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DOE OSTI2025

Predictive dynamic wetting, fluid–structure interaction simulations for braze run-out

Brazing and soldering are metallurgical joining techniques that use a wetting molten metal to create a joint between two faying surfaces. Here, the quality of the brazing process depends strongly on the wetting properties of the molten filler metal, namely the surface tension and contact angle, and the resulting joint can be susceptible to various defects, such as run-out and underfill, if the material properties or joining conditions are not suitable. In this work, we implement a finite element simulation to predict the formation of such defects in braze processes. This model incorporates both fluid–structure interaction through an arbitrary Eulerian–Lagrangian technique and free surface wetting through conformal decomposition finite element modeling. Upon validating our numerical simulations against experimental run-out studies on a silver-Kovar system, we then use the model to predict run-out and underfill in systems with variable surface tension, contact angles, and applied pressure. Finally, we consider variable joint/surface geometries and show how different geometrical configurations can help to mitigate run-out. This work aims to understand how brazing defects arise and validate a coupled wetting and fluid–structure interaction simulation that can be used for other industrial problems.

36 MATERIALS SCIENCE↗

DOE OSTI2020

Collisionless adiabatic afterglow

In this work, we study, by numerical and analytical means, the evolution of a collisionless plasma initiated between absorbing walls. The ensuing flow is described by rarefaction waves that travel inward from the boundaries, interact, and eventually vanish after crossing through, leading up to the asymptotic stage of the decay. Particle simulations indicate that the kinetic evolution strongly resembles one found in isentropic gas dynamics. Namely, a very gradual density profile forms in the expanding central region where the rarefaction waves interact, with an accompanying linear velocity profile. Asymptotically, the density falls off as 1/t. The density and the flux at the boundary show little variation over the period when rarefaction waves still exist. Plasma potential, on the other hand, drops quite rapidly (on the underlying ion-acoustic timescale) to less than initial electron temperature Te when over 70% of the particles still remain in the system. This is due to electron kinetics being governed by conservation of adiabatic invariant in a slowly varying potential well. Analytical model of the velocity distribution is presented to explain the simulations. The results have implications for afterglow plasmas used in material processing and also for ion-extraction devices. One property of potential interest is good uniformity of the decaying plasma that occurs after approximately one ion-acoustic time.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2023

Prediction and Validation of Flow Properties in Porous Lattice Structures

High-porosity metal foams have been extensively studied as an attractive candidate for efficient and compact heat exchanger design. With the advancements in additive manufacturing, such foams can be manufactured with controlled topology to yield highly tailorable mechanical and transport properties. In this study, a lattice Boltzmann method (LBM)-based pore-scale model is implemented to simulate the fluid flow in additively manufactured (AM) metal foams with unit cell topologies of Cube, Face Diagonal (FD)-Cube, Tetrakaidecahedron (TKD), and Octet lattices. The pressure gradient versus average velocity profiles predicted by the LBM model were validated against in-house measurements on the AM lattice samples with the same unit cell topologies. Based on the simulation results, a novel hybrid model is proposed to accurately predict the volume averaged flow properties (permeability and inertial coefficients) of the four structures. Specifically, the linear LBM (neglecting inertial forces) is first implemented to obtain the intrinsic permeability, and then the standard LBM is applied to obtain the inertial coefficient. Convenient correlations for those flow properties as a function of porosity and fiber diameter are constructed. The effects of the AM print qualities on the flow properties are also discussed. The advantages of the hybrid model compared to the polynomial fitting approach for determining flow properties are discussed and compared quantitatively. The hybrid model and presented results are valuable for flow and thermal transport evaluation when designing new metal foams for specific applications and with different materials and topologies. Finally, the presented correlations based on pore-scale simulations can also be conveniently used in volume-averaged models to predict the macroscale flow behavior in such complex structures.

