Engineering Papers⌕ Search

SEARCH · Engineering Papers

Results for “thermal load”

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.

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 433 records · Page 24
All sourcesNASA NTRSDOE OSTI
DOE OSTI2020

A novel shallow bore ground heat exchanger for ground source heat pump applications—Model development and validation

A novel ground heat exchanger design, the Underground Thermal Battery (UTB), was proposed as a low-cost alternative to the conventional vertical bore ground heat exchanger (VBGHE) for the application of ground source heat pumps (GSHPs). The UTB is designed to be installed in a shallow borehole (less than 6 m deep) and thus could cost much less than the conventional VBGHE, which usually is installed in vertical bores 60 m deep. By utilizing natural convection of water and phase change materials, the UTB tempers its temperature change in response to thermal loads, which helps improve the efficiency of GSHPs. A one-dimensional (1D) model of the UTB has been developed and validated with the measured performance data of a small-scale UTB, as well as the simulation results of a more detailed three dimensional (3D) numerical model, which accounts for both heat transfer and fluid dynamics in the UTB. Further, this 1D model is computationally much more efficient than the 3D model and thus can simulate the annual performance of the UTB with acceptable computation time. The 1D model has been used to evaluate the performance of the UTB so that it can be compared with the conventional VBGHE.

42 ENGINEERING↗
DOE OSTI2020

Large-scale production of 88 Y and 88 Zr/ 88 Y generators: A proof of concept study for a 70 MeV H – cyclotron

Here, the large-scale production of 88 Y with proton-induced reactions has been investigated from the perspective of new generation 70 MeV H – cyclotrons. Tandem target configurations are presented for both the direct production of 88 Y as well as for producing 88 Zr/ 88 Y generators. Based on the relevant excitation functions, physical yields have been derived for 88 Y production with Y 2 O 3 /SrCO 3 tandem targets and 88 Zr production with Zr/Y 2 O 3 tandem targets. Yields are presented for optimized targets (i.e. optimum yield) as well as for balanced thermal loads on the individual targets. Liquid 88 Zr/ 88 Y generators have been produced using both natural Zr and Nb target materials, the former for dedicated productions and the latter as a byproduct by processing spent irradiated Nb capsules which normally would constitute radioactive waste. These stock solutions, which contain both the target material and 88 Zr precursor, are retained virtually unchanged after processing except for the removal of 88 Y on AG MP-50 macroporous cation-exchange resin. Methods are presented for the preparation of Nb stock solutions in hydrofluoric acid and Zr stock solutions in sulfuric acid. It is shown that multi-Ci productions of 88 Y are feasible at a 70 MeV cyclotron facility, suitable for the needs of fracking applications. In addition, 88 Zr/ 88 Y generators can provide 88 Y with very high specific activity, suitable for labelling of biomolecules.

07 ISOTOPE AND RADIATION SOURCES↗
DOE OSTI2025

An economic and technical feasibility analysis of a dual-source heat pump using both the air and the ground

The study investigates the economic and technical performance of a novel dual-source heat pump (DSHP) compared with that of air-source heat pumps (ASHPs) and ground-source heat pumps (GSHPs). The DSHP can use both ambient air and the ground as a heat source or heat sink. It uses ambient air when its temperature is favorable for efficient heat pump operation. When the ambient temperature is too hot or cold, the ground source is used to retain high-efficiency heat pump operation. Since the DSHP can alternately use either the ground heat exchanger (GHE) or ambient air to meet the thermal load, the required size of GHE can be smaller than those of GSHPs. This study models the DSHP using a whole building energy simulation tool (EnergyPlus) coupled with a Python plug-in and Heat Pump Design Model (HPDM) to simulate its heating and cooling performance for a typical single-family home in 15 US climate zones. The required GHE size of the DSHP system is determined through simulations and compared with that of GSHPs. DSHP deployment can reduce electricity use compared to ASHPs, especially in cold climates where it shows a reduction of around 50%. When compared to GSHPs, DSHPs use 20%–40% more electricity in warm climates but consume around the same amount in moderate and colder climates. Since the DSHP can use air source when the ambient temperature is mild, the GHE size needed for the DSHP is about 40% less than that needed for GSHPs in hot climates and about 25% less in cold climates. In conclusion, the life cycle cost analysis shows that the DSHP is economically more feasible than ASHPs in colder regions and economically more feasible than GSHPs in hot and cold regions.

