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At least 415 records · Page 23

All sources NASA NTRS DOE OSTI

DOE OSTI2023

Cast or Additively Manufactured Coils with End Turn Enhanced Heat Transfer Surfaces for Spray or Jet Cooling

Cast or additively manufactured coils present a new opportunity for creativity in thermal management of electric machines. Improvements to the heat transfer of spray or jet cooling of coil end turns through the incorporation of pins or enhanced heat transfer surfaces in the cast end turn surfaces is explored. The thermal response of cast copper half-turns is measured for a range of spray/jet volumetric flow rates and ohmic loss heat fluxes. A significant reduction, ~30%, in the steady state temperature and increased spray cooling heat transfer coefficients was experimentally measured when the pins or enhanced heat transfer surfaces are incorporated.

33 ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2025

Using AMReX's Embedded Boundaries to Support MFIX-Exa’s Geometry Capabilities

MFIX-Exa is an AMReX-based application used for the simulation of chemically reacting multiphase flows inside reactors. The reactor geometry is mostly a combination of primitive shapes such as cylinders, cubes and spheres of varying dimensions connected together with potentially a lot of dead space between them. Additionally, the reactors may have particle-laden jets introduced at different parts of their geometry to enhance reactant mixing. This talk presents how MFIX-Exa uses OpenSCAD’s csg format to allow users to define the embedded boundary (EB) geometry and how it supports specifying inflow through certain sections of the EB. The talk will describe how MFIX-Exa leverages the EB features of grid-pruning, restart files and redistribution. Finally, the talk goes over some capabilities which are currently not available in MFIX-Exa but planned for the future, such as moving parts of the reactor geometry.

embedded boundaries↗

DOE OSTI2024

Development of a high-temperature Inconel 625 heat exchanger by model design and binder jetting additive manufacturing

A nickel-based Inconel 625 superalloy heat exchanger for high-temperature applications was developed via binder jetting additive manufacturing. The material properties were characterized first on printed and sintered parts. Two sintering temperatures were used to investigate the effects of the temperature on densification and microstructure. For channel geometry design, the heat transfer capabilities of the heat exchanger were optimized for the cross-section geometry of fluid flow channels in a counterflow configuration, and a stress analysis was conducted to investigate the effects of channel geometry. After headers were incorporated into the heat exchanger as a one-piece component, a prototype was printed. A complete depowdering was achieved via compressed air blowing, and sintering was performed with the developed profile. Ultimately, a one-piece heat exchanger with a nearly full density was obtained. Heat transfer tests were performed on this unit, and the results were compared with those from the simulations. In this study, systematic processes were developed for an additively manufactured Inconel-based heat exchanger for high-pressure, high-temperature heat transfer applications.

36 MATERIALS SCIENCE↗

DOE OSTI2020

The Amazonian Low-Level Jet and Its Connection to Convective Cloud Propagation and Evolution

In this work, we describe the existence of an Amazonian low-level jet (ALLJ) that can affect the propagation and life cycle of convective systems from the northeast coast of South America into central Amazonia. Horizontal winds from reanalysis were analyzed during March–April–May (MAM) of the two years (2014–15) of the GoAmazon2014/5 field campaign. Convective system tracking was performed using GOES-13 infrared imagery and classified into days with high and weak convective activity. The MAM average winds show a nocturnal enhancement of low-level winds starting near the coast in the early evening and reaching 1600 km inland by late morning. Mean 3-hourly wind speeds maximize at 9–10 m s -1 near 900 hPa, but individual days can have nighttime low-level winds exceeding 12 m s -1 . Based on objective low-level wind criteria, the ALLJ is present 10%–40% of the time over the Amazon during MAM depending on the location and time of day. The evolution of the ALLJ across the Amazon impacts the frequency of occurrence of cloud clusters and the intensity of the moisture flux. In addition, the ALLJ is associated with the enhancement of northeasterly flow in the midtroposphere during active convective days, when vertical momentum transport may be occurring in the organized cloud clusters. During the weakly active convective period, the ALLJ is weaker near the coast but stronger across the central Amazon and appears to be linked more directly with the South American low-level jet.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2022

Single-Phase Dielectric Fluid Thermal Management for Power-Dense Automotive Power Electronics