42 ENGINEERING↗

DOE OSTI2023

Tracking of Marangoni driven motion during laser powder bed fusion

Laser Powder Bed Fusion (LPBF) can be used to create Functionally Graded Materials (FGMs) by selectively distributing property augmenting particles throughout the build matrix. With this method parts can be created with nonhomogeneous properties tuned to spatially varied, pre-determined design constraints. To unlock this capability, the fluid motion that occurs in the molten liquid phase must be thoroughly understood. More importantly, the actual tracking of motion during the LPBF process is needed. Further, a numerical model of heat transfer and fluid flow in LPBF process was created. Using results from the model the motion of particles starting at many different locations was tracked. The average change in position for these particles based on starting location was calculated. The effects of non-dimensional parameters on melt pool size were examined. These results were validated experimentally and compared to what is available in the literature.

42 ENGINEERING↗

DOE OSTI2022

On the enhancement of boundary layer skin friction by turbulence: an angular momentum approach

Turbulence enhances the wall shear stress in boundary layers, significantly increasing the drag on streamlined bodies. Other flow features such as free stream pressure gradients and streamwise boundary layer growth also strongly influence the local skin friction. In this paper, an angular momentum integral (AMI) equation is introduced to quantify these effects by representing them as torques that alter the shape of the mean velocity profile. This approach uniquely isolates the skin friction of a Blasius boundary layer in a single term that depends only on the Reynolds number most relevant to the flow's engineering context, so that other torques are interpreted as augmentations relative to the laminar case having the same Reynolds number. The AMI equation for external flows shares this key property with the so-called FIK relation for internal flows (Fukagata et al. , Phys. Fluids , vol. 14, 2002, pp. L73–L76). Without a geometrically imposed boundary layer thickness, the length scale in the Reynolds number for the AMI equation may be chosen freely. After a brief demonstration using Falkner–Skan boundary layers, the AMI equation is applied as a diagnostic tool on four transitional and turbulent boundary layer direct numerical simulation datasets. Regions of negative wall-normal velocity are shown to play a key role in limiting the peak skin friction during the late stages of transition, and the relative strengths of terms in the AMI equation become independent of the transition mechanism a very short distance into the fully turbulent regime. The AMI equation establishes an intuitive, extensible framework for interpreting the impact of turbulence and flow control strategies on boundary layer skin friction.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗

DOE OSTI2022

Direct Multimodal Nanoscale Visualization of Early Phosphorus-Based Antiwear Tribofilm Formation

Understanding the mechanism of antiwear (AW) tribofilm formation and how to tune surface chemistry to control functionality is essential for the development of the next generation of oil lubricants. In particular, understanding and optimizing early AW tribofilm formation can increase the energy efficiency of mechanical systems. However, the mechanism for how these films form is not well understood. The majority of prior work has focused on analyzing only end-of-test surfaces long after the film has formed. In this work, we develop an in situ multimodal chemical imaging methodology to directly visualize the early formation of AW films on steel surfaces. We investigate an oil formulation containing a phosphorus-based additive commonly used to protect surfaces from wear and fatigue processes in machine elements, such as gears, bearings, and sliding contacts. Using nanoscale multimodal chemical imaging on combined platforms of atomic force microscopy (AFM) coupled directly with in situ nano-infrared (nano-IR) spectroscopy, and further combined ex situ with time-of-flight secondary ion mass spectrometry (ToF-SIMS), we demonstrate a direct correlation between changes in friction and local surface chemistry. In these experiments, the AFM probe acts as a single asperity contact to generate the tribofilm as well as a tool to analyze it in situ as it is forming. To verify our in situ measurements, we compare these results to the ex situ ToF-SIMS of macroscale block-on-ring tribometer-formed samples. We report the understanding gained here on how AW films form and how film properties can be modified by tuning the chemistry of the additives will facilitate developing transmission fluids to meet increasing demands for vehicle performance and efficiency.

