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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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At least 451 records · Page 25
All sourcesNASA NTRSDOE OSTI
DOE OSTI2019

Level-set Modeling Simulations of Chemical Vapor Infiltration for Ceramic Matrix Composites Manufacturing

Silicon-carbide (SiC) reinforced ceramic matrix composites (CMCs) are a key enabling technology to reduce fuel consumption and emissions of gas turbine engines. In one manufacturing approach, chemical vapor infiltration (CVI) is limited to only coating SiC fibers. The preform is then fabricated using a lay-up of basic plys or 2-D woven sheets composed of the precoated fibers. At the other extreme, CVI is used to completely densify a 3-D woven preform shaped almost like the gas turbine component itself. The latter approach is more suitable for highly engineered components which sit directly in the gas path of the engine, for example, a high pressure turbine blade. In this case, the geometry is necessarily complex for aerodynamic, stress, and lifing (multi-physics) requirements. Presently, optimizing the CVI-dominated manufacturing approach is largely by trial-and-error. In this work, a first-principles modeling of CVI is performed to realize optimization of SiC/SiC CMC manufacturing. The modeling is based on a level-set framework to describe the interface between the vapor and solid phases. A finite-difference numerical scheme using an immersed boundary method is developed for fixed, structured meshes. Massively parallel direct numerical simulations (DNS) of CVI through fiber-woven geometries are performed using one-step chemistry, and over a range of Thiele moduli. Illustrative applications of the resulting large DNS data sets are given, including the development of fiber-weave specific infiltration models and structure functions for mean-field (porous media) Computational Fluid Dynamics (CFD) simulations of CVI.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Method and apparatus for shape-based energy analysis of solids

A method of evaluating response of a physical structure to external stimulus includes defining a mesh of finite elements, each defined by edges, for a model of the physical structure. The method includes identifying a governing differential equation and associated complementary functions, which are each associated with a scalar multiplier. The method includes generating an energy optimization model that minimizes a difference between internal and external energies of the finite elements. The internal energy is based on strain energy in a volume defined by the edges of the finite element and resulting from deformations by the complementary functions. The external energy of each finite element is based on external work done by the external stimulus acting on the finite element as deformed by the complementary functions. The method includes solving the energy optimization model for the scalar multipliers and calculating a resulting parameter of interest of the physical structure.

42 ENGINEERING↗
DOE OSTI2016

TH-CD-207A-05: Lung Surface Deformation Vector Fields Prediction by Monitoring Respiratory Surrogate Signals

Purpose: In this study, we developed and evaluated a method for predicting lung surface deformation vector fields (SDVFs) based on surrogate signals such as chest and abdomen motion at selected locations and spirometry measurements. Methods: A Patient-specific 3D triangular surface mesh of the lung region at end-expiration (EE) phase was obtained by threshold-based segmentation method. For each patient, a spirometer recorded the flow volume changes of the lungs; and 192 selected points at a regular spacing of 2cm X 2cm matrix points over a total area of 34cm X 24cm on the surface of chest and abdomen was used to detect chest wall motions. Preprocessing techniques such as QR factorization with column pivoting (QRCP) were employed to remove redundant observations of the chest and abdominal area. To create a statistical model between the lung surface and the corresponding surrogate signals, we developed a predictive model based on canonical ridge regression (CRR). Two unique weighting vectors were selected for each vertex on the surface of the lung, and they were optimized during the training process using the all other phases of 4D-CT except the end-inspiration (EI) phase. These parameters were employed to predict the vertices locations of a testing data set, which was the EI phase of 4D-CT. Results: For ten lung cancer patients, the deformation vector field of each vertex of lung surface mesh was estimated from the external motion at selected positions on the chest wall surface plus spirometry measurements. The average estimation of 98th percentile of error was less than 1 mm (AP= 0.85, RL= 0.61, and SI= 0.82). Conclusion: The developed predictive model provides a non-invasive approach to derive lung boundary condition. Together with personalized biomechanical respiration modelling, the proposed model can be used to derive the lung tumor motion during radiation therapy accurately from non-invasive measurements.

