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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.

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At least 307 records · Page 17

Multi-fidelity uncertainty quantification strategies for large-scale multiphysics applications: PSAAP II particle-based solar energy receiver

The study of complex systems is often based on computationally intensive, high-fidelity, simulations. To build confidence or improve the prediction accuracy of such simulations, the impact of uncertainties in model inputs, or even the structure of the models, on the quantities of interest must be measured. This, however, requires a computational budget that is a possibly large multiple of the cost of a single simulation, and thus may become infeasible for expensive simulation models featuring a large number of uncertain inputs and highly non-linear behavior. Therefore, this work explores multi-fidelity strategies to accelerate the estimation of the effect of uncertainties. The main idea behind multi-fidelity methods is to utilize cheaper, lower-fidelity models – than the intended high-fidelity, expensive model of the problem – to generate a baseline solution that together with relatively small number of high-fidelity simulations can lead to accurate predictions. The methods are briefly presented, and their performance assessed on an irradiated particle-laden turbulent flow case related to Stanford’s PSAAP II particle-based solar energy receiver.

Physics↗

Multiphysics simulation of microscale copper printing by confined electrodeposition using a nozzle array

3D printing of metals at the microscale and nanoscale is crucial to produce high-density interconnects and intricate structures in electronic devices. Conventional melting and sintering processes are not suitable for these scales due to a reliance on individual metal particles in the size range of tens of micrometers. Confined electrodeposition (CED) is an established alternative to conventional metal 3D printing processes in which an electrolyte is used to selectively induce deposition of the metal on the printing surface. However, commercialization and efficiency of this process have been limited due to a reliance on sub-micrometer nozzles to achieve desirable deposition rates and single nozzle to achieve uniformity of printed structures. Here, we address these challenges by computationally analyzing an array of microscale nozzles. We tailor the convection within the electrolyte to alter both deposition rate and geometric uniformity of the printed structures. The results show that for large nozzles the evaporation alone is not sufficient to obtain high deposition rates, yet an external pressure can be used to increase deposition and alter uniformity (thickness) of printed structures. Our results can be used to design and analyze new experiments toward parallel multi-nozzle deposition using CED toward high-throughput metal printing.

3D printing↗

Multiphysics Analyses of the Bottom Components of the 3D Printed Transformational Challenge Reactor

This research presents multi-physics analyses on the bottom components of the Transformational Challenge Reactor (TCR) facility. These components include the bottom axial reflector and the steel exit cone. The bottom axial reflector is made of pure silicon carbide elements hosting helium cooling channels These elements are 3D printed and therefore can host any arbitrary shape of the helium cooling channels. The design of the bottom reflector considers the neutronics and thermo-fluid dynamics performances as well as the manufacturing process optimization. More precisely, the best design of the bottom reflector reduces neutron leakage by avoiding straight cylindrical helium channels that facilitate neutron leakage, minimizes the helium flow pressure drop, and reduces the number of 3D printed silicon carbide pieces. The exit cone steel structure collects the hot helium from the bottom fuel assemblies and channels the cold helium to the top of the fuel assemblies. The steel simultaneous contact with hot and cold helium flows sets a large thermal gradient. Different designs of the exit cone are proposed to reduce the steel equivalent stress from the helium thermal load. The multi-physics analyses have been performed using Ansys Fluent, Ansys Mechanical, STAR-CCM+, and Serpent computer programs.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

Advanced Multiphysics Code Coupling for Cladding Surface Thermocouples During Two-Phase Heat Transfer from Nuclear Fuel

Transient testing of nuclear fuel involves the evaluation of fuel performance under off-normal and accident conditions and is essential for proving design performance. Instrumentation included in such experiments commonly includes thermocouples attached to the outer surface of the cladding to provide temperature measurements throughout the transient. However, the presence of thermocouples on the cladding surface can alter the local heat transfer characteristics with the surrounding coolant. These localized effects can influence the temperature of the nearby cladding surface and introduce uncertainties in interpreting the thermocouple data. Understanding the impact of thermocouples attached to the outer surface of the cladding is crucial for accurate data interpretation as well as its effect on the thermomechanical behavior of the cladding. This paper presents a novel methodology for simulating the impact of outer cladding thermocouples during transient testing of nuclear fuels. The simulation framework leverages the thermal-hydraulic capabilities of RELAP5-3D coupled to the BISON fuel performance code through the RELAPCouplingApp interface. The methodology is compared against Accident Tolerant Fuel Reactivity Initiated Accident-1-E experiment performed at Idaho National Laboratory. The results reveal approximately 100°C difference between thermocouple-altered temperature and virgin cladding surface. The model overpredicts surface rewet time due to conservative correlations.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Interface learning of multiphysics and multiscale systems

Complex natural or engineered systems comprise multiple characteristic scales, multiple spatiotemporal domains, and even multiple physical closure laws. To address such challenges, we introduce an interface learning paradigm and put forth a data-driven closure approach based on memory embedding to provide physically correct boundary conditions at the interface. To enable the interface learning for hyperbolic systems by considering the domain of influence and wave structures into account, we put forth the concept of upwind learning toward a physics-informed domain decomposition. The promise of the proposed approach is shown for a set of canonical illustrative problems. Here, we highlight that high-performance computing environments can benefit from this methodology to reduce communication costs among processing units in emerging machine-learning-ready heterogeneous platforms toward exascale era.