This paper describes the design and performance of a dielectric fluid cooling concept for automotive power electronics. The concept combines a low-thermal-resistance package (which eliminates metalized ceramic substrates) with a high-performance convective cooling strategy (slot jets impinging on finned surfaces). Modeling was first used to design the cooling system to maximize thermal performance and minimize pumping power. Additionally, a prototype was then fabricated, and experiments were conducted to validate the model predictions using three fluids at various fluid flow rates (16.7 cm 3 /s [1 L/min] to 68.3 cm 3 /s [4.1 L/min]) and inlet temperatures (30C and 70C). The final design was compact (120-cm 3 total volume, including heat exchanger and conceptual power modules) and cooled 12 devices (e.g., silicon carbide). The validated model was then used to predict the junction-to-fluid thermal resistance and pumping power for various conditions, including 40C fluid temperature. The results predict thermal resistance values as low as 19 mm 2 K/W are possible using the dielectric fluid cooling approach. The dielectric fluid cooling system is predicted to provide thermal resistance and pumping power values that are approximately 56% and 90% lower, respectively, compared to an automotive power electronics cooling system.

30 DIRECT ENERGY CONVERSION↗

DOE OSTI2023

A detailed study of interpretability of deep neural network based top taggers

Abstract Recent developments in the methods of explainable artificial intelligence (XAI) allow researchers to explore the inner workings of deep neural networks (DNNs), revealing crucial information about input–output relationships and realizing how data connects with machine learning models. In this paper we explore interpretability of DNN models designed to identify jets coming from top quark decay in high energy proton–proton collisions at the Large Hadron Collider. We review a subset of existing top tagger models and explore different quantitative methods to identify which features play the most important roles in identifying the top jets. We also investigate how and why feature importance varies across different XAI metrics, how correlations among features impact their explainability, and how latent space representations encode information as well as correlate with physically meaningful quantities. Our studies uncover some major pitfalls of existing XAI methods and illustrate how they can be overcome to obtain consistent and meaningful interpretation of these models. We additionally illustrate the activity of hidden layers as neural activation pattern diagrams and demonstrate how they can be used to understand how DNNs relay information across the layers and how this understanding can help to make such models significantly simpler by allowing effective model reoptimization and hyperparameter tuning. These studies not only facilitate a methodological approach to interpreting models but also unveil new insights about what these models learn. Incorporating these observations into augmented model design, we propose the particle flow interaction network model and demonstrate how interpretability-inspired model augmentation can improve top tagging performance.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2021

Fabricating structured particles through rapid hardening and tailored collection methods

Fabrication of functional polymer-based particles by crosslinking UV-curable polymer drops in mid-air and collecting crosslinked particles in a solid container, a liquid suspension, or an air flow. The particles can contain different phases in the form or layered structures that contain one to multiple cores, or structures that are blended with dissolved or emulsified smaller domains. A curing system produces ultraviolet rays that are directed onto the particles in the jet stream from one side. A reflector positioned on other side of the jet stream reflects the ultraviolet rays back onto the particles in the jet stream.

Ye, Congwang↗

DOE OSTI2023

Fabricating structured particles through rapid hardening and tailored collection methods

Ye, Congwang↗

DOE OSTI2022

Occurrence of Low-Level Jets over the Eastern U.S. Coastal Zone at Heights Relevant to Wind Energy

Two years of high-resolution simulations conducted with the Weather Research and Forecasting (WRF) model are used to characterize the frequency, intensity and height of low-level jets (LLJ) over the U.S. Atlantic coastal zone. Meteorological conditions and the occurrence and characteristics of LLJs are described for (i) the centroids of thirteen of the sixteen active offshore wind energy lease areas off the U.S. east coast and (ii) along two transects extending east from the U.S. coastline across the northern lease areas (LA). Flow close to the nominal hub-height of wind turbines is predominantly northwesterly and southwesterly and exhibits pronounced seasonality, with highest wind speeds in November, and lowest wind speeds in June. LLJs diagnosed using vertical profiles of modeled wind speeds from approximately 20 to 530 m above sea level exhibit highest frequency in LA south of Massachusetts, where LLJs are identified in up to 12% of hours in June. LLJs are considerably less frequent further south along the U.S. east coast and outside of the summer season. LLJs frequently occur at heights that intersect the wind turbine rotor plane, and at wind speeds within typical wind turbine operating ranges. LLJs are most frequent, intense and have lowest core heights under strong horizontal temperature gradients and lower planetary boundary layer heights.