Dual-source heat pumps↗
DOE OSTI2023

Design, fabrication, and testing of a water-cooled tungsten-foam high-heat flux plasma-facing module

Here, we present a comprehensive study detailing the design, fabrication and testing a new modular “finger” component, featuring a hexagonal tungsten foam armor tile bonded to the top surface of the water-cooled finger unit. The mechanical, thermal, and particle transport properties of the tungsten foam armor were determined for a wide range of porosity and cell size, and then combined in an equivalent solid material with “effective” properties suitable for large-scale simulations. A series of 3-D multiphysics simulations for coupled thermal and mechanical behavior of the “finger” module are used to optimize the design before fabrication. The simulation results show that, for the expected experimental conditions, a safe range of heat flux and foam porosity is possible for both water-cooling and helium-cooling. Based on these multiphysics simulations, an optimum finger cooling module has been fabricated at Ultramet, Inc. A series of experiments were designed to study the thermomechanical performance of the “finger” unit under steady-state and transient thermal loading at surface heat flux up to 16 MW/m 2 in the High Energy Flux Test facility (HEFTY) at UCLA. Testing conditions included low-power, steady-state plasma exposure at 6 MW/m 2 , followed by severe high heat flux cycles at 16 MW/m 2 . Results of these tests are explained through comparisons with multiphysics simulations. To eliminate the effects of thermomechanical damage carried out on a module on its thermo-mechanical response on a subsequent test, three different yet identically designed and fabricated finger modules were tested. The results show that the current design is capable of cooling the walls of fusion devices at surface heat flux up to 6 MW/m 2 without failure, and that the failure heat flux limit is below 16 MW/m 2 .

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2021

Superhydrophobic heat exchangers delay frost formation and enhance efficency of electric vehicle heat pumps

The number of electric vehicles has rapidly expanded as high-performance automotive lithium-ion batteries have become more affordable. However, the range of electric vehicles decreases in cold climates partly because of the additional thermal loads associated with cabin heating. One way to improve the efficiency of cabin heating is to replace resistive heating elements with an air-source heat pump system. However, to gain the full benefit of heat pumping, frost formation on the outdoor heat exchanger must be minimized. In this work, we modified the surface wettability of aluminum louvered-fin automotive heat pump evaporators and tested them under realistic operating conditions in a transcritical carbon dioxide (CO 2 ) heat pump. Each heat exchanger underwent several consecutive frosting and defrosting cycles to understand the cyclic performance of the system. The heat exchanger with a superhydrophobic outer surface was able to delay frost formation and maintain higher heat transfer rates when compared to heat exchangers with higher surface energies (hydrophilic). The delayed frost formation resulted in a system efficiency benefit in the first few frosting cycles but diminished in later cycles due to water retention and incomplete defrosting. However, for most automotive applications the superhydrophobic heat exchanger showed substantial benefits for normal driving trips. We report the scalable and optimized superhydrophobic heat exchangers developed here have the potential to increase the efficiency of automotive heat pumps and consequently increase the range and reduce energy consumption of electric vehicles.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2024

Assessing the impacts of air-sealing on the sizing, operation, and economic feasibility of ground-source heat pumps for electrifying single-family houses in the US

According to recent studies and reports, in single-family houses (SFHs), air-sealing can significantly lower the thermal loads for space heating and cooling. Thus, air-sealing in SFHs could reduce the required size and cost of ground source heat pump (GSHP) systems for electrifying SFHs. Here, this study investigated the costs and benefits of integrating air-sealing with GSHPs for retrofitting existing SFHs when compared with air-source heat pumps. A whole building energy simulation tool integrated with an advanced design tool for modeling ground heat exchangers was used to calculate changes in required GSHP capacity, total borehole length, and building energy consumption with and without air-sealing in SFHs in 16 US climatic regions. The results from this study showed that reducing outdoor air infiltration from 0.8 air changes per hour (ACH) to the minimum ventilation requirement (0.35 ACH) can significantly reduce borehole length (up to 55 %), GSHP capacity (up to 48 %), and total heating electricity reduction, especially in cold climates (up to 44 %). The results also showed that for airtight homes (0.03 ACH infiltration) with a direct outdoor air system, the minimum required borehole length, GSHP capacity, and total heating electricity consumption can be reduced up to 70 %, 68 %, and 67 %, respectively, when compared with SFHs with 0.8 ACH infiltration. Moreover, the life cycle cost analysis showed that air-sealing in conjunction with a GSHP is more profitable than replacing the existing system with an air-source heat pump, even without any incentives for most climatic regions in the US (except for some hot regions).

