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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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47 records · Page 3
All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

Air-to-Liquid Heat Exchanger Fabricated Using Deposition-Based Additive Manufacturing Processes

Abstract This work describes the use of deposition-based additive manufacturing (AM) techniques to fabricate air-cooled, two-fluid heat exchangers. The project focused on a Heating, Ventilation and Air Conditioning application and used an industry-standard copper/aluminum heat exchanger manufactured with conventional technology as the basis for assessing performance. The manufacturing constraints associated with using deposition-based AM technology for this application include the need for a continuous tool path within each build layer that allows uninterrupted extrusion and therefore defect-free water channel walls that correspond to a reliably leak-tight heat exchanger. A geometry that respects these constraints was developed, simulated, optimized and finally manufactured and tested. The material used was a composite of polymer filled with conductive flakes in order to provide high conductivity in the direction that heat must flow in this heat exchanger, across the wall separating the fluids. The measured performance for several test coupons matched the predicted performance and the test coupons exhibited performance that approach and in some cases exceeds conventional technology

Engineering↗
DOE OSTI2020

The role of edge resonant magnetic perturbations in edge-localized-mode suppression and density pump-out in low-collisionality DIII-D plasmas

Two-fluid nonlinear MHD simulations using the TM1 code demonstrate that the formation of magnetic islands at the top and bottom of the H-mode pedestal, together with the strong screening of resonant fields in the gradient region of the pedestal, can account for ELM suppression and density pump-out by n = 2 resonant magnetic perturbations (RMPs) in low-collisionality DIII-D ITER similar shape (ISS) plasmas. Using experimentally relevant transport coefficients, neoclassical resistivity, electron collisionality, and RMP amplitudes, nonlinear MHD simulations reproduce the observed level of density reduction (density pump-out) in DIII-D due to the formation of narrow magnetic islands in the resistive foot of pedestal. For large amplitude RMPs ( B r / B t > 1 × 10 -4 ) simulations predict resonant field penetration and resulting in pressure reduction at the top of the pedestal, consistent with experimental observations at the onset of ELM suppression. The predicted reduction in the height and width of the pedestal by magnetic island enhanced collisional transport provides a quantitative mechanism for the stabilization of the peeling-ballooning mode (PBM). Importantly, these simulations predict strong screening of resonant fields in the steep gradient region of the pedestal due to strong E × B rotation and diamagnetic flows. Yet, if the plasma resistivity is made artificially larger (~ 10X) than neoclassical, the simulations predict magnetic stochasticity throughout the plasma edge and the collapse of the pedestal due to the reduction in the penetration threshold with increasing resistivity. A scaling relation for resonant field penetration at the pedestal top, using several hundred nonlinear simulations, reproduces the density and E × B rotation dependence of the ELM suppression threshold observed in DIII-D. Simulations using ITER model equilibria indicate that the penetration threshold at the top of the ITER pedestal will be lower than in DIII-D due to the anticipated lower perpendicular flow velocities in ITER, resulting in the weaker screening of resonant fields.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2025

Combined Influence of Rotation and Scrape-Off Layer Drifts on Recycling Asymmetries in Tokamak Plasmas

Coupled 2D fluid-kinetic simulations of a DIII-D high confinement tokamak plasma show that plasma rotation coupled with drift effects near the plasma edge play a significant role in the creation of the observed poloidal distribution of neutrals. It is observed that including either drift or rotation effects enhances particle flux at the inner target in the case of ion 𝐵×∇𝐵 drift toward the 𝑋-point. However, the particle flux asymmetry is significantly higher with the combination of drifts and rotation than either effect alone. The heightened particle flux asymmetry allows for improved simulation of the strong in-out asymmetry of the Lyman-𝛼 brightness profiles measured in the experiment. Enhancement of radial transport of parallel momentum changes the upstream scrape-off layer flow pattern, increasing the fraction of deuterium flux that reaches the inboard divertor entrance while lowering that which arrives at the outboard. In conclusion, this Letter indicates that by combining drifts, rotation, and viscous coupling, existing boundary plasma models can achieve a satisfactory agreement with experimentally measured neutral asymmetries.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2021

Comprehensive framework for data-driven model form discovery of the closure laws in thermal-hydraulics codes

The two-phase two-fluid model is a basis of many thermal-hydraulics codes used in design, licensing, and safety considerations of nuclear power plants. Thermal-hydraulics codes rely on the closure laws to close the system of conservation equations and describe the interactions between phases. These laws, derived from years of experimental investigations, are semi-empirical correlations that lack generality and have a limited range of applicability. Increase of computational power, availability of new experiments, and development of high-fidelity simulations has increased the number of validation data. The discrepancies between the code predictions and the validation data are a great source of knowledge. Missing physics that are not included in the model but are important for the considered phenomena can be discovered by propagating the information from the experimental results through the model. Furthermore, physics-discovered data-driven model form (P3DM) methodology integrates available integral effect tests and separate effects tests to determine the necessary corrections to the model form of the closure laws. In contrast to existing calibration techniques, the methodology modifies the functional form of the closure laws. Based on the functional form of the correction, the missing physics that were not included in the original model can be discovered. The methodology provides the alternative to the machine learning approach, in which the model is discovered in the form of the intractable black-box relation. In this work, the methodology was applied to the CTF subchannel code to improve the prediction of the two-phase flow phenomena.