36 MATERIALS SCIENCE↗

DOE OSTI2023

Machine learning predictions of diffusion in bulk and confined ionic liquids using simple descriptors

Ionic liquids have many intriguing properties and widespread applications such as separations and energy storage. However, ionic liquids are complex fluids and predicting their behavior is difficult, particularly in confined environments. We introduce fast and computationally efficient machine learning (ML) models that can predict diffusion coefficients and ionic conductivity of bulk and nanoconfined ionic liquids over a wide temperature range (350–500 K). The ML models are trained on molecular dynamics simulation data for 29 unique ionic liquids as bulk fluids and confined in graphite slit pores. This model is based on simple physical descriptors of the cations and anions such as molecular weight and surface area. Here, we also demonstrate that accurate results can be obtained using only descriptors derived from SMILES (simplified molecular-input line-entry system) codes for the ions with minimal computational effort. This offers a fast and efficient method for estimating diffusion and conductivity of nanoconfined ionic liquids at various temperatures without the need for expensive molecular dynamics simulations.

74 ATOMIC AND MOLECULAR PHYSICS↗

DOE OSTI2025

The mechanics of nucleation and growth and the surface tensions of active matter

Homogeneous nucleation, a textbook transition path for phase transitions, is typically understood on thermodynamic grounds through the prism of classical nucleation theory. However, recent studies have suggested the applicability of classical nucleation theory to systems far from equilibrium. Here, in this article, we formulate a purely mechanical perspective of homogeneous nucleation and growth, elucidating the criteria for the properties of a critical nucleus without appealing to equilibrium notions. Applying this theory to active fluids undergoing motility-induced phase separation, we find that nucleation proceeds in a qualitatively similar fashion to equilibrium systems, with concepts such as the Gibbs–Thomson effect and nucleation barriers remaining valid. We further demonstrate that the recovery of such concepts allows us to extend classical theories of nucleation rates and coarsening dynamics to active systems upon using the mechanically derived definitions of the nucleation barrier and surface tensions. Three distinct surface tensions—the mechanical, capillary, and Ostwald tensions—play a central role in our theory. While these three surface tensions are identical in equilibrium, our work highlights the distinctive role of each tension in the stability of active interfaces and the nucleation and growth of motility-induced phases.

Capillary waves↗

DOE OSTI2024

Assessing Critical Conditions for Scour Near Obstructions using Bed Shear, Particle Onset of Motion Balances, and CFD-DEM Modeling of Granular Beds

Computational Fluid Dynamics combined with a Discrete Element Method is one of the computational methods that can be used to model multiphase flows. In this method various phases, gas and liquid or solid, are present in the same computational domain. The local averaged Navier–Stokes equations determine the flow of the continuous phase fluid and are solved using the traditional CFD finite volume approach. DEM is based on a Lagrangian formulation, which solves the equations of motion, expressed in ordinary differential equations, for representative particles as they move in space and time. The interactions between the continuous fluid phase and discrete solid phase are modeled with the use of Newton’s laws of motion via drag force. The particles interact with each other and with the boundaries of the fluid continuum, and the resulting contact forces are included in the equations of motion. The properties of solid particles and boundaries are treated as elastic bodies, with specified density, elastic modulus, and Poisson’s ratio. Particle shapes may vary from single spherical particles to more complex-shaped composite particles. The particles may be introduced into the domain by random or structured injection at a point, surface, or volume, depending on the application. More details on the formulation can be found in the Simcenter STAR-CCM+ User’s Manual and OpenFOAM website.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2025

Linear Velocity Problems Part 2: Thermodynamic Considerations

A compressible polytropic gas, in one dimensional planar, cylindrical, or spherical coordinate systems, is examined through four thermodynamic properties: mass density, pressure, specific internal energy (SIE), and entropy, under the assumptions that the fluid velocity is linearly proportional to the radial coordinate and that the Euler gas dynamics equations assert a self similar solution class. The behavior of the thermodynamics is almost entirely determined by an arbitrary function that results from the derivation of the density distribution. Through physical and other arguments, the arbitrary function can be plotted spatially with time profiles, providing a deeper understanding of the system and how the arbitrary function affects the behavior of the compressible gas.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗

DOE OSTI2023

Architected stamps for liquid transfer printing

The present invention relates to architected stamps having beneficial printing properties. In particular, negative Poisson ratio structures and/or porous reservoirs can be employed to control fluid dynamics and to provide metered ink transfer.

