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DOE OSTI2025

MOSCATO Development and Integration in Fiscal Year 2025: Implementation of Multiphase, Multiphysics Modeling Capabilities for Molten Salt Systems

MOSCATO (Molten Salt Chemistry and Transport) is a multiphysics code that provides high-fidelity, coupled simulations of fluid flow, heat transfer, mass transfer, chemistry, electrochemical phenomena, and alloy corrosion for molten salt systems. In FY25, significant developments were made to the code package, enhancing its capabilities for modeling all relevant phenomena within operating moltens salt reactors (MSRs). The developments and activities in FY25 included: 1. Implementation of Level-Set methods to enable modeling of single-bubble behavior in molten salts. In FY25, the Level-Set two-phase flow modeling implementation was improved to simulate single bubble behavior with molten salt media. The large density and viscosity ratios between typical gases and molten salt liquids present challenges for these types of numerical solvers. With enhancements to the pressure projection method, MOSCATO’s Level-Set solver was able to be successfully validated to experiments related to helium bubble rise in stagnant molten salt. The simulated bubble rising velocity showed reasonable good agreement with experimental measurements. The bubble shape and dynamics were also visually compared with experimental snapshots, demonstrating a good qualitative match. 2. Generation of mass transfer correlations for multiphase flow systems. To enable calculations of the tritium transport across the interface between gas bubbles and salt, we modeled high- Schmidt-number mass transfer around a sphere across a broad range of Reynolds numbers. The mesh near the sphere surface was highly refined to resolve steep concentration gradients caused by the low diffusion coefficient. Literature-based mass transfer correlations were compared with the numerical results, and modifications were proposed to improve agreement, particularly at higher Schmidt numbers. These mass transfer correlations were subsequently provided to other national laboratories to help enable high quality mass transfer simulations using lower-order solvers under development within the NEAMS program. 3. Preliminary implementation of a bubbly flow solver. To model bubbly flow in molten salt, we implemented a bubbly flow solver for void fractions less than 5%. To do so, an algebraic relative velocity model that assumes small bubbles with rapid momentum equilibration was added to MOSCATO to compute bubble velocities. Preliminary comparisons with experimental data showed reasonable agreement, and further improvements are underway. 4. Generation of mass transfer correlations for MSRE subchannel The Molten-Salt Reactor Experiment (MSRE) was a landmark historical project that demonstrated the feasibility of molten-salt reactor technology. The MSRE campaign also generated a significant body of experimental data and reports that continue to support molten-salt–related research. In this report, the MSRE core subchannel was used as the reference geometry for a mass transfer study performed with MOSCATO. The geometry and computational mesh were adapted from a previous study, providing adequate resolution for the relatively low Reynolds number in this case. Additional mesh refinement was applied to reach higher Schmidt numbers, enabling the derivation of a reliable mass-transfer correlation for the present scenario. 5. Simulations of oxygen ingressions into molten salt. In the previous fiscal year, we initiated a study to simulate oxygen ingression in stagnant salt. As oxygen enters the salt through its surface, it reacts with Ce 3+ to form solid CeO 2 and other reaction products. To more fully capture the complex diffusion-convection-reaction mechanisms, capabilities for modeling natural convection in the salt vessel were added. These were needed as the flow of the ingressed gas induced flow in the salt caused by surface shear and non-isothermal effects. With these updated physics in place, we were able to successfully reproduce the experimental results for the rate of change of CeCl 3 concentrations versus time. 6. Flow corrosion model validation. In FY24, MOSCATO’s corrosion model was validated against static corrosion experiments. In FY25, this work was extended to a flow corrosion experiment, where FLiNaK salt was driven by natural convection, with initial salt impurities to initiate corrosion. Despite uncertainties in parameters such as elemental diffusion coefficients in the alloy and unknown H + concentrations, the simulations achieved good agreement with experimental results, especially in predicting sample mass losses.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2020

