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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 55 records · Page 3
All sourcesNASA NTRSDOE OSTI
DOE OSTI2026

Bio-inspired alula-based winglet design for enhanced heat transfer in high temperature fin-and-tube heat exchangers

Fin-and-tube heat exchangers (FTHEs) are widely used for high-temperature flue-gas heat recovery, but their performance is often limited by wake regions and non-uniform fin-surface temperatures. This study proposes and numerically evaluates four bio-inspired longitudinal vortex generator (VG) configurations in a high-temperature FTHE with flue-gas inlet temperature ∼1230 K: double-delta, curved double-delta, alula, and a new curved-alula geometry. The reference fin is not hydraulically plain; it already incorporates leading-edge separation columns and convex protrusions, so the alula-type winglets are assessed as downstream add-ons acting on a strongly disturbed flow. In a second step, perforations (one, two and three circular holes) are introduced into the curved-alula VGs to further tailor the flow field. Three-dimensional simulations with the Shear Stress Transpor (SST) $k - ω$ model, temperature-dependent flue-gas properties and conjugate conduction are carried out for gas-side Reynolds numbers $Re_g ≈ 8.0$ x $10^2 - 3.6$ x $10^3$ (mass flow rates 0.5 – 2.5 g/s), and the designs are compared in terms of surface heat flux, Nusselt number, friction factor and hydrothermal performance factor (HTPF). For this already-promoted fin, the additional downstream winglets provide moderate, incremental hydrothermal gains. At the highest Reynolds number, the best non-perforated design (curved-alula) increases surface heat flux from 1630.9 to 1794.7 kW/m² (∼ 10 % gain) and the Nusselt number from 227.6 to 242.6 (∼ 7 % gain), while the friction factor rises from 0.26 to about 0.30, yielding HTPF values close to unity (∼ 0.9 – 1.0). Introducing circular perforations into the curved-alula winglets acts mainly as a wake-bleeding refinement: the three-hole configuration provides a heat flux of 1824.7 kW/m² and a pressure drop of 127.9 Pa, with HTPF in the range ∼ 1.03 – 1.14 and a small (∼ 1 – 3 %) improvement over the solid curved-alula design. Flow-field analysis shows that the perforated curved-alula VGs shrink tube-wake regions, thin the thermal boundary layer and homogenize the fin-surface temperature (outlet-gas temperature ∼ 510 – 520 K and fin-surface temperature ∼ 420 – 421 K for the three-hole case). An optimal flue-gas mass flow rate of ∼ 1 g/s ($Re_g ≈ 1.5$ x $10^3$) is identified, beyond which additional heat-transfer gains are offset by rapidly increasing pressure losses. Overall, the results highlight that initial fin geometry and VG placement are as important as VG shape: alula-based winglets are expected to yield larger relative gains on simpler flat-fin layouts or when positioned closer to the fin leading edge and tube

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2025

High-Fidelity CFD Assessments of Flow Resistance in a 61-Pin Wire-Wrapped Assembly with Partially Blocked Channels

The examination of thermal-hydraulic behaviors in wire-wrapped rod bundles continues to be an active area of research. The sodium fast reactor, a prominent candidate in next-generation nuclear designs, utilizes a hexagonal configuration of wire-wrapped fuel pins. Here, the potential for channel blockage within this compact arrangement poses a significant safety challenge, spurring a number of recent experimental and computational investigations to evaluate its impact on flow and heat transfer. The present work aims to benchmark the high-fidelity NekRS computational fluid dynamics (CFD) solver in predicting the pressure drops associated with substantial blockages, using available experimental data as a reference. A 61-pin wire-wrapped fuel assembly with two flow blockage configurations has been simulated and investigated at a range of low to moderate Reynolds numbers (487 ≤ Re ≤ 14 600). The NekRS solver demonstrates an exponential reduction of spatial discretization error with increasing polynomial order. The high level of agreement between the numerical results and measured data confirms the accuracy and consistency of the present numerical approach. This benchmark study establishes the capability of NekRS to perform reliable hydrodynamic simulations for sodium fast reactor applications and supports its use in design, licensing, and safety analyses.

