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DOE OSTI2022

Computational Fluid Dynamics Simulations to Predict Oxidation in Heat Recovery Steam Generator Tubes

Heat Recovery Steam Generators (HRSGs) are widely used across United States in combined cycle power plants to recover waste heat from the gas turbine (GT). HRSGs are used either to generate electricity or to produce process steam for industrial applications. The primary components of HRSG consists of a duct and a heat exchanger (HX). It is known across the power industry that the high temperature oxidation and ensuing exfoliation problem is a major cause for the damage of HX materials of HRSG. Alloys and/or coatings that can prevent or mitigate oxidation are very expensive, therefore they must be used or applied on the select regions of the HX tubes where the tendency of oxide formation is the highest. The main goal of this project is to identify such regions through Computational Fluid Dynamics (CFD) simulations. Therefore, in this work, we developed a CFD framework using commercial code StarCCM+ for the prediction of the fluid flow and heat transfer in a HRSG and associated oxidation inside the tubes of the HX. The developed CFD framework was verified and validated with experimental data before deployment. We also developed an innovative method to model the effect of the fins on the heat transfer and the pressure drop using a porous media model (PMM) approach to keep the mesh size within reasonable limits. After validation, we performed high-fidelity CFD simulations of a real-scale HRSG using the PMM, with High Performance Computing (HPC) resources of ORNL. From the simulation results, we acquired oxide thickness maps for all the tubes of the select HX sections of HRSG prone to oxidation. These oxide maps can inform regions of the HX tubes that requires oxide-resistant coatings, thereby guiding engineers for cost-efficient manufacturing of the HX that can combat oxidation in HRSGs.

36 MATERIALS SCIENCE↗

NASA NTRS1982

Burner liner thermal/structural load modelling

The objective of this program is to develop a thermal data transfer computer program module for the Burner Liner Thermal-Structural Load Modelling Program. This will be accomplished by reviewing existing methodologies for thermal data transfer and selecting three heat transfer codes for application in this program, evaluating the selected codes to establish criteria for developing a computer program module to transfer thermal data from the heat transfer codes to selected stress analysis codes, developing the automated thermal load transfer module, and verifying and documenting the module. The overall objectives of this thermal transfer module are that it handle independent mesh configurations, perform the transfer in an accurate and efficient fashion and that the total system be flexible for future improvements.

Maffeo, R. J.↗

DOE OSTI2022

Development of Numerical Model of Metal Foam with PCM for the Estimation of Effective Thermal Conductivity

Global warming due to climate change is a threat to humankind. Nuclear energy is one of the promising solutions to reduce fossil fuel usage. Nuclear energy can handle the base load, compensating for the volatility of renewable energy. If nuclear energy could achieve load following capability, the combination with renewable energy would be more suitable. Thermal energy storage (TES) is one of the options for enabling load following of nuclear reactors. The TES makes it possible to store surplus nuclear thermal energy and release it later as needed. In Idaho National Laboratory (INL), a new concept of latent heat TES integrated with high-temperature heat pipe has been proposed and is under development, which is called Heat pipe-Integrated Thermal Battery (HITB). HITB exchanges thermal energy between the reactor system and TES via heat pipe. The heat transferred to TES medium, made of phase change material (PCM), stores energy as sensible heat and/or latent heat. As PCM typically has poor thermal conductivity, however, various heat transfer enhancement techniques are required to achieve a rapid charging cycle. There are many techniques to enhance the heat transfer ability of TES medium such as disk, fin, and metal foam. Among them, metal foam is an appropriate option to enhance the heat transfer because it maximizes the heat transfer area through metal wicks. Metal foam is a lightweight metal structure that has a high porosity of over 0.9. The typical materials for metal foam are Aluminum, Copper, Nickel, and Silicon Carbide (SiC). Metal foam not only enhances heat transfer via conduction but also increases contact surface area. In the HITB design , the metal foam is being considered as one of the options to enhance the heat transfer of TES medium (PCM) [1]. To predict the enhanced thermal performance of TES, one should properly estimate the effective thermal conductivity of metal foam combined with PCM material or calculate heat transfer in distributed model. There are many experimental works that provides effective thermal conductivity of metal foam with various PCM [2,3]. Also, many theoretical models were developed based on the unit cell model of metal foam [4,5]. With a distributed model, on the other hand, detail heat transfer characteristics between metal foam and PCM material can be analyzed considering the geometry or buoyancy effect. However, due to the complex geometry of metal foam pores, the computational cost for three-dimensional modeling highly increases. Therefore, if metal foam structure can be modeled in simple and repetitive design, the computational cost would decrease Among the various metal foam models [2], lattice model is one of the simple and extendable design. The porosity and pores per inch (PPI) can be characterized by the size and spatial distance of lattice structure. If the three-dimensional metal foam model consists of lattice structure could properly estimate the heat transfer, which is characterized by effective thermal conductivity, it would be a good option to assess the thermal performance of metal foam with PCM. In this study, a three-dimensional numerical model was developed to simulate conductive heat transfer between metal foam and PCM. The three-dimensional lattice structure of square pillars was selected as a basic structure of the metal foam. The calculation result was characterized by the effective thermal conductivity of the whole domain. A sensitivity study was conducted for mesh size, domain size, and PPI to check whether the calculation result gives a converged result or not. Lastly, the effective thermal conductivity from the lattice model was compared with existing experimental data to validate the model result

