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36 records · Page 2

Analyses of Fatigue and Fatigue-Crack Growth under Constant- and Variable-Amplitude Loading

Studies on the growth of small cracks have led to the observation that fatigue life of many engineering materials is primarily crack growth from micro-structural features, such as inclusion particles, voids, slip-bands or from manufacturing defects. This paper reviews the capabilities of a plasticity-induced crack-closure model to predict fatigue lives of metallic materials using small-crack theory under various loading conditions. Constraint factors, to account for three-dimensional effects, were selected to correlate large-crack growth rate data as a function of the effective stress-intensity factor range (delta K(sub eff)) under constant-amplitude loading. Modifications to the delta K(sub eff)-rate relations in the near-threshold regime were needed to fit measured small-crack growth rate behavior. The model was then used to calculate small- and large-crack growth rates, and to predict total fatigue lives, for notched and un-notched specimens under constant-amplitude and spectrum loading. Fatigue lives were predicted using crack-growth relations and micro-structural features like those that initiated cracks in the fatigue specimens for most of the materials analyzed. Results from the tests and analyses agreed well.

Newman, J. C., Jr.↗

An Analysis of Closure Mechanisms in the Plasma Wake of the TSS-1R Satellite

Collisionless Plasma Expansion (CPE), also known as "plasma expansion into a vacuum," in its most fundamental form, is the process by which a plasma expands into a void, or region highly depleted of particles. In CPE, the expansion is driven by the highly mobile electron constituent of the plasma as it moves across the density gradient and into the void region. A bi-polar electric field is set up between this rapidly expanding electron front and the massive ions, which have a low thermal speed and lag behind in the region of the plasma-void interface. These ions are quickly accelerated by the expansion electric field and can, theoretically, approach the thermal speed of the electrons. CPE is a fundamental and a very robust process in that it only requires that a sharp density gradient exist in a plasma. It has already been observed to exist in various plasmas ranging over five orders of magnitude in density. The range of phenomena in which CPE has been observed includes the closure of plasma wakes created in simulated space plasmas in the laboratory; it was found to be the process controlling the refilling of the wake created by the Space Shuttle in the ionospheric plasma; and recent in situ data, obtained by the WIND spacecraft as it passed through the wake of the earth's moon last year, have shown CPE to be involved in the closure of the Lunar wake. CPE is also expected to influence the morphology and physics of the solar wind interactions with Mercury and Mars, and has been suggested as a potential factor in such wide ranging phenomena as the acceleration of plasma away from the coma of comets and the energization of ions that underlies the upward expansion of the polar wind into the earth's magnetosphere. The Tethered Satellite System (TSS)-1R data provides an opportunity to test this process in situ under semi-controlled conditions. The available data shows the intensity, drift energy and angle of inclination to the wake of the converging ion streams at a down stream distance of one satellite radius (80 CM).

Stone, N. H.↗

An assessment of the small-crack effect for 2024-T3 aluminum alloy

Data on small-crack behavior were obtained for a single-edge-notched tensile specimen made of 2024-T3 Al alloy and used to evaluate the capability of a semiempirical crack-growth and closure model to predict the fatigue life of notched specimens. Fatigue tests were conducted under either constant-amplitude loading (with stress ratios of 0.5, 0, -1, and -2) or spectrum loading, using a replication technique to record growth. It was found that small cracks exhibited the 'small-crack' effect in that they grew faster than large cracks when subjected to the same stress intensity factor range. Experimental small-crack growth rates agreed well with the model predictions. For making predictions of fatigue life, an initial surface defect void size of 3 x 12 x 0.4 microns was used in all calculations; predicted fatigue lives agreed well with experimentally determined values obtained in all tests. The crack-closure model indicated that the 'small-crack' effect on fatigue life was greatest in tests involving significant compressive loads.

Newman, J. C., Jr.↗

Improvement of two-phase closure models in CTF using Bayesian inference

Under the Consortium for Advanced Simulation of Light Water Reactors (CASL) program, extensive capabilities have been developed in CTF to analyze light-water reactors (LWRs) for normal operating conditions, departure from nucleate boiling (DNB), and system transients. However, further improvements are required in the modeling and simulation of boiling water reactors (BWRs), which is a focus of the Nuclear Energy Advanced Modeling and Simulation (NEAMS) program. In this work, CTF validation results were used to optimize selected modeling coefficients by calibrating to experimental data using a Bayesian inference approach. Here, calibration studies were conducted to improve (vapor) void fraction prediction without worsening the two-phase pressure drop prediction, as well as to improve the two-phase pressure drop prediction. Calibration was performed for interfacial drag and wall shear models. Surrogates were developed to alleviate the computational expense required for sampling the parameter space using Markov chain Monte Carlo (MCMC). An assessment performed with calibrated models demonstrated an improvement of CTF in its prediction of key parameters such as void fraction and two-phase pressure drop.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