CFD Benchmarking↗
DOE OSTI2024

Flow maldistribution in plate heat exchangers – Impact, analysis, and solutions

Plate heat exchangers are commonly used in various industrial applications, such as refrigeration, air conditioning, heat pumps, powerplants, and chemical industries. Plate heat exchangers are well known for their superior heat transfer performance, compactness, and low refrigerant charge. Despite offering several advantages, they suffer from flow maldistribution issues. The flow maldistribution can deteriorate both the heat transfer and pressure drop performance, ultimately resulting in a lower system efficiency where plate heat exchangers are deployed. The flow maldistribution issues become more pronounced when the heat exchanger size is relatively large and the number of plates is higher, limiting the deployment of plate heat exchangers in larger industrial systems. Consequently, analyzing and understanding the flow maldistribution behavior in plate heat exchangers and finding ways to mitigate flow maldistribution related issues become essential topics of interest. Further, this review aims to address the effect of flow maldistribution on plate heat exchanger characteristics. First, the experimental and numerical works on flow maldistribution under single-phase and two-phase conditions are detailed. Subsequently, the end-channel and end-plate effects are discussed. Then, the methods to mitigate flow maldistribution in plate heat exchangers are outlined. Finally, based on a thorough literature survey and industrial requirements, future research directions are recommended.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2024

High-Temperature Fe-Based Fischer–Tropsch Synthesis: Experimentally Validated Kinetic Models Implemented at Pellet and Reactor Scales

Pellet- and reactor-scale models for Fischer–Tropsch synthesis (FTS) with a Fe–K/silica catalyst were developed to investigate the sensitivity of the hydrocarbon products and carbon dioxide selectivity to process conditions and feed composition at high temperature (350–400 °C), moderate pressure (1–10 bar), and a range of H 2 /CO ratios (3–1). The major objective of this paper is to develop, validate, and evaluate a high-temperature FTS model that is then used to assess the feasibility of process integration with syngas production. Since there is limited kinetic data available, in literature at these conditions, bench-scale reactor tests were conducted to obtain operational data for parameter fitting of kinetic expressions used in the model. This resulting kinetic model demonstrated agreement with the experimental data with an R 2 of 0.97 to the testing data set and, thus, was feasible to apply at pellet and reactor scales. Here, multiple pellet sizes were modeled to detail the role of transport limitations as the sphere’s diameter approached and exceeded 1 mm. Application of the reactor model indicated that hydrocarbon selectivity depended strongly on temperature, whereas the ratio of olefin to paraffin products decreased with increasing temperature, pressure, and H 2 /CO ratio. Product selectivity was not sensitive to the conversion of carbon monoxide. Furthermore, the roles of the pressure and H 2 /CO ratio were closely coupled. At a H 2 /CO ratio of 3, only slight variations in selectivity occurred over a pressure range of 1–20 bar, whereas at a ratio of 1, selectivity could vary by as much as 30% over the same pressure range. At pressures below 5 bar and temperatures above 350 °C, minimal selectivity to heavy hydrocarbons (C 12+ ) is obtained, and selectivity to midrange products (C 5–11 ) rapidly declined as pressure dropped below 5 bar, which indicated that an operational pressure of at least 5 bar is needed to achieve reasonable yields in this temperature range. These results, while tentative, provide guidelines for further experimentation and evaluation of integrated FTS processes.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2025

Utilization of Existing Pipelines in Hydrogen Transport: Literature Review Report

This report critically reviews the flow behavior of hydrogen-natural gas (H 2 -NG) mixtures in pipelines and examines the critical factors of hydrogen integration into existing natural gas infrastructure. It addresses the choking behavior characterized by velocity increase and pressure drop, as well as the effects of flow restrictions and pressure losses during hydrogen transport. Computational and analytical models are used to investigate these effects, and their effects on thermodynamic properties and system performance are evaluated. The study also reviews the energy efficiency and flow dynamics of hydrogen and methane-hydrogen mixtures and optimizes the hydrogen flow rate. In addition, the effects of these mixtures on the flow characteristics are discussed in detail, with special emphasis on the compressibility factor (z factor) and fluid properties based on equations of state for hydrogen-natural gas mixtures. The study also analyzes the mixture ratios and highlights the thermophysical properties, flow dynamics, and hydrogen-blended natural gas application potential. These investigations assess flow stability, material interactions, and operational feasibility of transporting hydrogen mixtures through natural gas pipelines, which contribute to developing sustainable and efficient energy systems.

