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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 OSTI2022

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↗
DOE OSTI2020

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↗
DOE OSTI2024

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↗
DOE OSTI2023

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↗
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

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↗
DOE OSTI2021

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↗