15 GEOTHERMAL ENERGY↗
DOE OSTI2023

The comparative strength and fracture toughness properties of commercial 95W-3.5Ni1.5Fe and 95W-3.5Ni1.5Cu tungsten heavy alloys

Due to the sharp surface cracks resulting from high and cyclic thermal loads, fracture toughness is a crucial property for fusion divertor materials. Tungsten heavy alloys (WHA) have emerged as a leading candidate for plasma facing component applications. Both the WNiFe and WNiCu WHAs have been considered. However, there is no fracture toughness data in the literature on the WNiCu WHA. Therefore, maximum load elastic–plastic fracture toughness (K Jm ) of a commercial 95W-3.5Ni1.5Cu (NiCu) WHA plate is reported here for the first time. The NiCu WHA K Jm is compared to a corresponding K Jm for commercial 95W-3.5Ni1.5Fe (NiFe) WHA, along with comparisons of their respective microstructures, microhardness, and tensile properties. Although their room temperature yield strengths are similar (≈ 600 MPa), the NiFe WHA has higher ultimate stress (818 MPa vs. 642 MPa) and total elongation (8% vs. 1.2%) compared to the NiCu WHA. Most notably, the room temperature elastic–plastic K Jm for the NiFe WHA of ≈ 80 ± 8 MPa$\sqrt{m}$, is nearly twice that of the NiCu WHA at ≈ 47 ± 4 MPa$\sqrt{m}$. Further, while the NiFe WHA experienced stable ductile tearing, the crack propagated unstably (approximately elastically) after reaching the maximum load in the NiCu WHA. The higher K Jm of the NiFe WHA is attributed to its higher flow stress and ductility, along with the energy dissipation and microcrack dilatational stress shielding, provided by a wide distribution of arrested process-zone microcracks, which are largely absent in the NiCu WHA. Since, the 95W-NiFe WHA has distinctly better mechanical properties than 95W-NiCu WHA, it is a more suitable candidate for the fusion reactor application.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2025

Porous Flow Modeling of Axial Gas Redistribution in Fragmented LWR Fuel Rods using MOOSE

Understanding how gas axially redistributes within fragmented fuel pellets is crucial for predicting the behavior of Light Water Reactor (LWR) fuel rods, particularly during transient and accidental scenarios. The time scale of this phenomenon plays a fundamental role in determining the progression and hazard of a Loss Of Coolant Accident (LOCA), especially when high burn-up fuel in a severe state of fragmentation is involved. Here, this study presents a Computational Fluid Dynamics (CFD) model developed within the Multiphysics Object-Oriented Simulation Environment (MOOSE) to predict the time-scale of plenum depressurization in Light-Water Reactor (LWR) fuel rods driven by axial gas transport through fragmented pellets. The model examines the effects of incorporating non-linearities in the friction term by comparing the results with experimental data. The experiment employed surrogate fuel rods containing pellets subjected to mechanical and/or thermal loadings to simulate various severity of cracking, and aimed at studying the influence of fuel conditions on axial gas redistribution. The results of this analysis indicate that under certain flow regime conditions - determined by the value of an equivalent Reynolds number - accounting for the non-linear friction term in Navier-Stokes equations guarantees better predictions for the time-scale of plenum depressurization. Also, the model enabled the simulation of the pressure decay by assigning distinct permeability values to each pellet instead of a single uniform value. Multiple simulations were run across all possible pellet position combinations, having each pellet assigned with values of permeability extracted from the experimental data. This allows to quantify the impact of the considering various non-uniform distributions of permeability on the dynamics of axial gas redistribution. The present work findings enhance the understanding of axial gas transport, and provide valuable insights for the integration of a model for predicting the axial gas redistribution during a LOCA scenario into the BISON fuel performance code.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2025

Modeling Framework to Predict Melting Dynamics at Microstructural Defects in TNT-HMX High Explosive Composites