08 HYDROGEN↗
DOE OSTI2026

Computational flow modeling of triply periodic minimal surfaces as feed channel spacers in ultra-high pressure reverse osmosis applications

Triply periodic minimal surfaces (TPMS) are a special class of mathematical surfaces characterized by a high surface area-to-volume ratio. They have generated considerable interest in fields such as acoustics, heat transfer, and membrane-based filtration processes. This study evaluates the performance of four different TPMS designs—Schoen Gyroid, Schoen Crossed Layers of Parallels (CLP), Schoen Transverse Crossed Layers of Parallels (tCLP), and Schwarz-Primitive—when used as feed channel spacers under ultra-high pressure reverse osmosis (UHPRO) conditions, at approximately 200 bar. Our experimentally validated computational fluid dynamics model reveal different flow patterns within the feed channels for each of the four TPMS designs, leading to varying hydrodynamic and permeation properties. Under the simulated UHPRO conditions, the Gyroid and tCLP designs yield up to a 23% increase in average permeate velocity and a 14% reduction in average membrane-surface concentration relative to a non-woven spacer of the same porosity. Furthermore, the enhanced performance comes with an increased feed channel pressure drop, although it only constitutes less than 4% of the operating pressure when extrapolated for a meter-long membrane module. Additionally, the study analyzes the effects of varying inlet velocity and spacer porosity on membrane performance. Overall, this research provides valuable insights into the potential use of TPMS spacers in UHPRO applications.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Extension of Clad Damage Propagation Model for Fission Gas Dispersal and Two-Phase Flow Effects in MOOSE SubChannel Module

This report presents an extension of the Clad Damage Propagation (CDAP) model implemented in the MOOSE SubChannel Module (SCM) to capture post-failure fission-gas dispersal and two-phase flow effects in sodium-cooled fast reactor assemblies. The extended model tracks discharged gas axially and radially, computes channel-averaged flow quality and void fraction using a Lockhart–Martinelli framework, evaluates two-phase frictional pressure-drop multipliers, determines inlet mass-flow degradation under fixed core pressures, and applies an intensified-void-based heat-transfer degradation to affected fuel pins. Radial plume expansion is parameterized using mineral-oil jet experiments mapped to sodium conditions via Reynolds–Weber similarity. Implementation details are documented, along with the new methods and user inputs needed to control plume mapping and two-phase behavior. Demonstration simulations for 19- and 37-pin bundles show that breach size and inlet velocity strongly influence propagation potential: small breaches (≤0.5 mm) produce limited degradation while larger breaches (~1 mm) can drive oscillatory temperature spikes and enhanced failure propagation, especially at higher velocities. These results demonstrate that the extended CDAP model provides a more complete framework for quantifying cladding damage propagation and evaluating propagation potential in transient scenarios. The approach remains computationally efficient, consistent with subchannel-level analysis, yet incorporates sufficient physics to bridge localized post-failure effects with bundle- and assembly-scale degradation.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2024

Additively Manufactured Molten Salt to Supercritical Carbon Dioxide Heat Exchanger

Design, fabrication, and experimental characterization of the performance of a molten salt (MS)-to-supercritical carbon dioxide (sCO 2 ) heat exchanger (HE) for concentrating solar power (CSP) applications using laser powder bed fusion (LPBF) additive manufacturing (AM) of nickel-based superalloys is presented in this report. The hypothesis is that such additively manufactured HEs will result in a monolithic, compact, low-pressure drop HE that is durable under cyclic operation at high temperature and high pressure in a corrosive salt environment. Two nickel-based superalloys were considered in the project- Haynes 230 (H230) and Haynes 282 (H282). Process windows for LPBF AM were established to provide dense low porosity parts for both alloys. Creep tests results on heat treated AM H230 and H282 samples showed that the AM fabricated specimens were as robust as the wrought specimens and showed no deficit in creep strength at high temperatures. Haynes 282 was down selected for the HE fabrication based on better dimensional tolerance, better corrosion resistance to chloride salt, and higher creep strength.

14 SOLAR ENERGY↗
DOE OSTI2024

Evaluation of Mechanical and Thermomechanical Water Vapor Compression Techniques for Enabling High Temperature Lift Hydration-Based Chemical Heat Pumps