60 APPLIED LIFE SCIENCES↗
DOE OSTI2016

The arbitrary order mixed mimetic finite difference method for the diffusion equation

Here, we propose an arbitrary-order accurate mimetic finite difference (MFD) method for the approximation of diffusion problems in mixed form on unstructured polygonal and polyhedral meshes. As usual in the mimetic numerical technology, the method satisfies local consistency and stability conditions, which determines the accuracy and the well-posedness of the resulting approximation. The method also requires the definition of a high-order discrete divergence operator that is the discrete analog of the divergence operator and is acting on the degrees of freedom. The new family of mimetic methods is proved theoretically to be convergent and optimal error estimates for flux and scalar variable are derived from the convergence analysis. A numerical experiment confirms the high-order accuracy of the method in solving diffusion problems with variable diffusion tensor. It is worth mentioning that the approximation of the scalar variable presents a superconvergence effect.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2025

Convergence study of wakefield simulations with GdfidL and ECHO3D

The interaction of charged particle beams with vacuum chamber components gives rise to electromagnetic wakefields, whose frequency-domain representation is known as beam coupling impedance. Geometric impedance arising from discontinuities and transitions in the vacuum chamber is the focus of this study. Minimizing this impedance is essential to mitigate adverse collective effects in modern storage rings operating with high-intensity particle beams. Accurate and reliable impedance simulations is a key factor of the vacuum chamber design. This paper presents the results of a convergence study of two widely used electromagnetic solvers, GdfidL and ECHO3D, applied to key vacuum-chamber components of the National Synchrotron Light Source II (NSLS-II) storage ring. Detailed comparisons are performed for several geometries, including flange absorbers, RF bellows, button-type beam position monitors, and an in-vacuum undulator (IVU). The results show notable differences in convergence and computational efficiency between the two codes. While GdfidL provides highly resolved results and serves as a common benchmark tool, ECHO3D yields consistent results with coarser meshes, significantly reducing simulation time and memory demands. Simulations with a full-geometry IVU model demonstrate that simplified taper-transition models can miss important impedance contributions. In conclusion, these findings provide practical guidelines for efficient and accurate impedance modeling to optimize design of vacuum chamber components for accelerators.

36 MATERIALS SCIENCE↗
DOE OSTI2013

Flux and Reaction Rate Kernel Density Estimators in OpenMC

Current methods for obtaining flux and reaction rate profiles in a Monte Carlo simulation rely on histogram tallies that can suffer from large uncertainties when fine detail is required. Recently, another density estimation technique has been applied to Monte Carlo radiation transport sim ulations: the Kernel Density Estimator (KDE) [Banerjee, K.]. KDEs are capable of calculating the flux at a point without the necessity of tracking particles on a spatial mesh, making KDEs ideal tools for multi-physics problems. Furthermore, KDEs allow for one collision or track length to contribute to the estimate of the flux at multiple points, circumventing the large statistical uncertainties associated with fine-mesh histogram tallies. However, KDEs have only been proven to be capable of estimating flux values at a series of points; no work has been done to estimate reaction rates or other quantities of interest. Furthermore, little work has been done in optimizing the KDE bandwidth for the energy-dependence of neutron transport simulations.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗
DOE OSTI2016

