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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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All sourcesNASA NTRSDOE OSTI
DOE OSTI2026

MFC 5.0: An exascale many-physics flow solver

Many problems of interest in engineering, medicine, and the fundamental sciences rely on high-fidelity flow simulation, making performant computational fluid dynamics solvers a mainstay of the open-source software community. Previous work MFC 3.0 was made a published, documented, and open-source solver via Bryngelson et al. Comp. Phys. Comm. (2021) with numerous physical features, numerical methods, and scalable infrastructure. MFC 5.0 is a significant update to MFC 3.0, featuring a broad set of well-established and novel physical models and numerical methods, as well as the introduction of GPU and APU (or superchip) acceleration. Here, we exhibit state-of-the-art performance and ideal scaling on the first two exascale supercomputers, OLCF Frontier and LLNL El Capitan. Combined with MFC’s single-accelerator performance, MFC achieves exascale computation in practice, and achieved the largest-to-date public CFD simulation at 200 trillion grid points as a 2025 ACM Gordon Bell Prize finalist. New physical features include the immersed boundary method, N-fluid phase change, Euler–Euler and Euler–Lagrange sub-grid bubble models, fluid-structure interaction, hypo- and hyper-elastic materials, chemically reacting flow, two-material surface tension, magnetohydrodynamics (MHD), and more. Numerical techniques now represent the current state-of-the-art, including general relaxation characteristic boundary conditions, WENO variants, Strang splitting for stiff sub-grid flow features, and low Mach number treatments. Weak scaling to tens of thousands of GPUs on OLCF Summit and Frontier and LLNL El Capitan achieves efficiencies within 5% of ideal to over 90% of their respective system sizes. Strong scaling results for a 16-times increase in device count show parallel efficiencies over 90% on OLCF Frontier. MFC’s software stack has undergone further improvements, including continuous integration, which ensures code resilience and correctness through over 300 regression tests; metaprogramming, which reduces code length while maintaining performance portability; and code generation for computing chemical reactions

Computational fluid dynamics↗
DOE OSTI2026

Gas-driven short disconnection mitigates thermal runaway in Li-ion batteries under mechanical abuse

Mechanical abuse poses a critical safety risk to Li-ion batteries by inducing internal short circuits that initiate thermal runaway. Remarkably, voltage recovery frequently emerges during thermal runaway initiation, a phenomenon that conventional theories fail to explain. Here, our study develops a new multiphysics mechanism to explain voltage recovery, termed gas-driven short disconnection, whereby internal gas pressure mechanically disengages short-circuit contacts and causes the cell voltage to rebound. This mechanism incorporates gas generation and its structural impact on the short circuit. Real-time optical and thermal imaging and X-ray computed tomography reveal fluid-structure interaction between internal gas flow and adjacent shorting contacts. We establish a mechanistic framework linking gas-driven short disconnection to cell-level voltage and temperature responses, elucidating the extension–truncation pattern of voltage recovery. Furthermore, thermal regime maps show that a voltage recovery duration exceeding 5 s correlates with limited temperature rise below 150 °C, indicating that sustained short-circuit disconnection suppresses Joule heating. Additionally, a dimensionless criterion is deduced from scaling analysis for physical plausibility of gas-driven short disconnection in mechanically abused cells. This finding inspires smart venting control, which regulates gas release to maintain the internal pressure while dissipating gas enthalpy, thereby providing a device-level strategy for thermal runaway mitigation.

Gas-driven short disconnection↗
DOE OSTI2026

Margin to onset of nucleate boiling and flow instability studies for preliminary MITR design-demonstration element thermal-hydraulics

This study covers the onset of flow instability (OFI) preliminary results obtained from leveraging correlations, in addition to the preliminary thermal hydraulics results such as pressure, flow velocity, temperature, and oxide layer over the design demonstration experiment (DDE) for the Massachusetts Institute of Technology Reactor (MITR). Current computational fluid dynamics (CFD) models in fluid structure interaction (FSI) have added the capability of assessing margins to onset of nucleate boiling (ONB). This study initiates the capability to model the margin to OFI and ONB presented for the MITR. Such study is supportive of the United States High Performance Research Reactor (USHPRR) program. Previous studies provided preliminary thermal-hydraulic and mechanical analyses of the hydrodynamic effects in the MITR DDE under conservative approximations for plate power distribution. In conclusion, this study focuses on providing insights into the OFI future research direction optimizing the transport of thermal energy, mass-flow rates, flow-channel geometries, and boundary conditions.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2023

