to calculate turbulent fluxes. Simulations are completed in a nested configuration with 3-km/750-m horizontal grid spacing over a 10-day case study in the Columbia River basin, and results are compared with observations from the Second Wind Forecast Improvement Project. Using event-averaged error metrics, potential temperature and wind speed errors are shown to decrease both with increased horizontal grid resolution and with improved treatment of horizontal diffusion over steep terrain. The 3D PBL scheme further reduces errors relative to a standard 1D PBL approach. Error reduction is accentuated during CAP erosion, when turbulent mixing plays a more dominant role in the dynamics. Last, the 3D PBL scheme is shown to reduce near-surface overestimates of turbulence kinetic energy during the CAP event. The sensitivity of turbulence predictions to the master length-scale formulation in the 3D PBL parameterization is also explored. Significance Statement In this article, we demonstrate how a new framework for modeling atmospheric turbulence improves cold pool predictions, using a case study from January 2017 in the Columbia River basin (U.S. Pacific Northwest). Cold pools are regions of cold, stagnant air that form within valleys or basins, and improved forecasts could help to mitigate the risks they pose to air quality, transportation, and wind energy production. For the chosen case study, our tests show a reduction in temperature and wind speed errors by up to a factor of 2–3 relative to standard model options. These results strongly motivate continued development of the framework as well as its application to other complex weather events.

17 WIND ENERGY↗
DOE OSTI2023

Tailoring resonant magnetic perturbation to optimize fast-ion confinement during ELM control in KSTAR

Abstract 3D resonant magnetic perturbation (RMP) is one promising way to control edge localized modes that can cause excessive material erosion of tokamak first walls. However, RMP can lead to undesired degradation of plasma confinement, including fast-particle losses, which can impact the performance and safety of the reactor. This work investigates the optimization of the poloidal spectrum of the 3D field to optimize fast ion confinement during edge localized mode (ELM) suppression. In the initial step, the validity of the modeling framework is tested against experimental data. Simulations successfully replicate an increase in poloidal limiter temperature with different poloidal spectra. Then, the simulation shows improvement of fast ion confinement with a reduction of core resonant response, while edge resonant magnetic fields are maintained above the threshold to sustain the ELM suppression. Reduction of the core resonant fields keeps the Kolmogorov–Arnold–Moser surface and reduces the fast particle losses due to the stochastic magnetic field lines. The results highlight the potential of edge localization of the resonant fields to enhance the performance of fusion reactors, but further investigation is needed to improve the validation of this approach.

3D field↗
NASA NTRS1994

Data assimilation and model evaluation experiment datasets

The Institute for Naval Oceanography, in cooperation with Naval Research Laboratories and universities, executed the Data Assimilation and Model Evaluation Experiment (DAMEE) for the Gulf Stream region during fiscal years 1991-1993. Enormous effort has gone into the preparation of several high-quality and consistent datasets for model initialization and verification. This paper describes the preparation process, the temporal and spatial scopes, the contents, the structure, etc., of these datasets. The goal of DAMEE and the need of data for the four phases of experiment are briefly stated. The preparation of DAMEE datasets consisted of a series of processes: (1) collection of observational data; (2) analysis and interpretation; (3) interpolation using the Optimum Thermal Interpolation System package; (4) quality control and re-analysis; and (5) data archiving and software documentation. The data products from these processes included a time series of 3D fields of temperature and salinity, 2D fields of surface dynamic height and mixed-layer depth, analysis of the Gulf Stream and rings system, and bathythermograph profiles. To date, these are the most detailed and high-quality data for mesoscale ocean modeling, data assimilation, and forecasting research. Feedback from ocean modeling groups who tested this data was incorporated into its refinement. Suggestions for DAMEE data usages include (1) ocean modeling and data assimilation studies, (2) diagnosis and theoretical studies, and (3) comparisons with locally detailed observations.

Lai, Chung-Cheng A.↗
NASA NTRS2002

The Influence of Tropospheric Processes in Modeling the Middle Atmosphere with Gravity Waves

Our Numerical Spectral Model (NSM) extends from the ground up into the thermosphere and has a vertical grid point resolution of about 0.5 km to resolve the interactions of gravity waves (GWs) described with Hines' Doppler Spread Parameterization (DSP). This model produces in the stratosphere and mesosphere the major features of QBO, SAO, tides, and planetary waves. The purpose of this paper is to discuss results from an initial study with our 3D model that shows how certain tropospheric processes can affect the dynamics of the middle atmosphere. Under the influence of tropospheric heating, and augmented by GW interactions, two distinct but related processes can be identified. (1) A meridional circulation develops in the stratosphere, with rising motions at low latitudes that are in magnitude comparable to the downward propagation of the QBO. As Dunkerton pointed out, a larger GW source is then required to reproduce the observed QBO, which tends to move us closer to the values recommended for the DSP. This has significant consequences for our model results that describe the upper mesosphere, considering the general importance of GWs for this region and in influencing planetary waves (e.g., 2-day wave) and tides in particular. (2) Tropospheric heating produces zonal jets near the tropopause that are related to latitudinal variations in pressure and reversing temperature variations (resembling the dynamical conditions near the mesopause), which in turn is conducive to generate baroclinic instability. Modeling results show that our ability to generate the QBO critically depends on the magnitude of the temperature reversal that is a measure of this instability. Planetary waves are generated in this process, which can apparently interfere with or augment the GW interactions. As originally demonstrated by Lindzen and Holton, the eastward propagating Kelvin waves and westward propagating Rossby gravity waves (generated by tropospheric convection) can in principle provide the acceleration to influence the QBO, and we were able to confirm this with our 3D model.