Predicting Fueled Experiment Swelling and Thermal Expansion Using STAR-CCM+

An experiment being designed at Idaho National Laboratory (INL) has an unusual temperature requirement. The surface temperature must remain above 300 C over the irradiation lifetime. The fuel in this experiment is composed of uranium-nitride (UN) tri-structural-isotropic (TRISO) particles encased in a cylindrical, SiC matrix. Increased swelling of SiC at lower temperatures is the basis for this lower temperature limit. For a typical thermal analysis, the focus is on some upper limit of the center-line temperature. This tends to be a more straight-forward process where the analyst makes a series of worst-case assumptions and demonstrates that the experiment - even under those conditions - cannot exceed the maximum temperature. The model used to ensure the experiment will always have a surface temperature in excess of 300 C has been developed using STAR-CCM+. Notable properties of the simulation include - Full 3D fluid and heat transfer modeling; - Geometry input taken directly from design engineer's CAD files; - Fuel swelling and thermal conductivity as functions of displacements per atom (DPA) and temperature; - Radial thermal expansion of fuel, rodlet, and capsule; - Jump gap and surface roughness implemented using equations from BISON. These things together have yielded a model with sufficient detail to predict minimum surface temperatures with the greatest precision attainable with available data. The only notable approximation is the zirconia insulator, which will actually be a sphere. This particular shape was chosen to expedite meshing, while maintaining a realistic degree of physical contact with adjacent components. Given temperature and irradiation dependent data for thermal conductivity and fuel swelling of a SiC matrix, it was possible to perform an in-depth thermal analysis to find an optimal configuration of radial gas gaps. Of greatest importance was that the fuel surface temperature remain above 300 C. This criteria was met with a healthy margin, even when considering machining tolerances of ±1 mil on the gas gaps.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2017

Snowflake: A Lightweight Portable Stencil DSL

Stencil computations are not well optimized by general-purpose production compilers and the increased use of multicore, manycore, and accelerator-based systems makes the optimization problem even more challenging. In this paper we present Snowflake, a Domain Specific Language (DSL) for stencils that uses a 'micro-compiler' approach, i.e., small, focused, domain-specific code generators. The approach is similar to that used in image processing stencils, but Snowflake handles the much more complex stencils that arise in scientific computing, including complex boundary conditions, higher-order operators (larger stencils), higher dimensions, variable coefficients, non-unit-stride iteration spaces, and multiple input or output meshes. Snowflake is embedded in the Python language, allowing it to interoperate with popular scientific tools like SciPy and iPython; it also takes advantage of built-in Python libraries for powerful dependence analysis as part of a just-in-time compiler. We demonstrate the power of the Snowflake language and the micro-compiler approach with a complex scientific benchmark, HPGMG, that exercises the generality of stencil support in Snowflake. By generating OpenMP comparable to, and OpenCL within a factor of 2x of hand-optimized HPGMG, Snowflake demonstrates that a micro-compiler can support diverse processor architectures and is performance-competitive whilst preserving a high-level Python implementation.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2015

Vectorization, threading, and cache-blocking considerations for hydrocodes on emerging architectures

This work reports on considerations for improving computational performance in preparation for current and expected changes to computer architecture. The algorithms studied will include increasingly complex prototypes for radiation hydrodynamics codes, such as gradient routines and diffusion matrix assembly (e.g., in [1-6]). The meshes considered for the algorithms are structured or unstructured meshes. The considerations applied for performance improvements are meant to be general in terms of architecture (not specifically graphical processing unit (GPUs) or multi-core machines, for example) and include techniques for vectorization, threading, tiling, and cache blocking. Out of a survey of optimization techniques on applications such as diffusion and hydrodynamics, we make general recommendations with a view toward making these techniques conceptually accessible to the applications code developer. Published 2015. This article is a U.S. Government work and is in the public domain in the USA.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2026

Towards a Unified Low-Cost Flow Plate, Flow-Field, PTL Solution for Proton Exchange Membrane Electrolyzers