Achieving high temperature lifts (>200 K) via a chemical heat pump based on salt hydration/dehydration reactions requires the transport of water vapor from low to high pressure. Alternative compression approaches require condensing of low-pressure water vapor, pumping of liquid water, and subsequent evaporation when the low-side pressure corresponds to sub-ambient water saturation temperatures. Thus, this study compares four steam compression methods for use within a chemical heat pump system based on a reversible calcium oxide hydration/dehydration reaction with a temperature lift from 350 °C heat to >600 °C. Purely mechanical and thermochemical/mechanical compression technologies are considered. A parametric study of maximum allowable temperature, the isentropic efficiency of mechanical compressors, the effectiveness of heat exchangers, and the assumed allowable heat exchanger pressure drop is conducted to determine the mechanical and thermal energy consumed per kilogram of compressed steam. The system complexity in terms of the number of main system components, maximum pressure ratio, and maximum allowable temperature is estimated. Model results show an absorption-based steam compressor has the highest exergetic efficiency for the required chemical heat pump required conditions. As a result, this system configuration was then experimentally demonstrated to illustrate the impact of system performance on component effectiveness.

Advanced reactors↗
DOE OSTI2025

Advancing 1D thermo-hydraulic tools for large cryogenic facilities

The Cryogenic Division at Fermilab develops large-scale cryogenic systems for particle accelerators and superconducting test facilities. To support design and diagnostics, a Python-based code was created to calculate pressure drops in components such as valves and pipes. This paper presents recent enhancements to the code, including new heat transfer functions that improve the accuracy of thermal and hydraulic predictions. The first application models pressure and temperature changes in PIP-II relief pipes, aiding pipe sizing and protecting relief valves. The second example analyzes heat load evolution in a pipe carrying sub-atmospheric helium, helping interpret temperature sensor data and understand gas return behavior to cold compressors. These improvements significantly expand the tool’s capabilities, offering a practical resource for designing and troubleshooting cryogenic systems under dynamic thermal and flow conditions.

Beckwith, Rosalyn [Fermilab]↗
DOE OSTI2025

Advancing 1D thermo-hydraulic tools for large cryogenic facilities

The Cryogenic Division at Fermilab develops large-scale cryogenic systems for particle accelerators and superconducting magnet test facilities. To support design and diagnostics, a Python-based code was created to calculate pressure drops in components such as valves and pipes. This paper presents recent enhancements to the code, including new heat transfer functions that improve the accuracy of thermal and hydraulic predictions. The first application models pressure and temperature changes in Proton Improvement Plant PIP-II relief pipes, aiding pipe sizing and protecting relief valves. The second example analyses heat load evolution in a pipe carrying sub-atmospheric helium, helping interpret temperature sensor data and understand gas return behavior to cold compressors. These improvements significantly expand the tool's capabilities, offering a practical resource for designing and troubleshooting cryogenic systems under dynamic thermal and flow conditions.

Beckwith, R. [Fermilab]↗
DOE OSTI2026

Predicting roughness effects in additively manufactured coolant channels with helical enhancements

Additive manufacturing (AM) is a promising technique for fabrication of complex geometries such as those expected to be utilized in the blanket, first wall, and divertor. In the case of cooling, metallic AM may be exploited to embed geometric enhancements (ribs, rifling, etc.) to improve cooling performance. However, due to the roughness of these unfinished internal AM surfaces, prediction of thermal hydraulic performance in such channels is difficult. In this work, we consider a methodology for predicting pressure drop and heat transfer in AM channels containing helical enhancements (e.g. helical ribs, twisted tapes) that allows the incorporation of roughness data through conventional pipe flow correlations. This methodology is tested using experimental friction factor and heat transfer coefficient data from high-pressure helium coolant flow measurements in AM stainless steel tubes fabricated by laser powder bed fusion. Both a featureless AM tube and one containing helical ribs were considered alongside a conventionally manufactured smooth tube. The AM surface roughness is obtained by profilometry and used to predict an equivalent sand-grain roughness, with this equivalent roughness confirmed through AM featureless tube measurements. Under the proposed methodology, this roughness information is incorporated into predictions of friction factor and Nusselt number for the rifled tube. Furthermore, these predictions agree well with experimental data across a large range of Reynolds numbers, encouraging the use of this methodology for thermal hydraulic analysis of similar systems and design of future coolant channel geometries.