Mayr, H. G.↗
NASA NTRS2018

Predictive Thermal Control (PTC) Technology to Enable Thermally Stable Telescopes

The Predictive Thermal Control (PTC) technology development project is a multiyear effort initiated in Fiscal Year (FY) 2017, to mature the Technology Readiness Level (TRL) of critical technologies required to enable ultra-thermally-stable telescopes for exoplanet science. During 2017/18 PTC has successfully progressed its three defined objectives: 1. Validate thermal optical performance models. 2. Derive thermal system stability specifications. 3. Demonstrate Predictive Thermal Control. by accomplishing or advancing three of its five quantifiable milestones: Milestone #1 (Complete): Created a high-fidelity STOP (Structural-Thermal-Optical-Performance) model of the1.5 meter ULE® AMTD (Advanced Mirror Technology Development)-2 mirror, including 3D CTE (Coefficient of Thermal Expansion) distribution and reflective coating, that predicts its optical performance response to steady-state and dynamic thermal gradients. Structural model was created using 3D X-Ray Computed Tomography; Milestone #2 (Complete): Derived specifications for thermal control system as a function of wavefront stability for a Vector Vortex Coronagraph; Milestone #3 (In-Process): Designed and started fabricating a predictive Thermal Control System for the AMTD-2 1.5 meter ULE® mirror that senses temperature changes and actively controls the mirror's thermal environment; Milestone #4 (In-Process): Performed preliminary STOP model validation tests of the 1.5-m ULE® mirror in a relevant thermal vacuum environment at the MSFC X-ray and Cryogenic Facility (XRCF) test facility; Milestone #5: Use validated model to perform trade studies to determine how thermo-optical performance can be optimized as a function of mirror design, material selection, mass, etc.

Stahl, H. Philip↗
NASA NTRS2015

Complete Tem-Tomography: 3D Structure of Gems Cluster

GEMS (glass with embedded metal and sulfide) grains in interplanetary dust particles (IDPs) are considered to be one of the ubiquitous and fundamental building blocks of solids in the Solar System. They have been considered to be interstellar silicate dust that survived various metamorphism or alteration processes in the protoplanetary disk but the elemental and isotopic composition measurements suggest that most of them have been formed in the protoplanetary disk as condensates from high temperature gas. This formation model is also supported by the formation of GEMS-like grains with respect to the size, mineral assemblage, texture and infrared spectrum by condensation experiments from mean GEMS composition materials. Previous GEMS studies were performed only with 2D observation by transmission electron microscopy (TEM) or scanning TEM (STEM). However, the 3D shape and structure of GEMS grains and the spatial distribution of Fe/FeS's has critical information about their formation and origin. Recently, the 3D structure of GEMS grains in ultrathin sections of cluster IDPs was revealed by electron tomography using a TEM/STEM (JEM-2100F, JEOL). However, CT images of thin sections mounted on Cu grids acquired by conventional TEM-tomography are limited to low tilt angles (e. g., less than absolute value of 75 deg. In fact, previous 3D TEM observations of GEMS were affected by some artifacts related to the limited tilt range in the TEM used. Complete tomographic images should be acquired by rotating the sample tilt angle over a range of more than absolute value of 80 deg otherwise the CT images lose their correct structures. In order to constrain the origin and formation process of GEMS grains more clearly, we performed complete electron tomography for GEMS grains. Here we report the sample preparation method we have developed for this study, and the preliminary results.

Matsuno, J.↗
DOE OSTI2020

A Monte Carlo Approach to Approximating the Effects of Pore Geometry on the Phase Behavior of Soil Freezing

Abstract Freezing in porous media is associated with a host of dynamic phenomena that stem from the presence and mobility of premelted liquid at subzero temperatures. Accurate assessments of the progressive liquid‐ice phase transition is required for predictive models of frost damage, glacier‐till coupling, and many other cold regions processes, as well as for evaluating the capacity for water storage in near‐surface extraterrestrial environments. We use a Monte Carlo approach to sample the pore space in a synthetic 3D packing of poly‐dispersed spherical particles and evaluate local geometrical constraints that allow us to assess changes in the relative proportions of pore fluid and ice. By approximating the phase boundary geometry in fine‐grained pores while considering both the curvature of the liquid‐ice interface and wetting interactions with matrix particles, our model predicts changes in phase equilibrium in granular media over a broad temperature range, where present accounting for the colligative effects of chloride and perchlorate solutes. In addition to formulating the constitutive behavior needed to better understand properties and processes in frozen soils, our results also provide insight into other aspects of phase equilibria in porous media, including the formation of methane hydrates in permafrost and marine sediments, and the partitioning between liquid water and vapor in the vadose zone.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2024