Proton exchange membrane (PEM) water electrolysis is a highly efficient method for hydrogen production. Research cells typically consist of one proton exchange membrane, two catalyst layers, two porous transport layers, two flow-field plates, and two endplates. In commercial systems, the machined flow-field plates that are employed in research cells are typically replaced by stamped parts or open mesh material solutions to reduce manufacturing cost at scale. Nonetheless, the cell contains about 8 total interfaces: bipolar plate / flow plate material / porous transport medium / electrode / membrane / electrode / porous transport medium / flow plate material / bipolar plate. All these materials and interfaces need to be optimized for maximum performance and efficiency. Reducing the amount of interfaces by combining individual cell components directly benefits the fabrication cost (by reducing the parts count and the needs for surface coatings) and the electrochemical performance (by reducing ohmic losses). We have designed a novel PEM electrolysis cell with a piece of channeled titanium felt functioning as both the anode flow-field and the PTL, referred to as the channeled diffusion layer (CDL). The pores of the felt facilitate both in-plane and through-plane diffusion, ensuring maximum catalyst utilization while also minimizing mass transport loss. The titanium felt can be mass manufactured with existing stamping and forming methods and is therefore a promising candidate to reduce the capital cost of PEM electrolyzers whilst improving hydrogen production efficiency. Experiments conducted with 3mg IrOx/cm2 loading MEAs have shown a approximately 40% boost in peak current by implementing the CDL design. Low catalyst-loading MEAs are being tested in ongoing experiments and their results will be discussed and compared.

08 HYDROGEN↗
DOE OSTI2022

Anderson acceleration stability in NDA-accelerated k-eigenvalue problems

Anderson acceleration (AA) has been used to improve the stability and convergence rate of multiphysics iterative methods for reactor analysis. Most applications studied assume a tightly converged solution for the different physics problems, and AA is usually applied to state variables like temperature, density, and heat generation rate. In this paper, we study the theoretical performance of AA in NDA-accelerated k-eigenvalue problems. The problems and algorithms studied are simplified from the coupled iteration scheme adopted by MPACT and many other high-fidelity whole-core reactor codes. Compared to previous analyses of AA for these iteration schemes, we study the case with a partially converged neutronics solution and possibly partially converged nonlinear diffusion acceleration (NDA)/coarse mesh finite difference (CMFD) solutions. We observe that the performance of the iteration scheme with AA is very sensitive to the initial guess and is affected by the partially converged CMFD solutions. When the NDA solution is fully converged, using AA cannot achieve the optimal convergence rate in large-sized problems. Conversely, if the NDA solution is partially converged, the iteration scheme with AA can diverge or converge extremely slowly. It is found that the loss of robustness for AA is due to the fact that it is applied to the iterative subspace of state variables rather than the fundamental unknowns of the governing equations. To improve the robustness, the scalar flux should also be considered in the implementation of AA. After considering the residuals of flux, we observe that the stability is regardless of the partial convergence of NDA solutions. (authors)

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2014

From h to p efficiently: optimal implementation strategies for explicit time-dependent problems using the spectral/ hp element method: FROM h TO p EFFICIENTLY

We investigate the relative performance of a second-order Adams–Bashforth scheme and second-order and fourth-order Runge–Kutta schemes when time stepping a 2D linear advection problem discretised using a spectral/hp element technique for a range of different mesh sizes and polynomial orders. Numerical experiments explore the effects of short (two wavelengths) and long (32 wavelengths) time integration for sets of uniform and non-uniform meshes. The choice of time-integration scheme and discretisation together fixes a CFL limit that imposes a restriction on the maximum time step, which can be taken to ensure numerical stability. The number of steps, together with the order of the scheme, affects not only the runtime but also the accuracy of the solution. Through numerical experiments, we systematically highlight the relative effects of spatial resolution and choice of time integration on performance and provide general guidelines on how best to achieve the minimal execution time in order to obtain a prescribed solution accuracy. The significant role played by higher polynomial orders in reducing CPU time while preserving accuracy becomes more evident, especially for uniform meshes, compared with what has been typically considered when studying this type of problem.