Modeling of the spray-induced wall stress acting on the ignition assistance device

This research introduces a novel wall-stress model called the Spray-Induced Wall Stress (SIWS) model, which considers the effects of spray-wall impingement and the resulting formation of wall stress within the Lagrangian spray modeling framework. The primary objective of this paper is to provide a mathematical description of the fundamental physics underlying the model. Subsequently, the proposed model is validated using existing experimental data. Here, the remainder of the study focuses on the practical application of the model to an ignition assistance device. Specifically, this device is installed in a compression ignition engine and designed to enhance ignition in aviation-fueled high-altitude aircraft propulsion systems. The research sheds light on the mechanical impulse caused by the high-speed impact of the spray jet, leading to the accumulation of mechanical stress on the rigid body of the ignition assistance device. Previous studies on fluid-structure interaction have only considered the interaction between the gas phase and the solid wall. However, the SIWS model incorporates the additional impact of the impinging liquid spray jet. Consequently, the simulated stress distribution on the ignition assistance device can be estimated by considering both the gas-phase-induced term and the spray-induced term simultaneously.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2024

Calibration of the 2-Phase Bubble Tracking Model for Liquid Mercury Target Simulation with Machine Learning Surrogate Models

The Spallation Neutron Source (SNS) at Oak Ridge National Laboratory is one of the most powerful accelerator-driven neutron sources in the world. The intense protons strike on SNS's mercury target to provide bright neutron beams, which also leads to severe fluid-structure interactions inside the target. Prediction of resultant loading on the target is difficult particularly when helium gas is injected into mercury to reduce the loading and mitigate the pitting damage on vessel walls. A 2-phase material model that incorporates the Rayleigh-Plesset (R-P) model is expected to address this multi-physics problem. However, several uncertain parameters in the R-P model require intensive simulations to determine their optimal values. With the help of machine learning and the measured target strain, we have studied the major uncertain parameters in this R-P model and developed a framework to identify optimal parameters that significantly reduce the discrepancy between simulations and experimental strains. The preliminary results show the possibility of using this mercury/helium mixture and surrogate models to predict a better match of target strain response when the helium gas is injected.

Lin, Lianshan↗
DOE OSTI2024

Identification of Dynamic Force Coefficients for an Additively Manufactured Hermetic Squeeze Film Bearing Support Damper Utilizing a Pass-Through Channel

Abstract The following paper presents breakthrough experimental results for a new hermetic squeeze film damper (HSFD) concept that is integrally designed within an externally pressurized tilting-pad radial gas bearing support. The flexibly damped gas bearing module was designed for a 7.2″ (183 mm) diameter shaft and fabricated using direct metal laser melting (DMLM); also known as additive manufacturing. The bearing and HSFD were sized based on ongoing studies for oil-free supercritical carbon dioxide (sCO2) power turbines in the 8.5 MW–10 MW power range. The development of the new damper concept was motivated by past dynamic testing on HSFD, which generated frequency-dependent stiffness and damping force coefficients. In efforts to eliminate the frequency dependency, a new HSFD architecture was conceived that adds accumulator volumes and a pass-through channel to previously conceived HSFD flow network designs. The other motivation for the work is the need to develop a cost-effective and reliable oil-free bearing technology that is scalable to large power turbomachinery applications. There were several objectives for the following work. The first objective was to successfully design and fabricate a single piece bearing-damper using additive manufacturing, while dimensionally controlling critical design features. The paper discusses the manufacturing steps and shows cut-ups that reveal adequate clearance control capability with internal damper clearances. The second objective was to perform experimental testing with the new HSFD design in efforts to extract stiffness and damping coefficients for excitation frequencies within 20–160 Hz and peak vibration amplitudes between 0.25 mils (6.35 microns) to 1 mil (25.4 microns). The test results for a single HSFD bearing module indicated that the design modifications to the HSFD architecture were successful in eliminating nearly all the frequency dependencies for the stiffness force coefficient. The dynamic tests yielded a stiffness coefficient that varied between 112 klb/in. (19.6 MN/m) and 96 klb/in. (16.8 MN/m). The damping force coefficient however, exhibited relatively more variation with frequency with values residing between 175 lb-s/in. (31 kN-s/m) to 214 lb-s/in. (37 kN-s/m). Finally, the paper advances a three-dimensional fluid-structure interaction (FSI) model using transient finite element analysis (FEA) coupled to a computational fluid dynamics (CFD) model. The FSI analysis performed between 20 Hz and 80 Hz was used to predict the stiffness and damping of the HSFD using a quarter-section model of the damper. The FSI analysis was able to support test results by showing only a 6–7.4% change in the magnitude of force coefficients. Stiffness predictions agree reasonably well with experiments whereas damping is underpredicted.