Relativistic Shear Boundary Layer and the Gamma-Ray Emission of GW170817

We present an analysis of the radiation characteristics of kinetic shear boundary layers created by relativistic plasma jets. Using a model of electromagnetic field data based on particle-in-cell simulations of an electron–ion plasma, we solve the motion of individual test electrons and compute their instantaneous radiated power and peak frequency. By analyzing a large number of test electrons in this manner, we find two distinct electron populations present around the shear boundary layer. The most highly radiative electrons execute looping motion due to crossed electric and magnetic fields as they are accelerated along the bulk flow of the jet, and eventually cross the shear boundary interface at steep angles. Electrons that never cross the shear boundary interface radiate much less energy as a group. Summing over all of the highly radiative electrons, we compute the distribution of the total radiated energy as a function of the angle relative to the bulk flow. Furthermore, this result has important potential implications for the observed radiation output of short gamma-ray bursts viewed at large angles from the jet axis, such as the neutron star merger event GW170817/GRB 170817A.

79 ASTRONOMY AND ASTROPHYSICS↗

DOE OSTI2025

Recovery of postconsumer mechanically recycled polymers

Mechanical recycling plays a key role in reducing landfill bound plastics that pollute our environment. This process converts plastic waste into marketable pellets by sorting, cleaning, grinding into flakes, compounding in the molten state, and ultimately pelletizing. A primary restriction for the widescale usage of mechanical recycling is the highly variable quality and mechanical properties of the plastic waste feedstock. Degradation can occur during the plastic life cycle with the consumer, during the mechanical processing itself, or during the complex sorting process required to produce the feedstock. This study explores how rheological characterization can mitigate the batch-to-batch variability and identify a potential application for each batch. Shear and extensional rheology of “application-specific” virgin high-density polyethylene (HDPE) and virgin polypropylene (PP) was used as the control for this categorization process. Recycled HDPE and PP from three different streams were then measured and compared to the results from the control study. Rheological measurements proved to be very effective at providing sufficient differentiation to categorize the recycled polymer as suitable for different applications such as injection molding, blow molding, or thermoforming. Finally, the usage of an additional step to sort the recycled polymers by their initial use application was found to achieve a remarkably consistent recovery of application-specific material properties. Furthermore, this secondary sorting could provide significant added value for mechanically recycled polymers.

Differential scanning calorimetry↗

DOE OSTI2024

Applying colloidal silica suspensions injection and sequential gelation to block vertical water flow in well annulus: laboratory testing on rheology, gelation, and injection

We evaluated the application of silica suspension injection and sequential gelation to block vertical water flow in the annuli of long-screened wells. First, we studied the viscosity, rheological behavior, and gelation performance of colloidal silica suspensions in batch tests. Then, we tested the injection of silica suspensions and the water flow blocking efficiency of the later formed silica gel in column and bench-scale sandbox experiments. Micron-sized fumed powder silica suspensions and nanosized silica suspensions recovered from geothermal fluids were tested in this work. Fumed silica suspensions showed shear thinning, while nanosized silica suspensions exhibited Newtonian flow behavior. During the gelation process, the nanosized silica suspension changed from a Newtonian fluid to a shear thinning fluid while increasing its overall viscosity. At comparable concentrations, the nanosized silica suspensions have much lower viscosity than that of the fumed silica suspensions. Increases in the Na + concentration and silica particle concentration in these suspensions shortened the gelation time. Silica suspension gelation in sand columns completely blocked the water flow and sustained the injection pressure up to 50 psig (344.7 kPa). A silica suspension was successfully injected into the target zone in the annulus of a bench-scale sandbox mimicking long-screened wells in the field. The silica gel formed in the annulus effectively blocked chemical transport through the gelled zone. Our research reveals that a process using silica suspension injection and sequential gelation technology is promising for blocking the vertical water flow and chemical transport through the filter pack in targeted zones within the annulus of long-screened well systems.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2025

Sediment transport and morphodynamic changes due to upstream variation and sea level rise on the Western Mekong Delta, Vietnam