The role of micro-inertia on the shock structure in porous metals

The behavior of porous materials under shock loading is a multi-scale problem bridging orders of magnitude across the macroscale geometry and the microscale pores. Under static loading, this problem is well understood, relating mechanisms of pore closure and crushing to the equivalent macroscale models. The dynamic response of porous solids under shock loading is related to the effects of viscoplasticity and micro-acceleration fields around the void boundaries. The significance of the micro-inertia effects in modeling the dynamic behavior of porous materials remains an open question. In this work, an experimental investigation on closed-cell porous aluminum with small porosity provides the evidence for the first time of micro-inertia’s fundamental role in describing the shock structure in these materials. Materials with different levels of porosity were manufactured using a modified process of additive manufacturing to achieve a mean pore size below 50$\mu$m. Plate impact experiments on porous aluminum samples were conducted at pressures in the range of 2 to 11 GPa. The structure of the steady shock was characterized as a function of porosity and shown to validate behavior revealed by an analytical approach (Czarnota et al. [J. Mech. Phys. Solids 107 (2017)]), highlighting the fundamental role of micro-inertia effects in such cases.

36 MATERIALS SCIENCE↗

Current collection and current closure in the Tethered Satellite System

Current collection and closure-path modeling are examined analytically with respect to the Tethered Satellite System (TSS). A particle-in cell code is compared with a one-dimensional unmagnetized fluid code to model the behavior of a positively charged satellite in the ionosphere. The morphology of the sheath and the sheath-region processes are thus examined, and the influence of ions leaving the sheath region is found to cause the attraction of an electron current that is 40 times greater than the steady state value. The enhancement is transient and enhances the acceleration of the electrons in the sheath. A set of modified MHD equations, including those for ion inertia, quasineutrality, and electron drift, is employed to model TSS current closure. Whistler modes are found to exist and can be excited as the TSS passes through the ionosphere. Important conclusions include a significant fluctuation level in the steady state sheath, an ion void which affects the electron population, and some long-lived electrons trapped in the settled sheath with respect to two directions.

Drobot, Adam↗

Interface capturing simulations of bubble population effects in PWR subchannels

As the computational power of high-performance computing (HPC) facilities grows, so too does the feasibility of using first principle based simulation to study turbulent two-phase flows within complex pressurized water reactor (PWR) geometries. Direct numerical simulation (DNS), integrated with an interface capturing method, allows for the collection of high-fidelity numerical data using advanced analysis techniques. The research presented here employs the massively parallel, finite-element based, unstructured mesh code, PHASTA, to simulate a set of two-phase bubbly flows through PWR subchannel geometries including auxiliary structures (spacer grids and mixing vanes). The main objective of the presented work is to analyze bubble dynamics and turbulence interactions at varying bubble concentrations to support the development of advanced two-phase flow closure models. Turbulent two-phase flows in PWR subchannels were simulated at hydraulic Reynolds numbers of 81,000 with bubble concentrations of 3%–15% by gas volume fraction (768–3928 resolved bubbles, respectively) and compared against a 1% void fraction case (262 bubbles) that had been previously simulated. The finite element mesh utilized for the study at higher bubble concentrations was composed of 1.55 billion elements, compared to the previous study which employed 1.11 billion elements, ensuring all turbulence scales and individual bubbles within the flow are fully resolved. For each case, the resolved initial bubble size was 0.65 mm in diameter (resolved with 25 grid points across the diameter). The simulations were analyzed to find flow features such as the mean velocity profile, bubble relative velocity and the effect of the bubbles on the turbulent conditions.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

Glass shell manufacturing in space

Highly-uniform, hollow glass spheres (shells), which are used for inertial confinement fusion targets, were formed from metal-organic gel powder feedstock in a vertical furnace. As a result of the rapid pyrolysis caused by the furnace, the gel is transformed to a shell in five distinct stages: (a) surface closure of the porous gel; (b) generation of a closed-cell foam structure in the gel; (c) spheridization of the gel and further expansion of the foam; (d) coalescence of the closed-cell foam to a single-void shell; and (e) fining of the glass shell. The heat transfer from the furnace to the falling gel particle was modeled to determine the effective heating rate of the gel. The model predicts the temperature history for a particle as a function of mass, dimensions, specific heat, and absorptance as well as furnace temperature profile and thermal conductivity of the furnace gas. A model was developed that predicts the gravity-induced degradation of shell concentricity in falling molten shells as a function of shell characteristics and time.