Additive manufacturing↗
DOE OSTI2025

Multi-physics Topology OPtimization and Additive Manufacturing for High-temperature Heat Exchangers

This research significantly advances the understanding of high-temperature heat exchanger design through an integrated approach that combines topology optimization (TO), triply periodic minimal surface (TPMS) structures, additive manufacturing (AM) and thermohydraulic testing. Each of these components contributes uniquely to a unified, high-performance design, fabrication and testing workflow. Topology optimization serves as the foundation of the design methodology by providing a systematic way to determine the most effective material layout for separating hot and cold fluids while maximizing thermal performance. The researchers introduced a novel three-material optimization framework using two density fields to represent hot fluid, cold fluid, and solid domains. This approach enables automated discovery of optimal shapes and flow paths that cannot be intuitively designed, especially under constraints imposed by manufacturing technologies. Furthermore, constraints such as minimal wall thickness and overhang angles were embedded into the optimization process, ensuring that resulting designs are not only thermally efficient but also manufacturable using modern additive techniques. In parallel, the study delves into the use of Gyroid-based TPMS geometries for constructing the core of the heat exchanger. TPMS structures are known for their high surface area, excellent fluid mixing capabilities, and minimal pressure drop characteristics. The researchers applied a data-driven modeling framework using Heteroscedastic Sparse Gaussian Process Regression (HSGPR) combined with genetic algorithms. This allowed for the rapid evaluation and optimization of key geometric parameters such as frequency, iso-value, and phase shift. The result was a set of Gyroid structures tailored for high heat transfer and low flow resistance, demonstrating clear improvements over conventional straight-channel designs. After the designing process, additive manufacturing played a critical role by turning these highly complex, optimized geometries into physical components. Utilizing Laser Powder Bed Fusion (LPBF) with Haynes 282, the study demonstrated the feasibility of fabricating these heat exchangers at high precision. Post-processing methods, including dilation-erosion operations, were applied to ensure local features adhered to self-supporting constraints. The fabricated structures were then subjected to thermohydraulic testing under conditions representative of supercritical CO 2 Brayton cycles, validating the predicted performance and confirming the viability of the full design-to-fabrication pipeline. Finally, thermohydraulic testing across the above studies served as a crucial experimental validation of advanced heat exchanger. Under consistent high-temperature and high-pressure conditions using supercritical CO 2 , the testing demonstrated that both TO and Gyroid-based TPMS designs significantly outperformed conventional straight-channel HXs. The TO design achieved a 115% increase in UA and NTU and a 27.6% boost in gravimetric power density, while the data-driven optimized Gyroid design delivered a 166% increase in UA and NTU and improved effectiveness from 68.7% to 86.1%. These results validate the simulation models, confirm the manufacturability of complex geometries under AM constraints, and provide key insights into design-performance trade-offs, thereby advancing the development of high-efficiency, compact heat exchangers for extreme environments.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Print-and-Plate Architected Electrodes for Electrochemical Transformations Under Flow

Flow cell electrodes are typically composed of porous carbon materials, such as papers, felts, and cloths. However, their random architecture hinders the fundamental characterization of electrode structure-performance relationships during in situ operation of porous electrochemical flow systems. This work describes a “print-and-plate” method that combines direct ink writing of micro-periodic lattices with a two-step metal plating process that converts them into highly conductive (sheet resistance 40 mΩ sq -1 ) electrodes. Their operando performance is assessed in an anthraquinone disulfonic acid half-cell using widefield electrochemical fluorescence microscopy, where output current and fluorescence intensity are in excellent agreement. The pressure drop associated with flow through three electrode designs is determined via simulations from which the most efficient design is identified and manufactured via print-and-plate. Confocal fluorescence microscopy is then used to create a 3D map of the state of charge (SOC) inside this print-and-plate electrode. The experimental state of the charge map is in good agreement with computational predictions. The rapid design, simulation, and fabrication of print-and-plate electrodes enable fundamental investigations of how architected porosity affects electrochemical performance under flow.

3D-printing↗
DOE OSTI2024

Direct air capture with amino acid solvent: Operational optimization using a crossflow air‐liquid contactor

Direct air capture (DAC) is a negative emission technology for removing CO2 from the atmosphere to maintain the CO 2 level within a reasonable range so as to address greenhouse effects. In this study, the operational optimization of lab-scale DAC has been investigated using a crossflow air-liquid contactor loaded with a three dimensionally printed Gyroid packing structure and a potassium sarcosinate solvent. The effects of various parameters, including feed air flow rate, liquid solvent flow rate, contactor geometry, and ambient temperature, are examined. The results demonstrate that the Gyroid packing design achieves comparable CO 2 capture performance to conventional packed beds but with a significantly lower pressure drop of up to 77.8%, suggesting its potential as an efficient and cost-effective solution for gas–liquid contactors in DAC. Additionally, the study explores the climate impact on CO 2 capture performance and finds that as the air temperature increases from 35 to 95°F at a fixed relative humidity of 80%, the CO 2 capture rate increased from 23.2% to 46.8% with better stability. The research highlights the importance of optimizing contactor design and operational conditions to improve the CO 2 capture rate and feasibility of DAC systems as a negative emission technology for addressing greenhouse effects.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2025