The hydrological and morphological dynamics across the Vietnam Mekong Delta (VMD) coastline are increasingly shaped by human interventions and climate change, affecting the sustainability of socio-economic environments. This study employs the TELEMAC-MASCARET modeling system (TELEMAC-2D, TOMAWAC, and SISYPHE modules) to simulate hydrodynamics, sediment transport, and morphological changes for a 10-year period under baseline (SC1) and future climate (SC2) scenarios, considering wave climatology of Northeast (NEM) and Southwest monsoons (SWM). The results of sedimentation and erosion were analyzed across five key coastal zones from Ca Mau Cape (KV1) to Ha Tien (KV5). Model results highlight distinct seasonal patterns of sediment redistribution shaped by monsoonal flows, wave action, and seabed morphology. During the NEM, sediment deposition is concentrated near estuarine zones, while the SWM favors offshore sediment accumulation due to perpendicular wave actions, and shallow, gently sloping bathymetry that dissipates wave energy. Coastal erosion predominantly occurs at convex shoreline features subjected to stronger coastal currents, particularly in fine-grained sediment areas. Under future sea level rise and land subsidence scenarios, reduced flow velocities lead to lower bottom shear stress, promoting deposition and mitigating erosion problems despite increased wave energy. Besides that, sediment transport analyses across 14 cross-sections (C-S) reveal a southward trend during the NEM and a northward reversal during the SWM, with upstream sediment reductions primarily influencing near-estuarine zones and exerting minimal impact beyond the mid-coastal regions. Furthermore, these findings advance the understanding of sediment redistribution processes under climate change and seasonal change, and provide a scientific basis for adaptive coastal management and sustainable development.

Climate change↗

DOE OSTI2020

Rheology and stability of nanoparticle-stabilized CO 2 foam under reservoir conditions

This work investigates the rheology and stability of nanoparticle-stabilized CO 2 foams under reservoir conditions (high temperature and high pressure) for fracturing applications. The effects of different parameters on foam apparent viscosity and foam stability were experimentally investigated including the effects of nanoparticle concentration, salinity, foam quality (Γ), shear rate and temperature. The power law model was applied to calculate foam apparent viscosity owing to its pseudo-plastic behavior, and the changes of foam heights over time were used to evaluate foam stability. Results showed that the CO 2 foam apparent viscosity featured a mountain-shaped curve versus Γ, with the peak apparent viscosity obtained at 70% foam quality. The increase of salinity (up to 11%) in the continuous phase improved both foam stability and rheology. Higher nanoparticle concentration could contribute to better foam stability, but there was a threshold concentration, above which the foam apparent viscosity remained stabilized. The CO 2 foam stabilized by nanoparticles displayed a shear-thickening behavior as the experiment flow rate increased from 6 mL/min to 18 mL/min. Further studies showed that as the total flow rate increased, the CO 2 foam became finer-textured with better stability. Elevated temperatures could undermine foam apparent viscosity and long-term stability. The results of this study could provide guidelines as to the design of foam fracturing systems for field applications.

03 NATURAL GAS↗

DOE OSTI2026

Zonal magnetic fields regulate nonlinear edge-localized-mode dynamics via self-consistent force balance

Edge-localized modes (ELMs) eject intense bursts of heat and particles that threaten plasma-facing components in fusion reactors. Nonlinear full-torus BOUT++ simulations show that turbulence-driven zonal magnetic fields (ZMFs) play an essential role in nonlinear ELM evolution by maintaining self-consistent force balance. Zonal flows mitigate the initial crash through shear but do not prevent continued radial transport. When ZMFs are self-consistently included, turbulence-driven zonal currents modify the parallel current distribution and magnetic tension and are associated with a reduction of the axisymmetric (𝑛 = 0) perturbed radial force imbalance. This coincides with a transition from convective, bursty propagation to more localized, diffusive transport. Similar behavior is observed across the regimes considered, including both resistive-ballooning and peeling-ballooning cases. Finally, associated signatures, including radial electric field shear and parallel current redistribution, provide experimentally accessible diagnostics for present devices and ITER-relevant conditions.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2020