42 ENGINEERING↗

Fourier Analysis-Based Evolutionary Multi-Objective Multiphysics Optimization of Liquid-Cooled Heat Sinks

Optimal heat dissipation in power modules can significantly increase their power density. Removing the generated heat is critical for capturing the benefits of advanced semiconductor materials and improving the reliability of the device operation. This article proposes a design optimization method for liquid-cooled heat sinks that use a Fourier analysis-based tool and an evolutionary optimization algorithm to optimize the heat sink geometry for specified objectives. The optimized heat sink geometry is then compared with state-of-the-art solutions in literature based on finite element analysis of different designs. The proposed methodology can develop complex geometries that outperform the conventional heat sink geometries.

Sahu, Raj↗

Coupling Exascale Multiphysics Applications: Methods and Lessons Learned

With the growing computational complexity of science and the complexity of new and emerging hardware, it is time to re-evaluate the traditional monolithic design of computational codes. One new paradigm is constructing larger scientific computational experiments from the coupling of multiple individual scientific applications, each targeting their own physics, characteristic lengths, and/or scales. We present a framework constructed by leveraging capabilities such as in-memory communications, workflow scheduling on HPC resources, and continuous performance monitoring. This code coupling capability is demonstrated by a fusion science scenario, where differences between the plasma at the edges and at the core of a device have different physical descriptions. This infrastructure not only enables the coupling of the physics components, but it also connects in situ or online analysis, compression, and visualization that accelerate the time between a run and the analysis of the science content. Results from runs on Titan and Cori are presented as a demonstration.

Choi, Jong Youl↗

Microwave sintering of complex shapes: From multiphysics simulation to improvements of process scalability

The microwave sintering homogeneity of large and complex shape specimens is analyzed. A new approach enabling the fabrication of complex shapes ceramics via 3D printing and microwave sintering is presented. The use of a dental microwave cavity is shown to enable a substantial level of densification of complex shape components while restricting the grain growth. The homogeneity of the processed samples during microwave sintering is studied by an electromagnetic-thermal-mechanical simulation. The realistic densification behavior, that phenomenologically takes into account the microwave effect, is included in the modeling framework. We observe that the simulation indicates the sharp correlation between the microwave field distribution in the cavity, the temperature profile, and the specimen's shape distortion.

36 MATERIALS SCIENCE↗

Coupled Multiphysics Modeling of Lithium-Ion Batteries for Automotive Crashworthiness Applications

Considerable advances have been made in battery safety models, but achieving predictive accuracy across a wide range of conditions continues to be challenging. Interactions between dynamically evolving mechanical, electrical, and thermal state variables make model prediction difficult during mechanical abuse scenarios. In this study, we develop a physics-based modeling approach that allows for choosing between different mechanical and electrochemical models depending on the required level of analysis. We demonstrate the use of this approach to connect cell-level abuse response to electrode-level and particle-level transport phenomena. A pseudo-two-dimensional model and simplified single-particle models are calibrated to electrical-thermal cycling data and applied to mechanically induced short-circuit scenarios to understand how the choice of electrochemical model affects the model prediction under abuse scenarios. These models are implemented using user-defined subroutines on ls-dyna finite element software and can be coupled with existing automotive crash safety models.

analysis and design of components↗

Multiphysics modeling of mesh piezoelectric atomizers

An ultrasonic clothes dryer was developed by researchers at Oak Ridge National Laboratory based on a novel approach of using high-frequency mechanical vibration instead of heat to extract moisture as a cold mist. This technology is based on direct mechanical coupling between mesh piezoelectric (PZT) transducers and wet fabric. The vibration introduces sufficient momentum to the droplets trapped in the fabric pores to atomize them and leave the garment in a cold state. In the vibrating transducer, deformation followed by the effects of boundary layer acoustic streaming results in ejection of the atomized droplets. The research presented bridges the vibration of a PZT mesh transducer to the induced acoustic field and to capillary-wave theory. Mathematical modeling studies free and forced vibrations of a mesh-like PZT structure, using the structural parameters identified by actuation testing in several case studies. Computational fluid–structure interaction modeling is performed to couple the vibrations of a PZT transducer with an in-contact droplet. The results obtained are used to investigate (1) the transverse deformation of the vibrating mesh transducer in contact with a droplet, (2) the resultant boundary layer acoustic streaming in the fluid surrounding the vibrating surface, and (3) the droplet deformation and fluid ejection. The physics of atomization are linked to the level of the near-wall droplet vibrations induced by the surface deformation of the transducer. Then the surface deformation is linked to the properties of the PZT mesh transducer and input actuation frequency and power.

Dupuis, Eric↗