Engineering↗
DOE OSTI2023

Enhancing Adaptive Physics Refinement Simulations Through the Addition of Realistic Red Blood Cell Counts

Simulations of cancer cell transport require accurately modeling mm-scale and longer trajectories through a circulatory system containing trillions of deformable red blood cells, whose intercellular interactions require submicron fidelity. Using a hybrid CPU-GPU approach, we extend the advanced physics refinement (APR) method to couple a finely-resolved region of explicitly-modeled red blood cells to a coarsely-resolved bulk fluid domain. We further develop algorithms that: capture the dynamics at the interface of differing viscosities, maintain hematocrit within the cell-filled volume, and move the finely-resolved region and encapsulated cells while tracking an individual cancer cell. Comparison to a fully-resolved fluid-structure interaction model is presented for verification. Finally, we use the advanced APR method to simulate cancer cell transport over a mm-scale distance while maintaining a local region of RBCs, using a fraction of the computational power required to run a fully-resolved model.

Roychowdhury, Sayan↗
DOE OSTI2025

High temporal frequency data from a four turbine, blade-resolved wind farm simulation with ExaWind

The data was generated with ExaWind (https://github.com/Exawind) which couples AMR-Wind (https://github.com/Exawind/amr-wind/), Nalu-Wind (https://github.com/Exawind/nalu-wind), TIOGA (https://github.com/Exawind/tioga), and OpenFAST (https://github.com/OpenFAST/openfast). This is a large-scale simulation of a blade-resolved wind farm using the ExaWind software stack. ExaWind couples together a background flow solver, AMR-Wind, and a near-body solver, Nalu-Wind, through an overset technique from the TIOGA application. Another application, OpenFAST, handles the structural dynamics of the turbine blades and towers, which informs the fluid-structure interaction of the wind turbines with the flow solvers. This particular simulation includes four blade-resolved wind turbines operating in a turbulent atmospheric boundary layer. The AMR-Wind solver uses 500 million cells and is being solved on 256 AMD GPUs of the Oakridge Leadership Computing Facility Frontier supercomputer. Each turbine is assigned its own Nalu-Wind solver with over 13 million elements per turbine and solved using 448 CPU cores, for a total of 1792 CPU cores. For each node, 56 cores contain Nalu-Wind, while 8 cores correspond to AMR-Wind operations on the GPUs. Consequently, ExaWind is entirely utilizing the CPUs and the GPUs of the nodes concurrently. The data used in the visualization is full flow field data output from the simulation. It is lossy-compressed to a specific accuracy using ZFP and written to disk every 16 time-steps to enable real-time flow visualization. The flow fields are sampled at a high temporal frequency to enable real-time, 24fps visualization. The flow fields are sampled every 12 simulation time steps (every 0.04132s).