42 ENGINEERING↗
DOE OSTI2022

Development of machine learning framework for interface force closures based on bubble tracking data

Interfacial force closures in the two-fluid model play a critical role for the predictive capabilities of void fraction distribution. However, the practices of interfacial force modeling have long been challenged by the inherent physical complexity of the two-phase flows. The rapidly expanding computational capabilities in the recent years have made high-fidelity data from the interface-captured direct numerical simulation become more available, and hence potential for data-driven interfacial force modeling has prevailed. In this work, we established a data-driven modeling framework integrated to the HZDR multiphase Eulerian-Eulerian framework for computational fluid dynamics simulations. The data-driven framework is verified in a benchmark problem, where a feedforward neural network managed to capture the non-linear mapping between bubble Reynolds number and drag coefficient and reproduce the void distribution resulting from the baseline model in the test case. The second focus is on utilizing the bubble tracking data set to form a closure for the bubble drag in the turbulent bubbly flow, in which the drag coefficient is set to be correlated with the bubble Reynolds number and the Eötvös number. Pseudo-steady state filtering in the Frenet Frame was carried out to obtain the drag coefficient from the turbulent bubbly flow data. The performance of the data-driven drag model is also examined through a case study, where improvement of model’s prediction near-wall is regarded necessary. In conclusion, discussion and further plans of investigation are provided.

42 ENGINEERING↗
DOE OSTI2023

Computational model development and validation of fuel dispersal phenomena

As the US nuclear industry is renewing efforts to extend the rod average burnup limits in existing pressurized water reactors, it becomes imperative to investigate the safety implications associated with high burnup fuel fragmentation and the potential dispersal of fragmented fuel into the reactor coolant system. Additionally, as there is a growing interest in transitioning to new nuclear fuel designs to accommodate higher fuel burnup levels, it becomes essential to conduct studies on fuel behavior during design basis accident scenarios, particularly during a postulated loss-of-coolant accident, in order to ensure the safe operation of light-water reactors. The present study develops a computational model to simulate the complex three-phase flow of the fuel dispersal phenomena that occur following a breach in the cladding, when the stream of solid fuel particles and carrier fission gas stream may interact with the surrounding liquid medium. Furthermore, the proposed framework considers the solid phase as discrete Lagrangian particles while the interpenetrating gas–liquid continuum is modeled using a Eulerian framework. The developed simulation framework is validated with experimental results performed in a separate-effect test facility by comparing predicted particle settlement locations with the experimental observations reported in the literature. Key highlights of this study include the interpretation of the high-pressure boundary conditions and the three-phase flow coupling strategy. Also discussed are the gas–liquid hydrodynamics and the behavior of particles as they are transported through the gas and liquid phases.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2026

Filament extension atomizers: A study of integration potential into spray dryers for high-viscosity and non-Newtonian fluids

Filament extension atomizers (FEAs) are an emerging class of spray nozzles designed to atomize high-viscosity and non-Newtonian fluids that are challenging for conventional pressure or two-fluid nozzles. In this study, we investigate the influence of roller geometry, surface velocity, roller material, and fluid rheology on the atomization performance of FEA systems using concentrated whey protein suspensions (50–70 wt. %). Extensional and shear rheology experiments, along with high-speed imaging and particle image velocimetry, reveal that filament breakup dynamics are governed by competition between inertial, capillary, and viscoelastic stresses. High roller rotational velocity leads to narrower spray cones, contradicting rheology experiments and suggests a significant inertial contribution to filament breakup. Smaller rollers operating at the same rotational velocity led to broader spray cones consistent with expectations. An FEA nozzle was integrated into a conventional dryer producing particles in the 100 μm range. Results suggest that FEA technology enables atomization of highly viscous fluids at industrially relevant spray cone angles similar to those generated by pressure nozzles, offering a pathway to improve energy efficiency in spray drying by enabling higher solids loading feedstocks. Furthermore, these insights provide critical guidance for optimizing FEA nozzle designs and process parameters across a range of applications.

Energy efficiency↗
DOE OSTI2020

Progress Toward Simulating Departure from Nucleate Boiling at High-Pressure Applications with Selected Wall Boiling Closures

