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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↗

NASA NTRS1996

Global Load Balancing with Parallel Mesh Adaption on Distributed-Memory Systems

Dynamic mesh adaption on unstructured grids is a powerful tool for efficiently computing unsteady problems to resolve solution features of interest. Unfortunately, this causes load imbalance among processors on a parallel machine. This paper describes the parallel implementation of a tetrahedral mesh adaption scheme and a new global load balancing method. A heuristic remapping algorithm is presented that assigns partitions to processors such that the redistribution cost is minimized. Results indicate that the parallel performance of the mesh adaption code depends on the nature of the adaption region and show a 35.5X speedup on 64 processors of an SP2 when 35% of the mesh is randomly adapted. For large-scale scientific computations, our load balancing strategy gives almost a sixfold reduction in solver execution times over non-balanced loads. Furthermore, our heuristic remapper yields processor assignments that are less than 3% off the optimal solutions but requires only 1% of the computational time.

Biswas, Rupak↗

NASA NTRS1996

Global Load Balancing with Parallel Mesh Adaption on Distributed-Memory Systems

Dynamic mesh adaptation on unstructured grids is a powerful tool for efficiently computing unsteady problems to resolve solution features of interest. Unfortunately, this causes load inbalances among processors on a parallel machine. This paper described the parallel implementation of a tetrahedral mesh adaption scheme and a new global load balancing method. A heuristic remapping algorithm is presented that assigns partitions to processors such that the redistribution coast is minimized. Results indicate that the parallel performance of the mesh adaption code depends on the nature of the adaption region and show a 35.5X speedup on 64 processors of an SP2 when 35 percent of the mesh is randomly adapted. For large scale scientific computations, our load balancing strategy gives an almost sixfold reduction in solver execution times over non-balanced loads. Furthermore, our heuristic remappier yields processor assignments that are less than 3 percent of the optimal solutions, but requires only 1 percent of the computational time.

Biswas, Rupak↗

NASA NTRS2017

Experimental Investigation of Shrouding on Meshed Spur Gear Windage Power Loss

Windage power loss in high-speed gearboxes result in efficiency losses and increased heating due to drag on the gear teeth. Meshed spur gear windage power loss test results are presented at ambient oil inlet temperatures both with and without shrouding. The rate of windage power loss is observed to increase above 10,000 ft.min., gear surface speed, similar to results presented in the literature. Shrouding is observed to become more effective above 15,000 ft.min., decreasing power loss by 10 at 25,000 ft.min. The need for gearbox oil drain slots limits the effectiveness of shrouding on reducing windage power loss. Also, windage power loss is observed to decrease with increasing gearbox temperatures and to increase with oil flow. Windage power losses for the unshrouded meshed spur gears are 7x more than losses determined from unshrouded single spur gear tests. A 6x to 12x increase in windage power is observed comparing shrouded single spur gear data with shrouded meshed spur gear data. Based on this preliminary study additional research is suggested to determine the effect of oil drain slot configurations, axial and radial shroud clearances, and higher gear surface speeds on windage power loss. Additional work is also suggested to determine the sensitivity of windage power loss to oil temperature and oil flow. Windage power loss of meshed spur gears tested in both the shrouded and unshrouded configurations is shown to be more than double versus the same spur gears run individually in the same shroud configurations. Further study of the physical processes behind these results is needed for optimizing gearbox shrouds for minimum windage power loss.

gear↗

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↗

NASA NTRS2016

Addressing the Big-Earth-Data Variety Challenge with the Hierarchical Triangular Mesh

We have implemented an updated Hierarchical Triangular Mesh (HTM) as the basis for a unified data model and an indexing scheme for geoscience data to address the variety challenge of Big Earth Data. We observe that, in the absence of variety, the volume challenge of Big Data is relatively easily addressable with parallel processing. The more important challenge in achieving optimal value with a Big Data solution for Earth Science (ES) data analysis, however, is being able to achieve good scalability with variety. With HTM unifying at least the three popular data models, i.e. Grid, Swath, and Point, used by current ES data products, data preparation time for integrative analysis of diverse datasets can be drastically reduced and better variety scaling can be achieved. In addition, since HTM is also an indexing scheme, when it is used to index all ES datasets, data placement alignment (or co-location) on the shared nothing architecture, which most Big Data systems are based on, is guaranteed and better performance is ensured. Moreover, our updated HTM encoding turns most geospatial set operations into integer interval operations, gaining further performance advantages.

SciDB↗

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 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↗

NASA NTRS2013

Performance Gains of Propellant Management Devices for Liquid Hydrogen Depots

This paper presents background, experimental design, and preliminary experimental results for the liquid hydrogen bubble point tests conducted at the Cryogenic Components Cell 7 facility at the NASA Glenn Research Center in Cleveland, Ohio. The purpose of the test series was to investigate the parameters that affect liquid acquisition device (LAD) performance in a liquid hydrogen (LH2) propellant tank, to mitigate risk in the final design of the LAD for the Cryogenic Propellant Storage and Transfer Technology Demonstration Mission, and to provide insight into optimal LAD operation for future LH2 depots. Preliminary test results show an increase in performance and screen retention over the low reference LH2 bubble point value for a 325 2300 screen in three separate ways, thus improving fundamental LH2 LAD performance. By using a finer mesh screen, operating at a colder liquid temperature, and pressurizing with a noncondensible pressurant gas, a significant increase in margin is achieved in bubble point pressure for LH2 screen channel LADs.