Development of a Comprehensive Two-Phase Flow Database for the Validation of NEK-2P

Three-dimensional (3-D) two-phase Computational Fluid Dynamics (CFD) codes are emerging as a powerful and potentially practical tool for applications in which detailed local flow information is needed. However, two-phase flow models and associated closure relations are not well established for CFD applications, which is partly due to the lack of high-quality validation data. The main objective of this work is to develop a comprehensive database of two-phase flows that can be used to validate two-phase CFD codes such as NEK-2P. In this project, four advanced local measurement systems, including Particle Image Velocimetry and Planar Laser-Induced Fluorescence (PIV-PLIF), high-speed imaging, x-ray densitometry, and multi-sensor conductivity probe are employed to measure the local two-phase flow parameters of both gas and liquid phases. By combining these techniques, the local void fraction, bubble velocity, interfacial area concentration, bubble frequency, liquid velocity, turbulence intensity, etc., in various two-phase flow regimes can be obtained. These local measurement techniques are first used in a 25.4 mm circular pipe test section. Seven air-water two-phase flow conditions spanning the bubbly, slug, churn-turbulent, and annular flow regimes are measured in this facility. The obtained database contains the radial profiles of both gas- and liquid-phase parameters at three axial locations along the test section. The second facility used in this work contains a 30 mm × 10 mm rectangular test section, in which three two-phase flow and two single-phase flow conditions are measured. Two-dimensional distributions of local two-phase flow parameters in the cross-sectional plane are measured in this facility at three axial locations as well. A facility featuring a 3×3 electrically heated rod bundle is also designed and being constructed in this project. This facility is specially designed for optical measurements and is expected to provide high-quality boiling data in the future. Preliminary analyses have been performed for the data taken in the 25.4 mm circular pipe. Both center-peaked and wall-peaked void fraction profiles have been observed in the data depending on the two-phase flow conditions and/or developing lengths. The 1-D drift-flux model was evaluated with the newly obtained datasets, in which both gas- and liquid-phases data were directly measured. The distribution parameter model has been optimized based on a new void-profile classification method proposed in this study. The optimized drift-flux model shows a significant improvement in predicting both gas velocity and void fraction. The measured liquid-phase turbulence was used to benchmark Sato’s turbulence model considering the bubble-induced shear stress for the three tested bubbly flows. The benchmark results showed good agreement between the PIV measurements and model predictions. In the bubbly flows tested that have low void fractions less than 3%, the effect of the bubble-induced turbulence was found not significant. However, the bubble-induced shear stress becomes important with the increase of the void fraction. The Conjugate Heat Transfer (CHT) model was developed and implemented in NEK-2P. This model allows the coupled simulation of the solid domain and two-phase fluid domain, allowing the specification of realistic boundary conditions. The CHT implementation was verified first with non-boiling simulations. The predicted temperatures in the fluid domain were shown to be identical in simulations with or without the CHT model. The CHT model was then validated through simulations of three Becker benchmark CHF tests performed under both Dryout (DO) and Departure from Nucleate Boiling (DNB) conditions. Reasonably good agreement was obtained between calculated wall temperatures and corresponding experimental data.

42 ENGINEERING↗

DOE OSTI2020

Shear-induced polydomain structures of nematic lyotropic chromonic liquid crystal disodium cromoglycate