Many high explosive (HE) formulations are composite materials whose microstructure is understood to impact functional characteristics. Interfaces are known to mediate the formation of hot spots that control their safety and initiation. Here, to study such processes at molecular scales, we developed all-atom force fields (FFs) for Octol, a prototypical HE formulation comprised of TNT (2,4,6-trinitrotoluene) and HMX (octahydro-1,3,5,7-tetranitro-1,3,5,7-tetrazocine). We extended a FF for TNT and recasted it in a form that can be readily combined with a well-established FF for HMX. The resulting FF was extensively validated against experimental results and density functional theory calculations. We applied the new combined TNT-HMX FF to predict and rank surface and interface energies, which indicate that there is an energetic driver for coarsening of microstructural grains in TNT-HMX composites. Finally, we assess the impact of several microstructural environments on the dynamic melting of TNT crystal under ultrafast thermal loading. We find that both free surfaces and planar material interfaces are effective nucleation points for TNT melting. However, MD simulations show that TNT crystal is prone to superheating by at least 50 K on subnanosecond time scales and that the degree of superheating is inversely correlated with surface and interface energy. The modeling framework presented here will enable future studies on hot spot formation processes in accident scenarios that are governed by strong coupling between microstructural interfaces, material mechanics, momentum and energy transport, phase transitions, and chemistry.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Disruption prediction with artificial intelligence techniques in tokamak plasmas

In nuclear fusion reactors, plasmas are heated to very high temperatures of more than 100 million kelvin and, in so-called tokamaks, they are confined by magnetic fields in the shape of a torus. Light nuclei, such as deuterium and tritium, undergo a fusion reaction that releases energy, making fusion a promising option for a sustainable and clean energy source. Tokamak plasmas, however, are prone to disruptions as a result of a sudden collapse of the system terminating the fusion reactions. As disruptions lead to an abrupt loss of confinement, they can cause irreversible damage to present-day fusion devices and are expected to have a more devastating effect in future devices. Disruptions expected in the next-generation tokamak, ITER, for example, could cause electromagnetic forces larger than the weight of an Airbus A380. Furthermore, the thermal loads in such an event could exceed the melting threshold of the most resistant state-of-the-art materials by more than an order of magnitude. In this work, to prevent disruptions or at least mitigate their detrimental effects, empirical models obtained with artificial intelligence methods, of which an overview is given here, are commonly employed to predict their occurrence—and ideally give enough time to introduce counteracting measures.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2024

Discovering tungsten-based composites as plasma facing materials for future high-duty cycle nuclear fusion reactors

Abstract Despite of excellent thermal properties and high sputtering resistance, pure tungsten cannot fully satisfy the requirements for plasma facing materials in future high-duty cycle nuclear fusion reactions due to the coupled extreme environments, including the high thermal loads, plasma exposure, and radiation damage. Here, we demonstrated that tungsten-based composite materials fabricated using spark-plasma sintering (SPS) present promising solutions to these challenges. Through the examination of two model systems, i.e., tungsten-zirconium composite for producing porous tungsten near the surface and dispersoid-strengthened tungsten, we discussed both the strengths and limitations of the SPS-fabricated materials. Our findings point towards the need for future studies aimed at optimizing the SPS process to achieve desired microstructures and effective control of oxygen impurities in the tungsten-based composite materials.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2020

Anodic arc discharge: Why pulsed?

Pulsed anodic arc discharge is a novel synthesis method of nanomaterials by means of low-temperature atmospheric plasma. The technique consists in periodically supplying DC power to two vertically aligned electrodes in the form of short unipolar pulses with peak currents of a few hundred Amperes in helium atmosphere. The pulsed arc plasmas are sustained at frequencies of the order of 1 Hz with around 10% of duty cycle. It constitutes a versatile technique thanks to a series of advantages compared to continuous DC arc processes, in particular: flexibility in the experimental conditions, process stability and repeatability, better utilization of ablating anode material, lower production of macroparticles, and lower thermal loads. Such features are discussed in this article. A brief overview concerning the recent accomplishments of pulsed arc discharge on deposition of carbon nanostructures (graphene and carbon nanotubes) and few-layer flakes of molybdenum disulphide (MoS 2 ) is provided, as well as an outlook on future applications of this method for the discovery of new materials with tailored functional properties.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2020