Hartwig, Jason W.↗

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↗

NASA NTRS2017

Experimental Investigation of Shrouding on Meshed Spur Gear Windage Power Loss

Windage power loss in high-speed gearboxes results in efficiency losses and increased heating due to drag on the gear teeth. Test results for meshed spur gear windage power loss are presented at ambient oil inlet temperatures, both with and without shrouding. The rate of windage power loss is observed to increase above a gear surface speed of 10,000 feet per minute (51 meters per second), similar to results presented in the literature. Shrouding is observed to become more effective above 15,000 feet per minute (76 meters per second), decreasing power loss by 10 percent at 25,000 feet per minute (127 meters per second). The need for gearbox oil drain slots limits the effectiveness of shrouding in reducing windage power loss. Windage power loss is observed to decrease with increasing gearbox temperatures and to increase with oil flow. Windage power losses for unshrouded meshed spur gears are 7 times greater than losses determined from unshrouded single spur gear tests. A 6- to 12-times increase in windage power loss is observed in the shrouded meshed spur gear data compared with shrouded single spur gear data. Based on this preliminary study, additional research is suggested to determine the effect of oil drain slot configurations, axial and radial shroud clearances, and higher gear surface speeds on windage power loss. Additional work is also suggested to determine the sensitivity of windage power loss to oil temperature and oil flow. Windage power loss for meshed spur gears tested in both the shrouded and unshrouded configurations is shown to be more than double versus windage power loss for the same spur gears run individually in the same shroud configurations. Further study of the physical processes behind these results is needed to optimize gearbox shrouds for minimum windage power loss.

drag↗

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↗

NASA NTRS1992

Adaptive mesh strategies for the spectral element method

An adaptive spectral method was developed for the efficient solution of time dependent partial differential equations. Adaptive mesh strategies that include resolution refinement and coarsening by three different methods are illustrated on solutions to the 1-D viscous Burger equation and the 2-D Navier-Stokes equations for driven flow in a cavity. Sharp gradients, singularities, and regions of poor resolution are resolved optimally as they develop in time using error estimators which indicate the choice of refinement to be used. The adaptive formulation presents significant increases in efficiency, flexibility, and general capabilities for high order spectral methods.

Mavriplis, Catherine↗

NASA NTRS2011

Crop and Substrate Tests with Single Use Rooting "Pillows" for the VEGGIE Plant Growth Hardware

VEGGIE is a small plant production chamber built by ORBITEC. This chamber can be collapsed for easy stowage and deployed in orbit. It is designed for gravity independent operation, and provides 0.17 square m of crop growth area with three primary subsystems: an LED light panel, extendable transparent Teflon bellows to enclose the plants, and a wicking reservoir. VEGGIE would provide the capability for astronauts to grow fresh foods for dietary supplementation. Initial planting concepts tested with the VEGGIE included direct seeding or plug placement on the reservoir surface. These options had issues of salt accumulation and eventual toxicity if the reservoir was filled with nutrient solution, and hardware reuse was limited due to sanitation. In response a rooting packet or "pillow" concept was developed: single-use bags of media containing time release fertilizer with a wicking surface contacting the VEGGIE reservoir. Pillows being tested are small electrostatic bags with a Nitex nylon mesh side, each holding 100 mL of dry media. Six pillows fit in one VEGGIE unit; however pillow size could vary depending on crop selected. Seeds can be planted directly in pillows and planted pillows can be hydrated in space as desired. Our goals were to define optimal media and crops for an ISS mission scenario. Plant tests in pillows were performed in a controlled environment chamber set to habitat-relevant conditions, and capillary reservoir analogs were utilized. Media tested within pillows included: a commercial peat-based potting mix, arcillite (calcined clay), perlite: vermiculite, and peat-based: arcillite blends. Testing included 15 types of leafy greens, snow pea, radish, and herbs. Media performance was crop dependent, but generally plants showed the greatest growth in the peat-based: arcillite mixes. Crops with the best performance in pillows were identified, and testing is underway with select leafy greens examining plant and microbial load response to repeated harvest. We plan to use findings from previous flight testing with media to evaluate the effects of capillary flow from the reservoir to pillows in microgravity.

Massa, Gioia↗

NASA NTRS1992

Towards a theory of automated elliptic mesh generation

The theory of elliptic mesh generation is reviewed and the fundamental problem of constructing computational space is discussed. It is argued that the construction of computational space is an NP-Complete problem and therefore requires a nonstandard approach for its solution. This leads to the development of graph-theoretic, combinatorial optimization and integer programming algorithms. Methods for the construction of two dimensional computational space are presented.

Cordova, J. Q.↗

NASA NTRS1984

On the design of contractions and settling chambers for optimal turbulence manipulations in wind tunnels

The sensitivity of a moderate axisymmetric contraction of turbulence to upstream conditions is parametrically investigated in terms of turbulence intensities and integral length scales. Semi-empirical correlations are derived to characterize the development of turbulence intensities and integral length scales downstream of typical wind-tunnel turbulence manipulators. A new approach is described, permitting wind-tunnel designers to select the characteristic mesh of the turbulence manipulators, a well as the distance from them to the contraction, in order to obtain certain required turbulence characteristics in the test section at the exit of the contraction. The design charts strongly suggest that it may not be possible to achieve small scales and low intensities simultaneously, when using a contraction ratio of nine or larger. The results also confirm that the rapid distortion theory is only valid, with a proper viscous dissipation correction, up to the 'critical point' of a contraction. At that point, the scales of the various components of the velocity are equal and intercomponent transfer from the lateral to the streamwise velocities commences.

Nagib, H. M.↗