Lyotropic chromonic liquid crystals (LCLCs) represent aqueous dispersions of organic disk-like molecules that form cylindrical aggregates. Despite the growing interest in these materials, their flow behavior is poorly understood. Here, we explore the effect of shear on dynamic structures of the nematic LCLC, formed by 14 wt% water dispersion of disodium cromoglycate (DSCG). We employ in situ polarizing optical microscopy (POM) and small-angle and wide-angle X-ray scattering (SAXS/WAXS) to obtain independent and complementary information on the director structures over a wide range of shear rates. The DSCG nematic shows a shear-thinning behavior with two shear-thinning regions (Region I at $\dot{\gamma}$ < 1 s -1 and Region III at $\dot{\gamma}$ > 10 s -1 ) separated by a pseudo-Newtonian Region II (1 s-1 < $\dot{\gamma}$ < 10 s -1 ). The material is of a tumbling type. In Region I, $\dot{\gamma}$ < 1 s -1 , the director realigns along the vorticity axis. An increase of [small gamma, Greek, dot above] above 1 s -1 triggers nucleation of disclination loops. The disclinations introduce patches of the director that deviates from the vorticity direction and form a polydomain texture. Extension of the domains along the flow and along the vorticity direction decreases with the increase of the shear rate to 10 s -1 . Above 10 s -1 , the domains begin to elongate along the flow. At $\dot{\gamma}$ > 100 s -1 , the texture evolves into periodic stripes in which the director is predominantly along the flow with left and right tilts. The period of stripes decreases with an increase of $\dot{\gamma}$. The shear-induced transformations are explained by the balance of the elastic and viscous energies. In particular, nucleation of disclinations is associated with an increase of the elastic energy at the walls separating nonsingular domains with different director tilts. The uncovered shear-induced structural effects would be of importance in the further development of LCLC applications.

36 MATERIALS SCIENCE↗

DOE OSTI2020

Liquid-phase turbulence measurements in air-water two-phase flows using particle image velocimetry

Liquid-phase turbulence plays a vital role in determining various gas-liquid two-phase flow parameters, such as void fraction distribution, bubble morphology, bubble-bubble interactions, and interfacial area concentration. In this study, a two-phase flow database including both the gas- and liquid-phases measurements was developed focusing on three bubbly flow conditions in an air-water two-phase flow loop with a vertical one-inch diameter circular pipe test section. A particle image velocimetry (PIV) system integrating an optical phase separation method, i.e., the planar laser-induced fluorescence (PLIF) technique using fluorescent particles and optical filtration, was applied to measure the liquid-phase turbulence information, including the time-averaged velocity, Reynolds stress, and turbulent kinetic energy for the liquid phase. The PIV measurements were taken at three ports along the test section at 14.5, 51.5, and 88.5 pipe inner diameters downstream of a bubble injector. In addition, a double-sensor conductivity probe was used to measure radial distributions of the local time-averaged void fraction and gas velocity. The measured liquid-phase turbulence was used to benchmark Sato's turbulence model considering the bubble-induced shear stress for the three tested bubbly flows. The benchmark results showed good agreement between the PIV measurements and model predictions. Lastly, in the two bubbly flows tested that have low void fractions being less than 3%, the effect of the bubble-induced turbulence was found not significant. However, the bubble-induced shear stress becomes important with the increase of the void fraction.

42 ENGINEERING↗

DOE OSTI2023

Taylor–Couette flow for astrophysical purposes

A concise review is given of astrophysically motivated experimental and theoretical research on Taylor–Couette flow. The flows of interest rotate differentially with the inner cylinder faster than the outer, but are linearly stable against Rayleigh’s inviscid centrifugal instability. At shear Reynolds numbers as large as 10 6 , hydrodynamic flows of this type (quasi-Keplerian) appear to be nonlinearly stable: no turbulence is seen that cannot be attributed to interaction with the axial boundaries, rather than the radial shear itself. Direct numerical simulations agree, although they cannot yet reach such high Reynolds numbers. This result indicates that accretion-disc turbulence is not purely hydrodynamic in origin, at least insofar as it is driven by radial shear. Theory, however, predicts linear magnetohydrodynamic (MHD) instabilities in astrophysical discs: in particular, the standard magnetorotational instability (SMRI). MHD Taylor–Couette experiments aimed at SMRI are challenged by the low magnetic Prandtl numbers of liquid metals. High fluid Reynolds numbers and careful control of the axial boundaries are required. The quest for laboratory SMRI has been rewarded with the discovery of some interesting inductionless cousins of SMRI, and with the recently reported success in demonstrating SMRI itself using conducting axial boundaries. Some outstanding questions and near-future prospects are discussed, especially in connection with astrophysics.