Kaehr, Bryan James↗

DOE OSTI2020

Borehole Disposal: Update on the Science, Technology, and Potentially Suitable Radioactive Wastes - 20170

A recent Special Issue of the Energies Journal on Deep Borehole Disposal of Nuclear Waste has delivered a timely update on the science and technology of borehole disposal and the types of radioactive wastes it could potentially accommodate. The Special Issue papers discuss (i) circumstances under which a national waste management programme might wish to consider deep borehole disposal [1], (ii) a status report of deep borehole disposal options in Germany [2], (iii) the use of deep horizontal drill-holes in sedimentary, metamorphic or igneous rocks for disposal of spent nuclear fuel and high-level radioactive waste [3], (iv) the analysis of corrosion performance of engineered barrier systems [4], (v) a review of the potential cementing systems suitable for deep borehole disposal [5], (vi) the thermal evolution around heat-generating waste for a wide range of material properties and disposal configurations [6], (vii) a geochemical analysis of deep brines focussed on fluid-rock interactions [7], (viii) post-closure performance assessment calculations for deep borehole disposal of Cs/Sr capsules [8], and (ix) an example safety case for deep borehole disposal of nuclear wastes [9]. This paper provides an overview of the main findings from these publications and highlights some of the technological and scientific challenges that need to be overcome when developing a deep borehole disposal concept. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2021

Integrated Heat Exchanger-Phase Change Material Thermal Energy Storage System

The purpose of this study is to experimentally investigate the thermal performance of an innovative thermal energy storage (TES) system that combines the advantages of the phase-change material (PCM)/graphite foam latent heat TES medium developed at Argonne National Laboratory (Argonne) and the internally supported plate-fin (ISPE) cell architecture heat transfer fluid (HTF) flow channels developed at Brayton Energy (Brayton). Several essential tasks were accomplished: (1) Thermal property characterization. Thermal properties of the graphite foam were characterized, providing necessary data for experimental result analysis and numerical simulation. (2) Design and optimization of lab-scale test module. Based on Brayton’s full-scale heat exchanger (HX)-TES system, the experimental test module was designed, optimized, and fabricated. (3) Thermal performance testing and data analysis. Five cycle tests were successfully conducted—including one with approximately 3.5 psig of pressure applied to the diaphragms—to investigate the thermal performance of the experimental test module for charging and discharging. Temperature profiles were generated for each charging test and discharging test as a function of time. The temperature profiles clearly show three TES stages: sensible heat (temperature increase), latent heat (melting), and sensible heat (temperature increase) for the charging process. Similarly, the temperature profiles clearly show three thermal energy release stages: sensible heat (temperature decrease), latent heat (solidification), and sensible heat (temperature decrease). Melting and solidification of the PCM generally occurred in relatively narrow temperature ranges, indicated by the flattened temperature regions in the temperature profiles. These phase changes ranged approximately 3°C for melting and 3.5°C for solidification. The charging and discharging temperature profiles were similar for similar experimental parameter tests whether or not pressure was applied to the diaphragm to eliminate the gap between the HX surface and the TES subsystem. This indicates that the effect of a small gap between the HX surface and the TES subsystem is insignificant for charging and discharging. (4) Comparison of experimental data and simulation results. We compared the experimental data to the numerical simulation results. Numerical simulations were conducted by using the ANSYS FLUENT 2019 R3 commercial computational fluid dynamics software. The predicted phase-change times agreed reasonably well with those from the experimental data. In most cases, the estimated time differences between the relative phase changes were within 16%. The predicted start and end times for the charging process agreed well with those from the experimental data. However, the simulation results showed earlier start and end times than the experimental data for the discharging process. Overall, the experimental data and its comparison with the simulation predictions verified the technical viability of the integrated ISPF HX-PCM/graphite foam latent-heat TES system.