42 ENGINEERING↗
DOE OSTI2015

Identifying finite-time coherent sets from limited quantities of Lagrangian data

A data-driven procedure for identifying the dominant transport barriers in a time-varying flow from limited quantities of Lagrangian data is presented. Our approach partitions state space into coherent pairs, which are sets of initial conditions chosen to minimize the number of trajectories that “leak” from one set to the other under the influence of a stochastic flow field during a pre-specified interval in time. In practice, this partition is computed by solving an optimization problem to obtain a pair of functions whose signs determine set membership. From prior experience with synthetic, “data rich” test problems, and conceptually related methods based on approximations of the Perron-Frobenius operator, we observe that the functions of interest typically appear to be smooth. We exploit this property by using the basis sets associated with spectral or “mesh-free” methods, and as a result, our approach has the potential to more accurately approximate these functions given a fixed amount of data. In practice, this could enable better approximations of the coherent pairs in problems with relatively limited quantities of Lagrangian data, which is usually the case with experimental geophysical data. We apply this method to three examples of increasing complexity: The first is the double gyre, the second is the Bickley Jet, and the third is data from numerically simulated drifters in the Sulu Sea.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
DOE OSTI2016

Development of a first-principles hybrid boiler model for oxy-combustion power generation system

The design of an oxy-combustion system for CO 2 capture involves the integration of multiple devices including air separation unit, coal-fired boiler, steam turbine, flue gas cleanup, recycle, and compression units. Thousands of design parameters for the entire system need to be optimized to achieve the lowest cost per kilowatt-hour of electricity generated. An appropriate first-principles based boiler model with short computer execution time but yet reasonable accuracy in both air-fired and oxy-fired configurations is highly desired. To this end, a hybrid boiler model with 1-D resolution for main flow and reaction related calculations and 3-D resolution for radiative heat transfer was developed as a part of the oxy-combustion subtask of the Carbon Capture and Simulation Initiative (CCSI) sponsored by U.S. Department of Energy. Furthermore, the developed model is able to automatically generate a 3-D mesh based on user-specified furnace shape for the calculation of radiative heat transfer using discrete ordinates method.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2017

Design Parameters for Subwavelength Transparent Conductive Nanolattices

Recent advancements with the directed assembly of block copolymers have enabled the fabrication over cm 2 areas of highly ordered metal nanowire meshes, or nanolattices, which are of significant interest as transparent electrodes. Compared to randomly dispersed metal nanowire networks that have long been considered the most promising next-generation transparent electrode material, such ordered nanolattices represent a new design paradigm that is yet to be optimized. Here in this paper, through optical and electrical simulations, we explore the potential design parameters for such nanolattices as transparent conductive electrodes, elucidating relationships between the nanowire dimensions, defects, and the nanolattices’ conductivity and transmissivity. We find that having an ordered nanowire network significantly decreases the length of nanowires required to attain both high transmissivity and high conductivity, and we quantify the network’s tolerance to defects in relation to other design constraints. Furthermore, we explore how both optical and electrical anisotropy can be introduced to such nanolattices, opening an even broader materials design space and possible set of applications.

36 MATERIALS SCIENCE↗
DOE OSTI2018

A Numerical Tool for the Design of Enhanced Geothermal Reservoirs based on Modeling of Thermo-Hydro-Mechanical Processes and Explicit Representation of 3D Discrete Fracture Networks