79 ASTRONOMY AND ASTROPHYSICS↗

DOE OSTI2024

Hypersonic Wake Velocity Measurements Using Acetone Molecular Tagging Velocimetry

A non-intrusive laser diagnostic known as molecular tagging velocimetry was used to find quantitative off-body velocity measurements in the wake of a sphere in the Mach 7 Ludwieg Tube Wind Tunnel located at The University of Texas at San Antonio. Acetone gas seeded in the flow was excited using the 4th harmonic of a pulse-burst Nd:YAG laser. The experimental results were used to validate and compare to simulations using a continuous Galerkin flow solver. Both the experimental and simulated results agreed on negative velocities in the viscous shear layer. Near the centerline of the sphere, average velocities of -200 m/s were observed due to reverse flow in the recirculation region. Outside of the shear layer, velocities of 800 m/s were observed in both the experimental and simulated results. The overall average uncertainty for the strut-mounted and free-flight case was estimated to be ±27 m/s. The flow features of the wake were visualized using schlieren imaging, and the experimental results agreed well with the simulated results.

Shoemake, Lawton↗

DOE OSTI2020

On the Cutting of Metals: A Mechanics Viewpoint

The mechanics of large-strain deformation in cutting of metals is discussed, primarily from viewpoint of recent developments in in situ analysis of plastic flow and microstructure characterization. It is shown that a broad range of deformation parameters can be accessed in chip formation—strains of 1–10, strain rates of 10–10 5 /s, and temperatures up to 0.7T m —and controlled. This range is far wider than achievable by any other single-stage, severe plastic deformation (SPD) process. The resulting extreme deformation conditions produce a rich variety of microstructures in the chip. Four principal types of chip formation—continuous, shear-localized, segmented, and mushroom-type—as elucidated first by Nakayama (1974, “The Formation of ‘Saw-Toothed Chip’ in Metal Cutting,” Proceedings of International Conference on Production Engineering, Tokyo, pp. 572–577) are utilized to emphasize the diverse plastic flow phenomena, especially unsteady deformation modes that prevail in cutting. These chip types are intimately connected with the underlying flow, each arising from a distinct mode and triggered by an instability phenomenon. The role of plastic flow instabilities such as shear banding, buckling, and fracture in mediating unsteady flow modes is expounded, along with consequences of the flow modes and chip types for the cutting. Sinuous flow is shown to be the reason why gummy (highly strain-hardening) metals, although relatively soft, are so difficult to cut. Synthesizing the various observations, a hypothesis is put forth that it is the stability of flow modes that determines the mechanics of cutting. Furthermore, this leads to a flow-stability phase diagram that could provide a framework for predicting chip types and process attributes.

42 ENGINEERING↗

DOE OSTI2023

Capturing plume behavior in complex terrain: an overview of the Nevada National Security Site Meteorological Experiment (METEX21)

METEX21 was an atmospheric tracer release experiment executed at the Department of Energy’s Nevada National Security Site (NNSS) in the southwestern U.S to study terrain-induced wind and thermodynamic conditions that influence local-scale (<5-km) plume transport under varying atmospheric forcing conditions. Meteorological observations were collected using 10-m tall meteorological towers, 2-m tall tripods with 3-d sonic anemometers, a 3-m tall eddy covariance flux tower, Doppler profiling lidars, Doppler scanning lidars, weather-balloon launched radiosondes, and a tethered balloon equipped with wind, temperature, and aerosol sensors at heights up to 800 m. A smoke tracer was released along three transects in the horizontal and vertical directions and observed with video cameras, aerosol sensors and lidars (via aerosol backscatter). The observations showed evidence of large-scale/synoptic transience as well as local-scale upslope and downslope flows, along-axis valley flows, recirculation eddies on leeward slopes, and periods of strong shear and veer aloft. The release days were classified as either synoptically-driven or locally-driven, and a single case day is presented in detail for each. Synoptically-forced days show relatively narrow smoke plumes traveling down the valley from north to south (with the predominant wind direction), with little deviation in transport direction regardless of the elevation or ground locations of the smoke releases, except near the presence of leeside recirculation eddies. Locally-forced days exhibit a wider range of plume behavior due to the combination of thermally-induced valley and slope flows, which are often flowing in different cardinal directions, and wind shear found aloft at higher altitudes and elevations. We saw evidence of smoke lofting on top of the mesas due to strong upslope flows on these days. A major finding of this experiment was the effectiveness of scanning lidars to measure 2-dimensional plume transport out to a 2–3 km distance; much farther than could be visibly observed. METEX21 was the first of three planned tracer experiments at NNSS, and future experiments will incorporate multiple tracers to improve individual plume identification so that finer resolution flow details can be attained from these measurements, as well as deploy a larger suite of meteorological instrumentation, including more temperature profiling data.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2023