25 ENERGY STORAGE↗

DOE OSTI2020

Development and Validation of Physics-Based Sub-Models of High-Pressure Supercritical Fuel Injection at Diesel Conditions Insert

The project sought to develop and validate accurate, physics-based, numerical submodels and implement them in computational fluid dynamics (CFD) software codes to enable accurate predictions of diesel sprays at pressures higher than the current systems. The combined experimental-computational effort has four main objectives: (1) acquire spatially and temporally resolved scalar measurements of fuel-oxidizer mixing in the near field of the fuel jet, (2) develop software modules to calculate thermo-physical properties of diesel surrogates and their mixtures with oxidizer of interest in real-gas operating regime, (3) integrate the real-fluid model into a commercial and an open-source CFD code to simulate fuel-air mixing in high-pressure diesel sprays, and (4) assess the robustness, accuracy, and uncertainty of the integrated CFD solvers in computing diesel sprays. Project accomplishments are consistent with the original goals of the project. Although we acquired spatially and temporally resolved scalar measurements, they were limited to refractive index difference and not to thermodynamic properties such as temperature and equivalence ratio. However, we successfully developed the theoretical background needed to acquire such measurements at diesel conditions and demonstrated the capability of the RSD for scalar measurements in a canonical turbulent jet flow replicating features of the diesel jet. Additional work will be needed to implement these procedures at high-pressure, high-temperature engine-like conditions of the CPFR. Mainly, we did not anticipate the need to find the liquid boundary and its statistical features or the state relationships between refractive index and thermodynamic properties, assuming the widely known Dale-Gladstone equation would suffice. Still, efforts devoted to these tasks were essential to fulfil the goals of the project and serves as the foundation on which many of the conclusions and key contributions of this project are based. Further assessment and application of the developed CFD codes is recommended to fully realize the benefits of this research.

33 ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2023

Insights into Waterflooding in Hydrocarbon-Bearing Nanochannels of Varying Cross Sections from Mesoscopic Multiphase Flow Simulations

Waterflooding is one of the geotechnique used to recover fuel sources from nanoporous geological formations. The scientific understanding of the process that involves the multiphase flow of nanoconfined fluids, however, has lagged, mainly due to the complex nanopore geometries and chemical compositions. To enable benchmarked flow of nanoconfined fluids, the architected geomaterials, such as synthesized mesoporous silica with tunable pore shapes and surface chemical properties, are used for designing and conducting experiments and simulations. This work uses a modified many-body dissipative particle dynamics (mDPD) model with accurately calibrated parameters to perform parametric flow simulations for studying the influences of waterflooding driven power, pore shape, surface roughness, and surface wettability on the multiphase flow in heptane-saturated silica nanochannels. Remarkably, up to 80\% reduction in the effective permeability is found for water-driven heptane flow in a baseline 4.5 nm-wide slit channel, when compared with the Hagen–Poiseuille equation. In the 4.5 nm-wide channels with architected surface roughness, the flow rate is found either higher or lower than the baseline case, depending on the shape and size of cross-sections. High wettability of the solid surface to water is essential for achieving high recovery of heptane, regardless of surface roughness. When the solid surface is less wetting or non-wetting to water, the existence of an optimal waterflooding driven power is found to allow for the highest possible recovery. A detailed analysis on the evolution of the transient water-heptane interface in those nanochannels is presented to elucidate the underlying mechanisms that impact or dictate the multiphase flow behaviors.

58 GEOSCIENCES↗

DOE OSTI2021

PREPARATION OF CLAY-COATED GLASS SURFACES FOR MICROFLUIDICS-BASED STUDY ON CLAY-FLUID INTERACTIONS

Unique characteristics of clay, even though make any clay abundant shales a good source of adsorbed gas, make them equally difficult to produce. The clay-water interaction can cause significant swelling and fines migration in the shale formation, both of which can significantly impair the overall hydrocarbon recovery from shale. Geomaterial micromodels, developed by functionalizing traditional glass or PDMS surface with geomaterials (e.g., calcite, quartz, clay) can represent the physico-chemical properties of the natural porous media and have been used during the last few years to understand and evaluate the solid-fluid physicochemical interactions. This study focuses on developing a clay-coated geomaterial surface and investigates the effect of base fluid's salinity on clay adsorption to the glass surface. Glass capillary tubes and straight channel borosilicate glass micromodels are coated with Illite clay minerals to represent the pore-scale clay chemistry of Caney Shale, a Mississippian unconventional play in Southern Oklahoma, USA. 10 wt.% of Illite clay slurries made with brines of four different salinities are used to coat the glass-capillary tubes to understand the effect of salinity in clay adsorption on the glass surface and overall coating quality. To achieve a stable coating and evaluate the impact of heat treatment on coating's stability, straight channel glass flow cells coated with Illite clay are heat-treated at low (25 °C) and high temperature (125 °C). Dynamic flooding tests were carried out with brines on the coated surface to evaluate the stability of the coating. The experiments' outcome indicated a strong relationship between the brine's salinity and the adsorption of clay particles on the glass surface. An increase in brine concentration resulted in improved adsorption of clay particles on the glass surface. Experiments involving heat treating the glass surface following the coating demonstrated significant improvement in the stability of the coating.