This project has developed a coupled thermo-hydro-mechanical numerical modeling tool for prediction of energy production from Enhanced Geothermal Reservoirs (EGS). The tool is unique because it can explicitly represent thousands of pre-existing natural fractures. The capabilities developed in this project were built on the already existing expertise of Itasca arising from thirty years of research and development in discrete element modeling of fractured rocks. A thermal module suitable for analysis of different heat transfer mechanisms in fractured rocks percolated by fluids was developed and coupled with the already existing hydro-mechanical calculation in 3DEC, a commercial software for analysis of jointed rock based on the discrete element method (DEM). The heat transfer module simulates heat conduction, heat advection by moving fluid in rock fractures, and convective heat exchange at the fracture walls between the rock and the moving fluid. Techniques for spatial discretization of heat transfer in EGS-type problems were evaluated, and a boundary layer meshing approach was developed. Also, given the significant differences in time scale of physical processes involved, temporal integration schemes for coupled advection-diffusion processes and coupled thermal-hydro-mechanical processes were developed by taking advantage of both implicit and explicit time integration and also optimizing the coupling intervals. These improvements were necessary for modeling EGS reservoirs. Also, the DFN capacities in 3DEC were extended to include a larger number of fractures. Research was carried out on approaches to simplify the DFN so that the model can meet computational demands, while preserving thermo-hydro-mechanical characteristics of the DFN. The developed modules were coupled with the already existing capabilities of 3DEC. The results were presented as a submitted conference paper (Riahi et al., 2018a). A series of benchmark and test examples showed the developed capabilities. Finally, the developed tool was tested for a large-scale reservoir model for longer periods of injection and production. The thermal draw-down curves were generated and presented. The project successfully met all the milestones laid out in the proposal. Results demonstrated the feasibility of developing a fast and reliable software for the EGS community to use for assessment and prediction of reservoir performance. Some of its applications include assessment of stimulated volume and produced temperature and power. It can also be used for improved engineering, design and optimization of EGS reservoirs as well as other unconventional resources such as shale gas. Finally, the 3D analysis presented in this study showed that simulating EGS reservoirs with tens of thousands of fractures is feasible, and confirmed that the developed tool can serve toward meeting the goals and objectives of Geothermal Technologies Office in overcoming technical barriers associated with commercial EGS development.

15 GEOTHERMAL ENERGY↗
DOE OSTI2019

Influence of scan pattern and geometry on the microstructure and soft-magnetic performance of additively manufactured Fe-Si

The influence of geometry and scan pattern on the microstructure evolution and magnetic performance of additively manufactured Fe-3Si components was investigated. To reduce eddy current losses, novel geometries were designed and built and the microstructure and properties of these samples were characterized. The laser scan pattern was shown to strongly influence both the as-built grain structure and strength of the crystallographic texture, resulting in measurable changes in the as-built magnetic performance. In thin wall samples, heat treatment resulted in an increase in the maximum relative magnetic permeability and decrease in power losses in most samples, consistent with grain growth. However, decreases in the spacing between thin walls to increase the stacking factor of the cross-section was shown to result in unwanted electrical shorting between walls and an increase in eddy current losses. Compared to simple parallel plate construction and a mesh structure, a novel cross-section design based on the Hilbert space filling curve was found to produce the lowest power losses. The mechanisms behind these results were explored using a combination of heat conduction and electromagnetic simulations, providing a route for future component and process optimization.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Role of Computational Parameters on Predicting Self-Consistent Residual Stress and Distortion during Wire Arc Additive Manufacturing

Production of three-dimensional metallic parts through integration of an articulated robot and gas metal arc welding, also known as wire arc additive manufacturing (WAAM), can produce large-scale components with moderate geometrical complexity. This technology is particularly appealing due to its high deposition rates, scalability, and cost-effective feedstock compared to other AM processes. Despite its advantages, WAAM adoption is hindered by challenges in ensuring geometric conformity without extensive distortion, defect-free structures, and consistent mechanical properties. Finite element analysis (FEA) is often used to address the challenge of geometrical conformity. As the size of parts increases, the best practices for mesh size and temporal resolution known in the literature become computationally unviable. This research examined the effects of mesh and time-step resolutions during transient FEA of a large-scale (248 layers) metallic part. The impact of computational parameters on the thermal history, displacement, and residual stress distributions were evaluated. The results showed that predicted distortion was consistent across resolutions, while time-step length significantly affected predicted thermal history, and mesh size influenced residual stress distributions. To investigate this relationship further, directionally biased meshes were considered and analyzed. The results indicated that increasing mesh resolution perpendicular to the welding path yielded stress predictions that aligned closely with higher-resolution models while offering substantial computational savings. In conclusion, the significances of this research are related to verification and validation of WAAM models for widespread industrial adoption and pragmatic guidelines for optimizing computation parameters for balancing computational efficiency and predictive accuracy of residual stress and distortion.

Solsbee, Brandon [Univ. of Tennessee, Knoxville, T↗