Downs, R. L.↗

MODELLING FIBER ORIENTATION DURING ADDITIVE MANUFACTURING COMPRESSION MOLDING PROCESSES

The production of high-performance thermoplastic composites reinforced with short carbon fibers can be achieved by a novel “additive manufacturing-compression molding” technique. An advantage of such combination is two-fold: controlled fiber orientation in additive manufacturing and less void content by compression molding. In this study, a computational fluid dynamics model has been developed to predict the behavior of printed layers during fiber-reinforced thermoplastic extrusion and subsequent compression molding. The fiber orientation was modelled with a simple quadratic closure model. The interaction between the fibers is included using a rotary diffusion coefficient which becomes significant in concentrated regimes. Finally, the second order orientation tensor is coupled with the momentum equation as an anisotropic part of the stress term. The effect of processing parameters on the behavior of printed layers was investigated to determine the favorable printing scenarios. The developed numerical model enables design of high-performance composites with tunable mechanical properties.

Seta, Berin↗

Small-crack effects in high-strength aluminum alloys

The National Aeronautics and Space Administration and the Chinese Aeronautical Establishment participated in a Fatigue and Fracture Mechanics Cooperative Program. The program objectives were to identify and characterize crack initiation and growth of small cracks (10 microns to 2 mm long) in commonly used US and PRC aluminum alloys, to improve fracture mechanics analyses of surface- and corner-crack configurations, and to develop improved life-prediction methods. Fatigue and small-crack tests were performed on single-edgenotch tension (SENT) specimens and large-crack tests were conducted on center-crack tension specimens for constant-amplitude (stress ratios of -1, 0, and 0.5) and Mini-TWIST spectrum loading. The plastic replica method was used to monitor the initiation and growth of small fatigue cracks at the semicircular notch. Crack growth results from each laboratory on 7075-T6 bare and LC9cs clad aluminum alloys agreed well and showed that fatigue life was mostly crack propagation from a material defect (inclusion particles or void) or from the cladding layer. Finite-element and weight-function methods were used to determine stress intensity factors for surface and corner cracks in the SENT specimens. Equations were then developed and used in a crack growth and crack-closure model to correlate small- and large-crack data and to make life predictions for various load histories. The cooperative program produced useful experimental data and efficient analysis methods for improving life predictions. The results should ultimately improve aircraft structural reliability and safety.

Newman, J. C., Jr.↗

Subchannel codes: CTF and VIPRE-01

In this chapter, two state-of-the-art and well-used subchannel codes are presented: CTF and VIPRE-01. As part of the Consortium for Advanced Simulation of Light Water Reactors, CTF is being used for single- and two-phase flow analysis under light-water reactor normal and anticipated transient operating conditions. Accurate determination of flow distribution, pressure drop, and void content is crucial for predicting margins to thermal crisis and ensuring more efficient nuclear power plant performance. In preparation for the intended applications, CTF is extensively validated against data from experimental facilities. Meanwhile, the licensed commercial code VIPRE-01 is used to generate a baseline set of simulations for the targeted tests and the solution parameters are compared to CTF results. The closure models in CTF that are in the greatest need of improvement are highlighted and discussed.

Zhao, Xingang↗

Anticipated Electrical Environment Within Permanently Shadowed Lunar Craters

Shadowed locations ncar the lunar poles arc almost certainly electrically complex regions. At these locations near the terminator, the local solar wind flows nearly tangential to the surface and interacts with large-scale topographic features such as mountains and deep large craters, In this work, we study the solar wind orographic effects from topographic obstructions along a rough lunar surface, On the leeward side of large obstructions, plasma voids are formed in the solar wind because of the absorption of plasma on the upstream surface of these obstacles, Solar wind plasma expands into such voids) producing an ambipolar potential that diverts ion flow into the void region. A surface potential is established on these leeward surfaces in order to balance the currents from the expansion-limited electron and ion populations, Wc find that there arc regions ncar the leeward wall of the craters and leeward mountain faces where solar wind ions cannot access the surface, leaving an electron-rich plasma previously identified as an "electron cloud." In this case, some new current is required to complete the closure for current balance at the surface, and we propose herein that lofted negatively charged dust is one possible (nonunique) compensating current source. Given models for both ambipolar and surface plasma processes, we consider the electrical environment around the large topographic features of the south pole (including Shoemaker crater and the highly varied terrain near Nobile crater), as derived from Goldstone radar data, We also apply our model to moving and stationary objects of differing compositions located on the surface and consider the impact of the deflected ion flow on possible hydrogen resources within the craters