17 WIND ENERGY↗

DOE OSTI2022

Tank 49H solids disturbance analysis

Tank 49H serves as the feed tank for the Salt Waste Processing Facility (SWPF). Transfers into Tank 49H may disturb any solids that have settled to the bottom of the tank, resulting in feed that may exceed the insoluble solids content limit of 1,200 mg/L of the SWPF Waste Acceptance Criteria (WAC). During a transfer into Tank 49H, material that free falls into Tank 49H through a downcomer could potentially disturb any solids on the bottom of the tank and scour or suspend solids from a settled solids layer or turbid region. A previous analysis and report evaluated the potential to disturb solids when transferring into Tank 49H through the B4 riser and recommended a minimum tank level of 120 inches to prevent disturbing any solids in the bottom of the tank. The scope of this task is to perform additional fluid flow analysis to determine whether accounting for disturbed particle settling and particle mixing and dispersion during transfer could allow the minimum liquid level to be reduced below 120 inches. The analysis utilized models from the technical literature to calculate the size and shape of the “plunging jet” as a function of input parameters such as initial velocity, initial jet diameter, elevation of the initial jet, liquid level in the tank, and solids depth. The analysis relied on the M-Star® simulations performed for the previous analysis to provide bounding estimates of the amount of solid particles disturbed and used the MStar® software to calculate the dispersion and mixing of the disturbed solids with other liquid in the tank as the solids are transported to the transfer pump. The analysis showed that with a solid particle size of 5 micron or less, a liquid level of 120 inches should be maintained to prevent significant disturbance of the solid layer at the bottom of Tank 49H.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2023

Automotive Silicon Carbide Power Module Cooling With A Novel Modular Manifold And Embedded Heat Sink

The next generation of integrated power electronics packages will implement wide-bandgap devices with ultrahigh device heat fluxes. Although jet impingement has received attention for power electronics thermal management, it is not used in commercial electric vehicles (EVs) because of the associated pressure drop and reliability concerns. Here, in this paper, we present a modular thermal management system designed for automotive power electronics. The system achieves superior thermal performance to benchmarked EVs, while adhering to reliability standards and with low pumping power. The system utilizes a low-cost and lightweight plastic manifold to generate jets over an optimized heat sink, which is embedded in the direct-bonded-copper (DBC) substrate. The embedded heat sink concept leverages additive manufacturing to add elliptical pin fins to the DBC substrate. The heat sink geometry is optimized for submerged jet impingement using a unit-cell model and an exhaustive search algorithm. The model predictions are validated using unit-cell experiments. A full-scale power module model is then used to compare the DBC-embedded heat sink against direct DBC cooling and baseplate-integrated heat sinks for single-sided (SS) and double-sided (DS) cooling concepts. Using the SS and DS DBC-embedded cooling concepts, the models predict a thermal resistance that represents a reduction of 75% and 85% compared to the 2015 BMW i3, respectively, for the same water-ethylene glycol inverter flow rate. We have shown that an inverter with a 100-kilo-Watt-per-liter power density is achievable with the proposed design.

33 ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2023

Massively-parallel Lagrangian particle code and applications

Massively-parallel, distributed-memory algorithms for the Lagrangian particle hydrodynamic method (Samulyak et al., 2018) have been developed, verified, and implemented. The key component of parallel algorithms is a particle management module that includes a parallel construction of octree databases, dynamic adaptation and refinement of octrees, and particle migration between parallel subdomains. The particle management module is based on the p4est (parallel forest of k-trees) library. The massively-parallel Lagrangian particle code has been applied to a variety of fundamental science and applied problems. A summary of Lagrangian particle code applications to the injection of impurities into thermonuclear fusion devices and to the simulation of supersonic hydrogen jets in support of laser-plasma wakefield acceleration research has also been presented.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2020

O · , H · , and · OH radical etching probability of polystyrene obtained for a radio frequency driven atmospheric pressure plasma jet