Large-Eddy Simulation of Flow Over Boeing Gaussian Bump Using Multiagent Reinforcement Learning Wall Model: Preprint

We develop a wall model for large-eddy simulation (LES) that takes into account various pressure-gradient effects using multi-agent reinforcement learning. The model is trained using low-Reynolds-number flow over periodic hills with agents distributed on the wall at various computational grid points. It utilizes a wall eddy-viscosity formulation as the boundary condition to apply the modeled wall shear stress. Each agent receives states based on local instantaneous flow quantities at an off-wall location, computes a reward based on the estimated wall-shear stress, and provides an action to update the wall eddy viscosity at each time step. The trained wall model is validated in wall-modeled LES of flow over periodic hills at higher Reynolds numbers, and the results show the effectiveness of the model on flow with pressure gradients. The analysis of the trained model indicates that the model is capable of distinguishing between the various pressure gradient regimes present in the flow. To further assess the robustness of the developed wall model, simulations of flow over the Boeing Gaussian bump are conducted at a Reynolds number of 2 x 10^6, based on the free-stream velocity and the bump width. The results of mean skin friction and pressure on the bump surface, as well as the velocity statistics of the flow field, are compared to those obtained from equilibrium wall model (EQWM) simulations and published experimental data sets. The developed wall model is found to successfully capture the acceleration and deceleration of the turbulent boundary layer on the bump surface, providing better predictions of skin friction near the bump peak and exhibiting comparable performance to the EQWM with respect to the wall pressure and velocity field. We also conclude that the subgrid-scale model is crucial to the accurate prediction of the flow field, in particular the prediction of separation.

boundary layer↗

DOE OSTI2022

Flow and arrest in stressed granular materials

Flowing granular materials often abruptly arrest if not driven by sufficient applied stresses. Such abrupt cessation of motion can be economically expensive in industrial materials handling and processing, and is significantly consequential in intermittent geophysical phenomena such as landslides and earthquakes. Using discrete element simulations, we calculate states of steady flow and arrest for granular materials under the conditions of constant applied pressure and shear stress, which are also most relevant in practice. Here the material can dilate or compact, and flow or arrest, in response to the applied stress. Our simulations highlight that under external stress, the intrinsic response of granular materials is characterized by uniquely-defined steady states of flow or arrest, which are highly sensitive to interparticle friction. While the flowing states can be equivalently characterized by volume fraction, coordination number or internal stress ratio, to characterize the states of shear arrest, one needs to also consider the structural anisotropy in the contact network. Here, we highlight the role of dilation in the flow-arrest transition, and discuss our findings in the context of rheological transitions in granular materials.