17 WIND ENERGY↗
DOE OSTI2025

High fidelity blade-resolved and actuator line data from a 16 turbine wind farm simulation using ExaWind

This data was generated with the ExaWind code suite (https://github.com/Exawind) as a demonstration of a large, 16 turbine wind farm simulation, calculated using two different levels of fidelity. The lower level of fidelity approach uses an actuator line approach to represent the turbines, and was simulated with AMR-Wind (https://github.com/Exawind/amr-wind/) as the background flow solver, coupled to OpenFAST (https://github.com/OpenFAST/openfast). The higher level of fidelity simulation uses a blade-resolved approach, and is done using AMR-Wind, Nalu-Wind (https://github.com/Exawind/nalu-wind), OpenFAST, and TIOGA (https://github.com/Exawind/tioga). In the blade-resolved simulation, ExaWind couples together a background flow solver, AMR-Wind, and a near-body solver, Nalu-Wind, through an overset technique from the TIOGA application. OpenFAST handles the structural dynamics of the turbine blades and towers, which informs the fluid-structure interaction of the wind turbines with the flow solvers. In the actuator line simulation, a mesh of 295M elements was used for a 5km x 5km domain, and it was simulated using 256 nodes (2048 GPU's) on the Oak Ridge Leadership Computing Facility Frontier supercomputer. For the blade-resolved simulation, 1.5B element mesh was used in the AMR-Wind background 5km x 5km domain, and 16M elements were used for each turbine in the Nalu-Wind domains, for a total of 1.7B elements. This was simulated using 384 nodes on Frontier, with each node using 56 cores for Nalu-Wind and 8 GPU cores. The data in this archive includes the turbine outputs from OpenFAST, 2D sampling planes from AMR-Wind, and full-field solution files from AMR-Wind and Nalu-Wind.

17 WIND ENERGY↗
DOE OSTI2024

50 MW Segmented Ultralight Morphing Rotors for Wind Energy

A multi-institutional team designed a 50 Megawatt (MW) rated wind turbine featuring downwind aeroelastic morphing to reduce blade loads and allow an ultralight segmented rotor (mass reduction of about 25% compared to a conventional upwind rotor). The team used a control co-design approach with state-of-the art simulations including for the rotor and tower design using non-linear fluid-structure interactions and control algorithms, and the team also designed, built, and field-tested an aeroelastically-scaled downwind rotor to demonstrate this novel technology and validate the design tool fidelity. In a follow-on phase, these results were used along with an updated Levelized Cost Of Energy (LCOE) methodology to co-design a more detailed set of 25 MW rated turbine designs (including individual pitch control) based on minimum LCOE with highly flexible blades for an Atlantic Ocean offshore fixed-bottom design targeted towards market technology evaluation. A set of upwind and downwind designs at 25 MW rated scales were found to provide the best LCOE, with strong improvements over all previous offshore reference turbines (NREL 5MW, DTU 10 MW and IEA 15 MW). The optimized design would represent the world’s largest offshore turbine design, which combines several state-of-the-art structural, aerodynamic, and control technologies into a new and optimized system concept.

17 WIND ENERGY↗
DOE OSTI2024

Impacts of Irradiation Structural Behavior on Thermal Hydraulics Safety Analysis to Support MURR LEU Conversion