Farrell, W. M.↗

Intergalactic Hydrogen Clouds at Low Redshift: Connections to Voids and Dwarf Galaxies

We provide new post-COSTAR data on one sightline (Mrk 421) and updated data from another (I Zw 1) from our Hubble Space Telescope (HST) survey of intergalactic Ly(alpha) clouds located along sightlines to four bright quasars passing through well-mapped galaxy voids (16000 km/s pathlength) and superclusters (18000 km/s). We report two more definite detections of low-redshift Ly(alpha) clouds in voids: one at 3047 km/s (heliocentric) toward Mrk 421 and a second just beyond the Local Supercluster at 2861 km/s toward I Zw 1, confirming our earlier discovery of Ly(alpha) absorption clouds in voids (Stocke et al., ApJ, 451, 24). We have now identified ten definite and one probable low-redshift neutral hydrogen absorption clouds toward four targets, a frequency of approximately one absorber every 3400 km/s above 10(exp 12.7/sq cm column density. Of these ten absorption systems, three lie within voids; the probable absorber also lies in a void. Thus, the tendency of Ly(alpha) absorbers to 'avoid the voids' is not as clear as we found previously. If the Ly(alpha) clouds are approximated as homogeneous spheres of 100 kpc radius, their masses are approximately 10(exp 9)solar mass (about 0.01 times that of bright L* galaxies) and they are 40 times more numerous, comparable to the density of dwarf galaxies and of low-mass halos in numerical CDM simulations. The Ly(alpha) clouds contribute a fraction Omega(sub cl)approximately equals 0.003/h(sub 75) to the closure density of the universe, comparable to that of luminous matter. These clouds probably require a substantial amount of nonbaryonic dark matter for gravitational binding. They may represent extended haloes of low-mass protogalaxies which have not experienced significant star formation or low-mass dwarf galaxies whose star formation ceased long ago, but blew out significant gaseous material.

Shull, J. Michael↗

Improving the modeling of near-wall interphase heat transfer in porous media models of Pebble Bed Reactors

Here, this work aims to improve capabilities for modeling localized effects in porous media models of Pebble Bed Reactors. The wall-channeling effect is the primary local phenomenon of interest in a PBR, where the presence of the reflector wall disrupts the pebble packing, causing the pebbles near the wall to pack less efficiently and creating large void regions. Accurate modeling of the near-wall region is important as it will affect core bypass flow and temperature predictions. Porous media models are commonly used for design scoping and plant-level simulations of PBRs. Although these models have some capabilities to model the near-wall region, the correlations that are available in porous media codes are often inaccurate when a multi-region model is used to discretize the near-wall region. This work employs a high-to-low analysis to study the accuracy of available interphase heat transfer closures. NekRS, a spectral element computational fluid dynamics code, is used to perform Large Eddy Simulations. These LES simulation results are compared to porous media model results from the Pronghorn porous media code. The friction term of the KTA drag closure is first improved, reducing the error in the prediction of the near-wall velocity from over 50% to less than 5%. This is combined with improvements to the form term from previous works to produce a drag closure that is capable of accurately modeling the wall-channeling effect across a variety of flow conditions. The Nusselt number predictions of several heat transfer correlations are compared to the high-fidelity results where it is found that the KTA heat transfer correlation is capable of accurately predicting the local Nusselt numbers that were determined in the high-fidelity simulation. Comparison of the radial solid temperature profiles, however, reveal discrepancies between NekRS and Pronghorn. It is discovered that the implementation of the interphase heat transfer coefficient that exists in many current porous media codes is not valid when local porosities are modeled. Instead, it is suggested that the interphase heat transfer coefficient should be dependent on the local porosity, the Nusselt number, and the local solid surface-to-volume ratio. Implementation of this change produces improvement in the agreement between the results obtained by NekRS and Pronghorn while using the KTA heat transfer correlation.

interphase heat transfer↗

Dual-Purpose Canister Filling Demonstration Project Progress Report at ORNL, 2023