02 PETROLEUM↗

DOE OSTI2024

Hydrothermal solubility of Dy hydroxide as a function of pH and stability of Dy hydroxyl aqueous complexes from 25 to 250 °C

The rare earth elements (REE) have important applications in green energy technologies. The formation of mineral deposits in geologic systems commonly involves hydrothermal fluids which can mobilize the REE. However, the REE speciation is not well known as a function of pH. The thermodynamic properties of REE hydroxyl complexes used in geochemical models are based on the Helgeson-Kirkham-Flowers (HKF) equation of state parameters which were derived by extrapolation of low temperature experimental and estimated data. In this study, Dy hydroxide solubility experiments are combined with available literature data to improve these models from 25 to 250 °C and optimize the thermodynamic properties of Dy 3+ and Dy hydroxyl complexes using GEMSFITS. Batch-type solubility experiments were conducted from 150 to 250 °C and at saturated water vapor pressure in perchloric acid solutions with initial pH values of 2 to 5 in 0.5 pH unit increments. The measured solubility of Dy hydroxide is retrograde with temperature and decreases with pH. The logarithm of total dissolved Dy molality ranges from –2.3 to –5.3 at 150 °C (pH 4.7–5.5), from –2.4 to –5.6 at 200 °C (pH 3.9–5.1), and from –3.7 to –6.9 at 250 °C (pH of 3.4 and 5.0). The optimized standard partial molal Gibbs energies of formation (Δ f G° T ) derived for Dy 3+ and DyOH 2+ display a close to linear relationship with temperature, fitting with previous optimizations based on DyPO 4 solubility data in the literature. A comparison of the optimized ΔfG°T values for aqueous Dy species with predictions from available HKF parameters indicates significant differences ranging from +11 to –26 kJ/mol between 25 and 250 °C. The experimental fits are used to derive the Dy hydroxide solubility products (K s0 ) and formation constants for the hydrolysis of Dy (β n with n = 1 to 3; Dy 3+ + nOH – = DyOH n 3-n ) as a function of temperature. The optimization method presented yields accurate thermodynamic properties for the Dy 3+ aqua ions and the DyOH 2+ species at the acidic to mildly acidic pH studied whereas more experimental work is needed at near-neutral and alkaline conditions to better constrain the other hydroxyl complexes. Furthermore, the optimized thermodynamic data have a significant impact on geochemical modeling of the mobility and solubility of REE minerals in acidic hydrothermal fluids.

58 GEOSCIENCES↗

DOE OSTI2022

A Computational Fluid Dynamic Study on Polymer Heat Exchangers

Polymer heat exchangers have been developed for the applications involving weight restrictions or chemical compatibility and fouling issues owing to the low density, anticorrosive properties, and low thermal expansion of polymers. Recently development of additive manufacturing also brings new opportunities to make polymer heat exchangers with desired design that was hard to realize before. However, due to the lower thermal conductivity polymer composite, the overall heat transfer performance is still a challenge in the polymer heat exchanger technology. In present work, a computational fluid dynamic (CFD) model has been developed to study the overall heat transfer performance of additively manufactured polymer heat exchangers. The CFD results offer an insight of fluid flow and temperature distribution in the polymer heat exchangers. This study provides a guidance not only on the polymer material selection but also on the design of polymer heat exchangers. The conclusions will be helpful to design a polymer heat exchanger whose overall heat transfer performance is comparable to a metal heat exchanger.

Zhang, Mingkan↗