Atmospheric pressure plasma jets have great potential for the surface modification of polymers. In this work, the authors report on polystyrene etching by a radio frequency driven atmospheric pressure plasma jet with a focus on the role of H · , O · , and · OH radicals in this process. The absolute flux of H · , O · , and · OH radicals reaching the surface of the polymer was determined by a COMSOL MULTIPHYSICS reacting fluid dynamics model incorporating detailed transport phenomena in the boundary layer near the substrate. The simulated results of H · and · OH densities in the jet effluent were experimentally verified by two-photon absorption laser induced fluorescence and laser induced fluorescence, respectively. The carbon atom removal flux from the polystyrene surface was taken from previously reported measurements using the same plasma source. The authors show that the boundary layer effects in the interfacial region above the substrate can have a significant impact on the calculated etching probabilities. The reaction probability (β) has a significant uncertainty although a variation of 2 orders of magnitude in β leads to uncertainties of approximately 1 order of magnitude variation in the determined etching probability. The etching probability of polystyrene by · OH radicals was confirmed to be at least an order of magnitude larger than the polystyrene etching probability by O · radicals. The authors also confirmed the weak polystyrene etching probability by H · radicals. The model suggests that the presence of a 30 ppm O 2 impurity can lead to the production of · OH radicals in the far effluent of the Ar + 1% H 2 plasma jet close to the substrate at sufficient densities to enable effective etching.

36 MATERIALS SCIENCE↗

DOE OSTI2026

Design of a SiC-Si moving packed-bed particle-to-sCO 2 heat exchanger for high temperature concentrating solar power applications

Particle-based concentrating solar power systems integrated with sCO 2 power cycles offer high thermal efficiencies but require durable heat exchangers to transfer heat from high-temperature particles to the sCO 2 working fluid. Here, this study presents the design and optimization of a silicon carbide-silicon moving packed-bed heat exchanger for fabrication via binder jetting additive manufacturing. The heat exchanger was designed to withstand a 20 MPa sCO 2 pressure and operate at particle inlet temperatures up to 750 °C. The final design features 152 sCO 2 channels distributed across 19 plates, with elliptical corners and a minimum wall thickness of 3 mm. Flow restrictors at the sCO 2 channel inlets significantly improved flow uniformity, reducing thermal stresses and achieving a structural reliability of 99 % under representative operating conditions. The heat exchanger delivers a thermal duty of 9 kW and a volumetric power density of approximately 1 MW/m 3 in the channel region. Sensitivity studies confirmed the heat exchanger’s robustness under varying operating conditions, demonstrating its viability as a high-performance alternative to metallic heat exchangers for particle-based high-temperature concentrating solar power applications.

Barua, Bipul [Argonne National Laboratory (ANL), A↗

DOE OSTI2020

Additive Manufacturing Interface Profiles for Jet Studies on the Vertical Shock Tube

Understanding the mixing between two fluids of disparate densities (i.e., variable density mixing) is important for the lab's mission. Experiments are required to validate our codes, such as RAGE, FLAG, and the BHR mix model. The role initial conditions (ICs) have on instability growth and the transition to turbulence is not completely understood and comparisons with experiments are needed. The Extreme Fluids team focuses on experiments at Los Alamos that utilize gases and low shock velocities (Mach <2 in air). These experiments have the advantage of high fidelity diagnostics capable of temporally and spatially resolved velocity and density measurements. One main difficulty is setting up a specific interface profile between the two gases. While attempts have been made to do so without the aid of a solid structure (i.e., a membrane), the results are limited in the range of possible shapes and reproducibility. Membranes provide the best way to provide a deterministic initial condition. However, fragments from the membrane can interfere with the flow and instability growth, as well as the diagnostics. In this project, we focused on exploring the materials and techniques available via modern additive manufacturing (i.e., 3D printing) to test if they could address some of the shortcomings of prior membrane designs. Our goal was to find a material that would have minimal impact on our experiment while also providing us with a means to produce complex initial conditions. This report details our work to explore the range of additive manufacturing capabilities and the jet-like structures we were able to generate using three-dimensional initial conditions.