36 MATERIALS SCIENCE↗

DOE OSTI2022

Mesoscale simulations of pressure-shear loading of granular tungsten carbide

Numerical simulations of pressure-shear loading of a granular material are performed using the shock physics code CTH. A simple mesoscale model for the granular material is used that consists of a randomly packed arrangement of solid circular or spherical grains of uniform size separated by vacuum. The grain material is described by a simple shock equation of state, elastic perfectly plastic strength model, and fracture model with baseline parameters for WC taken from previous mesoscale modeling work. Simulations using the baseline material parameters are performed at the same initial conditions of pressure-shear experiments on dry WC powders. Except for some localized flow regions appearing in simulations with an approximate treatment of sliding interfaces among grains, the samples respond elastically during shear, which is in contrast to experimental observations. By extending the simulations to higher shear wave amplitudes, macroscopic shear failure of the simulated samples is observed with the shear strength increasing with increasing stress confinement. The shear strength is also found to be strongly dependent on the grain interface treatment and on the fracture stress of the grains, though the variation in shear strength due to fracture stress decreases with increasing stress confinement. At partial compactions, the transverse velocity histories show strain-hardening behavior followed by formation of a shear interface that extends through the transverse dimensions of the sample. Near full compaction, no strain hardening is observed and, instead, the sample transitions sharply from an elastic response to formation of an internal shear interface. Agreement with experiment is shown to worsen with increasing confinement stress with simulations overpredicting the shear strengths measured in experiment. The source of the disagreement can be ultimately attributed to the Eulerian nature of the simulations, which do not treat contact and fracture realistically.

36 MATERIALS SCIENCE↗

DOE OSTI2026

Bio-inspired alula-based winglet design for enhanced heat transfer in high temperature fin-and-tube heat exchangers

Fin-and-tube heat exchangers (FTHEs) are widely used for high-temperature flue-gas heat recovery, but their performance is often limited by wake regions and non-uniform fin-surface temperatures. This study proposes and numerically evaluates four bio-inspired longitudinal vortex generator (VG) configurations in a high-temperature FTHE with flue-gas inlet temperature ∼1230 K: double-delta, curved double-delta, alula, and a new curved-alula geometry. The reference fin is not hydraulically plain; it already incorporates leading-edge separation columns and convex protrusions, so the alula-type winglets are assessed as downstream add-ons acting on a strongly disturbed flow. In a second step, perforations (one, two and three circular holes) are introduced into the curved-alula VGs to further tailor the flow field. Three-dimensional simulations with the Shear Stress Transpor (SST) $k - ω$ model, temperature-dependent flue-gas properties and conjugate conduction are carried out for gas-side Reynolds numbers $Re_g ≈ 8.0$ x $10^2 - 3.6$ x $10^3$ (mass flow rates 0.5 – 2.5 g/s), and the designs are compared in terms of surface heat flux, Nusselt number, friction factor and hydrothermal performance factor (HTPF). For this already-promoted fin, the additional downstream winglets provide moderate, incremental hydrothermal gains. At the highest Reynolds number, the best non-perforated design (curved-alula) increases surface heat flux from 1630.9 to 1794.7 kW/m² (∼ 10 % gain) and the Nusselt number from 227.6 to 242.6 (∼ 7 % gain), while the friction factor rises from 0.26 to about 0.30, yielding HTPF values close to unity (∼ 0.9 – 1.0). Introducing circular perforations into the curved-alula winglets acts mainly as a wake-bleeding refinement: the three-hole configuration provides a heat flux of 1824.7 kW/m² and a pressure drop of 127.9 Pa, with HTPF in the range ∼ 1.03 – 1.14 and a small (∼ 1 – 3 %) improvement over the solid curved-alula design. Flow-field analysis shows that the perforated curved-alula VGs shrink tube-wake regions, thin the thermal boundary layer and homogenize the fin-surface temperature (outlet-gas temperature ∼ 510 – 520 K and fin-surface temperature ∼ 420 – 421 K for the three-hole case). An optimal flue-gas mass flow rate of ∼ 1 g/s ($Re_g ≈ 1.5$ x $10^3$) is identified, beyond which additional heat-transfer gains are offset by rapidly increasing pressure losses. Overall, the results highlight that initial fin geometry and VG placement are as important as VG shape: alula-based winglets are expected to yield larger relative gains on simpler flat-fin layouts or when positioned closer to the fin leading edge and tube

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