The University of Missouri Research Reactor (MURR) located in Columbia, Missouri is one of six U.S. High Performance Research Reactors (USHPRR), including one critical facility, that is actively collaborating with U. S. Department of Energy (DOE) National Nuclear Security Administration (NNSA) Material Management and Minimization (M3) Office of Reactor Conversion and Uranium Supply to convert from the use of highly enriched uranium (HEU; ≥20 wt% U-235) to low-enriched uranium (LEU; <20 wt% U-235) fuel. A new type of very high-density LEU fuel based on an alloy of uranium and 10 wt% molybdenum (U-10Mo) is expected to allow the conversion to LEU of MURR, as well as four other USHPRR. MURR has been working with the Reactor Conversion Pillar at Argonne to perform fuel element design and fuel cycle performance analyses, steady-state thermal hydraulics safety analysis, and accident safety analyses in preparation for the conversion of MURR and to support a preliminary safety analysis report for conversion to LEU fuels. Subsequent analyses have also been performed, including transition cycles where all-fresh LEU fuel elements are introduced upon conversion and progressing through reactor operations the core is brought to equilibrium. Thermal hydraulics safety analyses performed as part of the above have employed an assumption on channel gap reduction due to burnup-related phenomena including fuel swelling, irradiation creep, and oxide layer buildup. Recently, a series of structural analyses have been performed on the MURR LEU fuel plates and an element due to significant differences between the plate and element designs of the MURR HEU and LEU fuels. In addition, NUREG-1537 indicates that structural phenomena are to be evaluated. Two separate types of structural analyses were performed for the MURR LEU fuel element: fluid-structure interaction (FSI) and irradiation thermo-mechanical. The FSI analysis evaluated the effects of hydraulic forces on the MURR LEU fuel element to quantify the flow-induced plate deflection, and a minimal impact to the channel gap thickness was predicted under prototypic and bounding conditions. The irradiation thermo-mechanical analysis evaluated the effects of fuel swelling, irradiation creep, and thermal expansion for the MURR LEU plates and the element for prototypic thermal and irradiation conditions based on a high-fidelity approach multiphysics approach. Overall, this thermo-mechanical analysis predicts smaller gap thickness changes in previously limiting regions. Larger changes are predicted in the middle of channels, and for end channels where power density is not typically a maximum. An additional thermo-mechanical analysis was performed for the outermost HEU fuel plate, which showed a similar magnitude of deflection as the outermost LEU plate. Due to substantial differences between the channel gap reductions assumed for the previous safety analyses and those predicted by the irradiation thermo-mechanical analysis, a need to evaluate their impact on the thermal hydraulics safety analyses arose. This report presents the results from the steady-state safety analyses for normal operation as well as the accident analyses for the two most limiting accident scenarios.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2024

Open-Source Tidal Energy Converter (OSTEC) Testbed: Design Basis Report

This report describes the design basis and design details for an instrumented marine turbine system intended to serve as the DOE’s marine tidal turbine test bed for foundational open-source R&D and data generation to advance our understanding and to identify knowledge gaps on the techno-economic performance of tidal energy converters (TEC) under real tidal flow conditions and at sufficiently large scale to enable upscaling of fluid-structure-interactions and component and material load responses

16 TIDAL AND WAVE POWER↗
DOE OSTI2026

Dynamic Wind Loading on Compliant, Floating PV Arrays: Cooperative Research and Development (Final Report)

PV panels are subjected to wind loads during normal outdoor operation, where th wind speed, wind direction, panel angle, and array layout play a large role in the overall loading magnitude. For floating PV systems, where panels are installed on floating rafts, these forces can lead to a dynamic displacement of the raft and mounted PV hardware. The Contractor and Participant will perform fluid-structure interaction simulations of this phenomenon for a variety of wind speeds, directions, and panel angles to characterize these forces and help design mooring/tethering lines to resist and anchor raft movement.

14 SOLAR ENERGY↗
DOE OSTI2025

Preliminary Plan to Inform Testing of a Heat Exchanger Test Article

This report presents a preliminary plan to guide the qualification testing of advanced heat exchanger (HX) components for nuclear-to-industrial heat transfer applications. The objective is to establish a defensible, physics-based methodology that integrates computational modeling, targeted experimentation, and in-service inspection considerations to demonstrate component performance and reliability under representative reactor conditions. The analysis identifies Sodium-cooled Fast Reactor (SFR) and High-Temperature Gas-cooled Reactor (HTGR) systems as reference configurations in terms of temperature, pressure, and chemical environment. Within these operating envelopes, dominant degradation mechanisms— including creep–fatigue interaction, flow-induced vibration, corrosion, and diffusion-bond deterioration—were evaluated to define test requirements. A comprehensive computationalexperimental framework is proposed to support life prediction and qualification activities. The framework couples high-fidelity structural-mechanics, thermal-hydraulic, and fluid-structure interaction models with accelerated degradation testing to produce a traceable linkage between microstructural evolution, mechanical performance, and remaining useful life (RUL). The approach adheres to established Verification, Validation, and Uncertainty Quantification (VVUQ) standards (ASME V&V 10/20; NUREG-2152) and incorporates a digital-twin architecture for continuous model refinement through data assimilation. The plan further outlines testing methodologies, including pre-test analyses, test-loop design parameters, and sensor placement strategies that maximize information yield while maintaining mechanistic fidelity. Complementary sections describe in-service inspection (ISI), on-line monitoring (OLM), and structural-health-monitoring (SHM) techniques applicable to compact HX geometries typical of advanced reactors. Collectively, these activities establish the technical foundation for demonstrating 40-60-year equivalent service life of advanced heat exchangers in support of the U.S. Department of Energy’s Advanced Reactor and Integrated Energy Systems programs. The forthcoming phase will execute the defined pre-test analyses, initiate hardware fabrication, and implement the integrated testing campaign to validate the proposed qualification methodology.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2025