Thermo-hydraulic steam pipe models for district heating simulations: Simplifications to balance accuracy and simulation speed

Steam piping networks are essential for optimizing performance in industrial processes and district heating systems. However, dynamic models that balance thermo-hydraulic accuracy with computational efficiency remain limited. In response, this paper presents a new discretized steam pipe model based on the plug flow approach, capturing key thermo-hydraulic behaviors while simplifying steam phase change processes. Implemented in Modelica, the model accurately calculates temperature and pressure distributions along steam pipelines. To improve computational efficiency for district-scale simulations, five model simplifications are introduced: lumped thermo-hydraulic functions, empirical correlations, fluid state approximations, steady-state dynamics and inclusion of flow derivatives. These simplified models achieve 85%-98% accuracy in predicting pressure drop and condensation losses, including dynamic condensate behavior during pipe warm-up—a factor often overlooked in existing models. The models support diverse network configurations, scaling effectively to systems with multiple distribution pipes and connected building loads. Discrete models provide detailed insights but exhibit a cubic increase in simulation time as the network scales by N connected building O(N 2.42 ). In contrast, lumped models simulate 10–28 times faster than discrete, offering quadratic scaling of simulation time O(N 1.73 ). However, they still require 6 times more computation time than a lossless network, highlighting the inherent computational challenges of modeling compressible fluid flow. In conclusion, the steady-state lumped variant, with its near-linear scalability in computational time O(N 1.01 ), emerges as an efficient solution for preliminary design evaluations and extensive parametric studies.

15 GEOTHERMAL ENERGY↗
DOE OSTI2025

Butterfly valve performance factors using the multiphysics object oriented simulation environment

Butterfly valves are typically used in nuclear reactors to control incompressible fluid flow with high inlet velocities. Performance factors for butterfly valves include the pressure drop across the valve and the loss coefficient from which hydrodynamic torque and flow coefficients can be computed. This work explores a computational fluid dynamics approach for butterfly valve performance factors using the open-source Multiphysics Object Oriented Simulation Environment (MOOSE) framework. While MOOSE is often used in the nuclear energy modeling and simulation community for simulations ranging from fuel characterization to heat pipe simulation, this work employs the MOOSE open-source Navier–Stokes solver capability for simulating butterfly valve performance factors and compares those to experimentally measured results from the Advanced Test Reactor at Idaho National Laboratory at Reynolds numbers in the order of 10 6 for the partially opened configuration. The MOOSE framework results are compared against experimentally measured butterfly valve performance factors across five valve opening angles using meshes with order 10 4 – 10 5 elements. This validation serves to enable MOOSE-based multiphysics simulations incorporating the open-source Navier–Stokes module.

97 - MATHEMATICS AND COMPUTING↗
DOE OSTI2025

CFD modeling of turbulent air flow in self-heated gyroid TPMS structures: Thermal-hydraulic performance and validation

The application of mathematically derived geometries, such as triply periodic minimal surface (TPMS) lattices, has garnered significant interest across various fields, including the nuclear sector, due to their superior thermal-hydraulic characteristics for heat transfer compared to traditional plain or finned tubes. Here, this study validates a computational fluid dynamics (CFD) model, evaluates different turbulence models and CFD model settings, and performs uncertainty quantification to provide a comprehensive analysis. Despite extensive research on CFD modeling of TPMS lattices, such as gyroid and diamond geometries, there is a notable lack of publicly available literature providing comprehensive details on numerical analysis aspects, including convergence and methodological best practices. This study embarks on a benchmark analysis of a gyroid geometry to evaluate its thermal-hydraulic performance under turbulent flow conditions and scrutinize various CFD model configurations. The main contributions of this work include validating the CFD model, assessing and comparing different turbulence models, and enhancing pressure drop and temperature prediction capabilities. The results aim to support the development of methodologies needed to benchmark and enhance numerical analysis techniques for TPMS lattices. This work seeks to complement the existing body of knowledge, support the development of TPMS reactor concepts, and improve best practices for CFD modeling of TPMS lattices, ultimately advancing methodologies to support future applications in this domain.

22 - GENERAL STUDIES OF NUCLEAR REACTORS↗