Energy considerations regarding pulsed arc production of nanomaterials

Atmospheric arc discharge volumes have been estimated from the light distribution emitted during evaporation of graphite and molybdenum disulphide (MoS 2 ) anodes. These data have been correlated to the peak power in the case of pulsed arc discharge held at different frequencies (1, 2 and 5 Hz). The measured power density values and the corresponding specific energies per particle have been compared to DC values, and showed that pulsed arc discharges deliver electrical power more efficiently than DC arc discharges do with yet lower thermal loads. In particular, the power density of ≈1 kW/cm 3 characteristic of pulsed arcs (10-20 kW/cm 3 in DC) suffices to provide 15 eV/particle to the arc plasma (≈10 eV/particle or less in DC). Such an energy balance resulted in high ionization rates of the ablated material and production yields of carbon nanotubes around 10 11 cm -2 kWh -1 . Lastly, in situ probe experiments showed that pulsed arcs enhance the transport to substrate of the generated nanoparticles, such as graphene and MoS 2 monolayers. Pulsed anodic arcs open the possibility to generate further nanomaterials thanks to a more rational power investment and a better control of the discharge region.

42 ENGINEERING↗
DOE OSTI2024

Exploring mounting solutions for cryogenically cooled thin crystal optics in high power density x-ray free electron lasers

This study investigates three mounting methods—clamping, soldering, and a hybrid clamping–soldering approach—for cryogenically cooled thin diamond crystals crucial to stable operation of X-ray Free Electron Laser (XFEL) systems. While clamping methods exhibit temperature resilience and flexibility, meticulous design is required to prevent stress-induced warping and reduce thermal contact area. Soldering methods offer reliable mechanical and thermal bonding but encounter challenges due to the coefficient of thermal expansion mismatch at cryogenic temperatures. The hybrid method, integrating clamping and soldering with strain relief cuts, effectively mitigates overall distortion caused by mounting and XFEL thermal loads. These findings offer a novel mounting solution for high-performance x-ray optics in XFEL research and applications, ensuring stability and optimal functionality in cryogenic conditions.

Instruments & Instrumentation↗
DOE OSTI2025

Structured light approaches in laser-based plasma diagnostics

There is a growing demand for plasma diagnostics suitable for industrial plasma reactors employed in semiconductor nanofabrication, especially relevant to microelectronics and quantum information systems. Such reactors typically have limited optical access and pose considerable diagnostic challenges, including intense background emission, significant thermal loads, and contamination of optical viewports. In this study, we outline research into structured light techniques (laser beams with tailored spatial, temporal, or phase characteristics) that effectively overcome these issues using laser-induced fluorescence (LIF) as an example. The focus of presented diagnostics is on ion kinetics analysis within an industrial plasma source, although this approach is broadly applicable to other plasma systems and diagnostic contexts. We present a confocal LIF implementation using an axicon-generated Bessel annular beam, achieving spatial resolutions of approximately 5 mm at a focal distance of 300 mm, with potential improvements to about 1 mm. This approach matches conventional orthogonal LIF performance but requires only one optical port. Wavelength-modulation LIF employs nonlinear laser wavelength tuning to measure spectral line derivatives, suppressing background emission and enhancing details of spectral line shape. Additionally, we present new results on applying vortex beams (laser beams carrying orbital angular momentum, OAM) for LIF measurements in an industrial plasma device. These measurements enable simultaneous axial and tangential velocity determination using a single laser beam and have been tested with xenon ion transition. Initial quantification of results was performed. Together, these structured-light approaches provide robust, background-resilient, multi-dimensional diagnostics for complex plasma environments.

Romadanov, Ivan [Princeton Plasma Physics Laborato↗
DOE OSTI2022

Multiphysics Analyses of the Bottom Components of the 3D Printed Transformational Challenge Reactor

This research presents multi-physics analyses on the bottom components of the Transformational Challenge Reactor (TCR) facility. These components include the bottom axial reflector and the steel exit cone. The bottom axial reflector is made of pure silicon carbide elements hosting helium cooling channels These elements are 3D printed and therefore can host any arbitrary shape of the helium cooling channels. The design of the bottom reflector considers the neutronics and thermo-fluid dynamics performances as well as the manufacturing process optimization. More precisely, the best design of the bottom reflector reduces neutron leakage by avoiding straight cylindrical helium channels that facilitate neutron leakage, minimizes the helium flow pressure drop, and reduces the number of 3D printed silicon carbide pieces. The exit cone steel structure collects the hot helium from the bottom fuel assemblies and channels the cold helium to the top of the fuel assemblies. The steel simultaneous contact with hot and cold helium flows sets a large thermal gradient. Different designs of the exit cone are proposed to reduce the steel equivalent stress from the helium thermal load. The multi-physics analyses have been performed using Ansys Fluent, Ansys Mechanical, STAR-CCM+, and Serpent computer programs.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