Recently, a Eulerian-based two-fluid computational fluid dynamics (CFD) framework with a wall heat flux partitioning approach has been intensively investigated for departure from nucleate boiling (DNB) simulation under the U.S. Department of Energy–funded Consortium for Advanced Simulation of Light Water Reactors (CASL) program. Understanding of the DNB characteristics over a range of pressurized water reactor–like operating conditions and accurate prediction of boiling crisis in the nuclear power system have been grand challenges because of the large impact of DNB on reactor safety and operational economics. The ultimate goal of this task in the CASL program is to introduce a robust multiphase CFD–based DNB modeling framework that is capable of characterizing an entire boiling history in which the wall boiling mode experiences the following through multiple stages of heat transfer mode: (1) single-phase convective heat transfer, (2) nucleate boiling heat transfer, and (3) identification of the departure of nucleate boiling. To validate the CASL boiling model, we have benchmarked simulated DNB over three different flow channel configurations (pipe flow, 5 × 5 fuel bundle with mixing vane tests, and 5 × 5 fuel bundle without mixing vane tests) against experimental measurements, and the validation result with open literature is reported. The DNB detection criteria in the simulation are checked by monitoring the peak wall temperature, wall dryout factor, and net energy balance. In addition to the DNB performance test, some preliminary sensitivity results on closure model selection are reported to address the prediction capability of local void profile against measurements. The boiling simulation tested in this study exhibits a maximum deviation of 24% from the measured DNB value in a high-pressure (i.e., 138 bars) subcooled pipe flow test. The ranges of operating conditions are as follows: 1650 to 2650 kg/m 2 ·s for mass flux and 8.5 to 96 K for subcooled inlet temperature. The deviation is even reduced to 7% when the subcooled temperature is less than 40 K. Besides accuracy, base practice guidelines for DNB detection criteria are tested by monitoring three simulation variables: (1) maximum wall temperature, (2) wall dryout factor (i.e., K-value), and (3) energy balance. Numerical robustness of DNB simulation is largely achieved in most of the validation test except for a few high subcooled test cases.

42 ENGINEERING↗
DOE OSTI2021

Local wave-number model for inhomogeneous two-fluid mixing

We analyze the local wave-number (LWN) model, a two-point spectral closure model for turbulence, as applied to the Rayleigh-Taylor (RT) instability, the flow induced by the relaxation of a statically-unstable density stratification. Model outcomes are validated against data from 3D simulations of the RT instability. In the first part of the study we consider the minimal model terms required to capture inhomogeneous mixing and show that this version, with suitable model coefficients, is sufficient to capture the evolution of important mean global quantities including mix-width, turbulent mass flux velocity, and Reynolds stress, if the start time is chosen such that the earliest transitions are avoided. However, this simple model does not permit the expected finite asymptote of the density-specific-volume covariance b. In the second part of the study, we investigate two forms for a source term for the evolution of the spectrum of density-specific-volume covariance for the LWN model. The first includes an empirically motivated calibration of the source to achieve the final asymptotic state of constant b. Here, the second form does not require calibration but, in conjunction with enhanced diffusion and drag captures the full evolution of all the dynamical quantities, namely, the mix-layer growth, turbulent mass-flux velocity, Reynolds stress, as well as the desired behavior of b.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
DOE OSTI2020

Statistical properties of homogeneous and isotropic turbulence in He II measured via particle tracking velocimetry

Despite being a quantum two-fluid system, superfluid helium-4 (He II) is observed to behave similarly to classical fluids when a flow is generated by mechanical forcing. This similarity has brought up the feasibility of utilizing He II for high Reynolds number classical turbulence research, considering the small kinematic viscosity of He II. However, it has been suggested that the nonclassical dissipation mechanism in He II at small scales may alter its turbulent statistics and intermittency. In this work, we report our study of a nearly homogeneous and isotropic turbulence (HIT) generated by a towed grid in He II. We measure the velocity field using particle tracking velocimetry with solidified deuterium particles as the tracers. By correlating the velocities measured simultaneously on different particle trajectories or at different times along the same particle trajectory, we are able to conduct both Eulerian and Lagrangian flow analyses. Spatial velocity structure functions obtained through the Eulerian analysis show scaling behaviors in the inertial subrange similar to that for classical HIT but with enhanced intermittency. The Lagrangian analysis allows us to examine the flow statistics down to below the dissipation length scale. Interestingly, abnormal deviations from the classical scaling behaviors are observed in this regime. Lastly, we discuss how these deviations may relate to the motion of quantized vortices in the superfluid component in He II.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2021

Deterministic Calibration of MFiX-PIC, Part 1: Settling Bed

The Particle-in-cell (PIC) numerical approach for modeling granular solids in fluid flow has gained significant interest in recent years. Valued for its often shorter time-to-solution, the PIC formulation relies on modeling statistical groupings of particles called parcels in cooperation with a solids stress model to affect local solids velocity. This is in contrast to the discrete element model (DEM) where every particle in a system is modelled individually and directly coupled to local solids velocity through Newtonian mechanics. The U.S. Department of Energy (DOE), National Energy Technology Laboratory (NETL) develops and maintains Multiphase Flow with Interphase eXchanges (MFiX), a collection of open-source computational fluid dynamics (CFD) solvers. Included in the MFiX suite are traditional two-fluid model (TFM) and DEM solvers, and a recently added PIC solver (NETL, 2021). In general, PIC methodologies offer an accuracy trade-off in lieu of computational speed; and therefore, it is important to assess the credibility of MFiX-PIC simulations. For this purpose, a systematic verification, validation and uncertainty quantification (VVUQ) effort was initiated at NETL to assess the new PIC solver

42 ENGINEERING↗