The US DOE Office of Nuclear Energy is investigating the feasibility of direct disposal of dual-purpose canisters (DPCs) in a hypothetical geological repository to offset the potential requirement to repackage spent nuclear fuel (SNF) from existing DPCs into smaller, disposal-ready canisters. Oak Ridge National Laboratory (ORNL) is currently evaluating the feasibility of filling void space in loaded DPCs with an engineered material to prevent a criticality event caused by groundwater/moderator intrusion. Metal alloys are being investigated as a filler material because of their relatively low viscosities when molten, which may facilitate their injection via an existing drainpipe that runs almost the full length of the DPC. ORNL’s strategy for evaluating filler viability includes simulations and physical demonstrations of filling and casting behavior, as well as evaluations of materials for compatibility in the repository environment. Filling of DPCs in this manner is expected to mitigate the risk associated with a post-closure criticality event during the repository performance assessment time frame (10,000 years or greater). Efforts in this fiscal year focused on (1) destructive analysis of experimental filler castings made in FY 2022, (2) a report outlining a conceptual design of a DPC filling facility (Fortner et al., 2023, M3SF 23OR010305044/ ORNL/SPR-2023/2921, May 31, 2023), (3) a report on affected features, events, and processes (FEPs) due to DPC filling (Price et al., 2023, M3SF-23SN010305093, issuance pending), (4) developing and testing a more practical alloy filler based upon a Sn-Al eutectic, and (5) modeling the heating and cooling dynamics of a DPC subjected to molten metal filling. The preliminary results from each of these tasks support the feasibility of filling DPCs with metal as a strategy against the possibility of criticality in the repository. The FY 2022 casting was found to penetrate even very small orifices in the mold and internal structures. Preliminary testing of the Sn-Al eutectic indicate little interaction of the melt with Zircaloy cladding. Thermal modelling shows that a filled DPC will cool to manageable temperatures within 2-3 days, which is likely manageable in a facility.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

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↗

Benchmark of interfacial area concentration approaches for the two-fluid model in gas-dispersed condensing flow

Accurate predictions of interfacial area concentration (IAC) are required for closure of the condensation phase change term. The interfacial area transport equation (IATE) can dynamically predict interfacial area concentration and is increasingly being used in the benchmarking of phase change flows over static based correlations which require a flow regime map. For higher flow regimes, the two-group two-fluid IATE model can separately model the transport of spherical bubbles and cap/slug bubbles. Recently, a modified formulation of the one-group and two-group two-fluid model with interfacial area transport equation was proposed for gas-dispersed condensing flows. Three datasets have been used for validation consisting of condensing two-phase flow data in the unheated section of a vertical annulus with conditions spanning a range of pressures, inlet subcoolings and mass fluxes for benchmarking the various IAC approaches. For bubbly flows, the coupled void transport - IATE simulation results in good agreement in the predictions of the void fraction and the interfacial area concentration under nearly all sixty conditions. Considering the proposed two-group two-fluid IATE model formulation, the group-2 Nusselt number correlation is investigated to account for the appropriate heat transfer length scale for group-2 bubbles. Validation of the proposed two-group two-fluid model against the new dataset shows good agreement with experimental data with significant improvement over the one-group IATE model for conditions with substantial group-2 void fraction throughout the simulation domain.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

Development of CTF modeling of interfacial drag, wall shear, and interfacial heat transfer for bubbly and annular-mist flow regimes

This milestone report discusses improvements to CTF closure models for modeling of bubbly and annular mist two-phase flow conditions, which are important for accurate modeling and simulation for boiling water reactor (BWR) conditions. Models that were improved include the two-phase wall shear, wall boiling, and phase mass and heat transfer. A new flow regime map was implemented to improve on the prediction of transition to annular flow, which was generally largely over-predicted by the legacy CTF flow regime map. The annular mist interfacial drag models were also reviewed and new models were proposed for implementation into the code. In addition to implementing new models, an activity was performed to calibrate these new models to experimental data using a Markov Chain Monte Carlo technique, thus further improving their accuracy. Finally, new experiments were implemented into the CTF validation matrix which add more two-phase pressure drop and void measurements for the assessment of CTF for modeling of BWRs. The results show that the Chisholm model, which was implemented and then calibrated, results in significantly improved comparison against the Riso two-phase pressure drop data. Furthermore, improvements in the implicit heat transfer and wall boiling models resulted in good agreement with the void measurement data.

42 ENGINEERING↗