Wind Turbine Rotor Design Using High-Fidelity Aerostructural Optimization

Large wind turbines yield more energy but demand careful aeroelastic blade design. Coupled multiphysics design strategies can reduce wind energy costs by exploiting fluid-structure interactions. This work presents the first high-fidelity aerostructural optimization study of a large wind turbine rotor. We use blade-resolved fluid dynamics and structural solvers in a monolithic gradient-based optimization framework to explore steady-state torque and blade mass tradeoffs. The coupled-adjoint approach computes gradients efficiently, enabling the optimization of over 100 structural and geometric parameters simultaneously. Our optimization study modifies a DTU 10 MW benchmark with a simplified structure and isotropic material properties. The tightly coupled optimizations increase torque by 14% while reducing rotor mass by 9% or reduce blade mass by 27% while maintaining torque. Blade-resolved models provide greater design freedom, enabling 5% higher mass reductions than conventional parameterizations at equal torque. This framework paves the way for more detailed high-fidelity optimization studies to complement conventional design approaches.

17 WIND ENERGY↗
DOE OSTI2024

A hybrid finite volume method and smoothed particle hydrodynamics approach for efficient and accurate blast simulations

Modeling strong shock waves in fluids remains a persistent challenge in computational physics. Essential to research efforts in industry and defense, numerous methods have been devised to improve the accuracy and efficiency of shock simulations. A novel, hybrid Finite Volume Method (FVM)-Smoothed Particle Hydrodynamics (SPH) approach is capable of further improving efficiency and retaining accuracy by exploiting the favorable characteristics of each respective method. This hybrid approach is presented for shock capturing in compressible fluids. The Python framework Pyro2 is employed to simulate a coarse FVM mesh, while the Python framework PySPH is utilized to model the fluid in regions with high gradients through SPH particles. The performance of the hybrid FVM-SPH scheme, compared to the individual FVM and SPH methods, is assessed in 1 kt and 10 kt blast simulations. Our results indicate that the hybrid approach offers higher computational efficiency than SPH while preserving its accuracy and characteristics. The hybrid approach had a relative speedup of 11.3x and 22.3x over the FVM and SPH approaches for the 1 kt simulation and a relative speedup of 14.7x and 20.9x over the FVM and SPH approaches for the 10 kt simulation. The hybrid SPH algorithm enables future compressible fluid simulations with more extensive capabilities than grid-based methods alone, presenting potential applications in modeling fluid-structure interactions and solid deformation and fracturing in blast simulations.

Myers, Conner↗
DOE OSTI2024

Simulating Wind-Driven Loading on PV Systems

As PV modules continue to trend toward larger, thinner, and more flexible forms they grow more susceptible to damage from dynamic wind loading. As a result, understanding the impact of wind on PV systems, particularly when mounted on compliant solar-tracking hardware, and identifying robust, stable array layouts and stow strategies is becoming increasingly important for the PV community. We are developing an open-source software package, PVade (PV aerodynamic design engineering), to simulate the cascading fluid-structure interaction that occurs within single-axis, solar-tracking arrays to enable researchers to test hardware, layout, and tracker control changes, leading to enhanced stability and a reduction in wind-driven damage. We will give an overview of the PVade software and present the latest outcomes from our ongoing validation campaign in which we compare time series and statistical structural responses with field data. From there, we will present simulated results from a larger, multi-row array and highlight the effect of varying tracker angles on stability and the differences between positive and negative tilt angles.

fluid↗