Prediction of transport in the JET DTE2 discharges with TGLF and NEO models using the TGYRO transport code

Abstract The JET Deuterium-Tritium-Experiment Campaign 2 (DTE2) has demonstrated the highest-ever fusion energy production. To forecast the transport dynamics within these discharges, the TGLF and NEO models within the TGYRO transport code were employed. A critical development in this study is the new quasilinear transport model, TGLF-SAT2, specifically designed to resolve discrepancies identified in JET deuterium discharges. This model accurately describes the saturated three-dimensional (3D) fluctuation spectrum, aligning closely with a database of nonlinear CGYRO turbulence simulations, thereby enhancing the predictive accuracy of TGYRO simulations. In validating against the JET DTE2 discharges across two primary operating scenarios, TGYRO effectively predicted the temperature profiles within a broad radial window ( ρ ∼ 0.2–0.85), though with minor ion temperature discrepancies near the core. However, a consistent underprediction of electron density profiles by 20% across the simulation domain was noted, indicating areas for future refinement. To achieve a self-consistent steady-state solution based on the JET DTE2 discharges, an integrated modeling workflow TGYRO-STEP within the OMFIT framework was introduced. This workflow iterates among the core transport, the pedestal pressure and the MHD equilibrium, ultimately yielding a converged solution that significantly reduces dependence on experimental boundary conditions for temperature and density profiles. The integrated simulation results show negligible differences in electron density and temperature profiles compared to standalone TGYRO modeling, while the ion temperature profile is lower due to the updated boundary condition in TGYRO-STEP. The application of the TGYRO-STEP workflow to JET DTE2 discharges serves as a crucial test to validate its robustness and highlights its limitations, providing valuable insights for its potential future application in ITER and Fusion Power Plant deuterium and tritium prediction modeling.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2025

Vector-level feedforward control of LPBF melt pool area using a physics-based thermal model

Laser powder bed fusion (LPBF) is an additive manufacturing technique that has gained popularity thanks to its ability to produce geometrically complex, fully dense metal parts. However, these parts are prone to internal defects and geometric inaccuracies, stemming in part from variations in the melt pool. Here, this paper proposes a novel vector-level feedforward control framework for regulating melt pool area in LPBF. By decoupling part-scale thermal behavior from small-scale melt pool physics, the controller provides a scale-agnostic prediction of melt pool area and efficient optimization over it. This is done by operating on two coupled lightweight models: a finite-difference thermal model that efficiently captures vector-level temperature fields and a reduced-order, analytical melt pool model. Each model is calibrated separately with minimal single-track and 2D experiments, and the framework is validated on a complex 3D geometry in both Inconel 718 and 316L stainless steel. Results showed that feedforward vector-level laser power scheduling reduced geometric inaccuracy in key dimensions by 62%, overall porosity by 16.5%, and photodiode root-mean-squared deviation by 38.5% on average. Overall, this modular, data-efficient approach demonstrates that proactively compensating for known thermal effects can significantly improve part quality while remaining computationally efficient and readily extensible to other materials and machines.

Additive manufacturing↗
DOE OSTI2021

Micro-cantilever beam experiments and modeling in porous polycrystalline UO 2

Understanding the impact of microstructure on the thermo-mechanical behavior of oxide nuclear fuels is vital to predicting their performance through multiscale models. Evaluating the mechanical properties at the sub-grain length scale is key to developing these multiscale models. In this work, 3D finite element (FE) models were constructed to simulate the micrometer-scale bending of micro-cantilever beams fabricated using porous polycrystalline uranium dioxide (UO 2 ) and tested at room temperature. Here, the results showed that the porosity and elastic anisotropy of individual grains can play a significant role in determining the effective mechanical properties of the material deduced from the tests. Specifically, the porosity had a non-negligible effect, given that the pore size was of the same order of magnitude as the dimensions of the micro-beams. Correlations between load-deflection data, pore location, and elastic properties (effective Young's modulus) were investigated using UO 2 micro-beam FE models, where pore clusters were included and placed at different locations along the length of the beam. Results indicated that the presence of pore clusters near the substrate, i.e., the clamp of the micro-cantilever beam, has the strongest effect on the load-deflection behavior, with the porosity leading to a reduction of stiffness that is the largest for any location of the pore clusters. Furthermore, it was also found that pore clusters located towards the middle of the span and close to the end of the beam have a comparatively small effect on the load-deflection behavior. Therefore, it is concluded that accurate estimates of Young's modulus can be obtained from micro-cantilever experiments after accounting for porosity on the one third of the beam length close to the clamp. This, in turn, provides an avenue to improve microscale experiments and their analysis in porous, anisotropic elastic materials.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