36 MATERIALS SCIENCE↗

DOE OSTI2023

On the melt pool dynamic of voxel-controlled metal matrix composites via hybrid additive manufacturing: Laser powder bed fusion and ink-jetting

In this study, the effect of the addition of reinforcement nanoparticles to the 316L matrix by adopting ex-situ and in-situ method (drop on demand jetting) to produce 316L/Al 2 O 3 nanocomposite was investigated. In the ex-situ method, the Al 2 O 3 nanoparticles (NPs) were lightly mixed with 316L powder and processed by laser powder bed fusion. In the in-situ method, an ethanol-based ink containing Al 13 nanoclusters (NCs) was added to 316L powder and then processed by laser. Both ex-situ and in-situ method produced nanocomposites with Al-Si-Mn-O-enriched precipitations within the 316L matrix. The addition of NPs/NCs to the 316L matrix, altered the geometrical characteristic of the single-track melt pools. At the same laser power, with increasing the amount of Al 2 O 3 NPs and Al 13 NCs the melt pool deepened due to reduced thermal conductivity and prolonged liquid presence. Further, as a result, 316L/1 wt% Al 13 NCs deposited single track showed larger grains in comparison to 316L single track. At a high laser power of 150W, the Marangoni flow and the buoyancy force caused the nanoparticles to agglomerate and float to the top surface of tracks; therefore, the wt% fraction of precipitation was drastically reduced due to the loss of Al. The 316L/Al 2 O 3 NPs and 316L/Al 13 NCs exhibited the microhardness of 285 ± 13 HV and 293 ± 7 HV, respectively, higher than the deposited 316L single track, 265 ± 15 HV. Lastly, a hybrid LPBF+ink-jet printer was adopted to selectively change the composition of different zones by adding Al 13 NCs ink to 316L and producing a voxel-controlled metal matrix composite.

316L↗

DOE OSTI2025

System size and energy dependence of the mean transverse momentum fluctuations at the LHC

Event-by-event fluctuations of the event-wise mean transverse momentum, $\langle$p T $\rangle$, of charged particles produced in proton–proton (pp) collisions at $\sqrt{s}$ = 5.02 TeV, Xe–Xe collisions at $\sqrt{s_{NN}}$ = 5.44 TeV, and Pb–Pb collisions at $\sqrt{s_{NN}}$ = 5.02 TeV are studied using the ALICE detector based on the integral correlator $\langle$$\langle$Δp T Δp T $\rangle$$\rangle$. The correlator strength is found to decrease monotonically with increasing produced charged-particle multiplicity measured at midrapidity in all three systems. In Xe–Xe and Pb–Pb collisions, the multiplicity dependence of the correlator deviates significantly from a simple power-law scaling as well as from the predictions of the HIJING and AMPT models. The observed deviation from power-law scaling is expected from transverse radial flow in semicentral to central Xe–Xe and Pb–Pb collisions. In pp collisions, the correlation strength is also studied by classifying the events based on the transverse spherocity, S 0 , of the particle production at midrapidity, used as a proxy for the presence of a pronounced back-to-back jet topology. Low-spherocity (jetty) events feature a larger correlation strength than those with high spherocity (isotropic). The strength and multiplicity dependence of jetty and isotropic events are well reproduced by calculations with the PYTHIA 8 and EPOS LHC models.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗

DOE OSTI2021

Comparing Global Spray Combustion Characteristics and Local Shot-to-Shot Variations in a Reacting n -Heptane Spray

In support of efforts to develop improved models of turbulent spray behavior and combustion in diesel engines, experimental data and analysis must be obtained for guidance and validation. For Reynolds-averaged Navier–Stokes (RANS)-based Computational fluid dynamics (CFD) modeling approaches, representative ensemble average experimental results are important. For high-fidelity models such as large eddy simulations (LES)-based CFD, precise individual experimental results are desirable. However, making comparisons between a given experiment and LES is a challenge since local parameters cannot be directly compared. In this work, an optically accessible constant pressure flow rig (CPFR) is utilized to acquire diesel-like fuel injection and reaction behavior simultaneously with three optical diagnostic techniques: rainbow Schlieren deflectometry (RSD), OH* chemiluminescence (OH*), and two-color pyrometry (2CP). The CPFR allows a large number of repeated injection experiments to be performed for statistical analysis and convergence using ensemble-averaging techniques, while maintaining highly repeatable test conditions. Even for stable test conditions, variations in local turbulent fuel–air mixing introduce variability, which manifests as significant differences in OH* and 2CP results. Experimental measurements of characteristic parameters including liquid and vapor jet penetration, liftoff length, soot temperature and concentration, and turbulent flame speed, along with the shot-to-shot variability of each dataset, are presented and discussed. Finally, a statistical method is utilized to analyze the extent of this variability, and to identify superlative injections within the dataset for discussion and analysis of shot-to-shot variations.

42 ENGINEERING↗