25 ENERGY STORAGE↗

NASA NTRS2006

Accuracy Quantification of the Loci-CHEM Code for Chamber Wall Heat Transfer in a GO2/GH2 Single Element Model Problem

All solutions with Loci-CHEM achieved demonstrated steady state and mesh convergence. Preconditioning had no effect on solution accuracy and typically yields a 3-5times solution speed-up. The SST turbulence model has superior performance, relative to the data in the head end region, for the rise rate and peak heat flux. It was slightly worse than the others in the downstream region where all over-predicted the data by 30-100%.There was systematic mesh refinement in the unstructured volume and structured boundary layer areas produced only minor solution differences. Mesh convergence was achieved. Overall, Loci-CHEM satisfactorily predicts heat flux rise rate and peak heat flux and significantly over predicts the downstream heat flux.

West, Jeff↗

DOE OSTI2022

User-Oriented Improvements in the MOOSE framework in support of Multiphysics Simulation

The MOOSE Framework is a foundational capability used by NEAMS to create over 15 different simulation tools for advanced nuclear reactors. Due to this ubiquity, improvements to the framework in support of modeling and simulation goals are critical to the program. These improvements can take many forms including optimization, improved user experience, streamlined APIs, parallelism, and new capability. The work transcribed in the report was in direct support of the simulation tools and is already deployed or will be deployed in the coming months. The capabilities implemented were, in the same order as this report, chainable execution objects or executors, support for transfers between applications at the same level in a coupling scheme, support for boundary/subdomain restricted transfers, support for transfers between applications with different coordinate or unit systems, support for MOOSE applications in the NEAMS workbench, deployment of MOOSE application of the INL HPC OnDemand platform, addition of a triangular meshing library in libMesh and increased support of face variables.

97 MATHEMATICS AND COMPUTING↗

NASA NTRS1999

NCC: A Multidisciplinary Design/Analysis Tool for Combustion Systems

Liu, Nan-Suey↗

NASA NTRS2001

Overview of the NCC

A multi-disciplinary design/analysis tool for combustion systems is critical for optimizing the low-emission, high-performance combustor design process. Based on discussions between then NASA Lewis Research Center and the jet engine companies, an industry-government team was formed in early 1995 to develop the National Combustion Code (NCC), which is an integrated system of computer codes for the design and analysis of combustion systems. NCC has advanced features that address the need to meet designer's requirements such as "assured accuracy", "fast turnaround", and "acceptable cost". The NCC development team is comprised of Allison Engine Company (Allison), CFD Research Corporation (CFDRC), GE Aircraft Engines (GEAE), NASA Glenn Research Center (LeRC), and Pratt & Whitney (P&W). The "unstructured mesh" capability and "parallel computing" are fundamental features of NCC from its inception. The NCC system is composed of a set of "elements" which includes grid generator, main flow solver, turbulence module, turbulence and chemistry interaction module, chemistry module, spray module, radiation heat transfer module, data visualization module, and a post-processor for evaluating engine performance parameters. Each element may have contributions from several team members. Such a multi-source multi-element system needs to be integrated in a way that facilitates inter-module data communication, flexibility in module selection, and ease of integration. The development of the NCC beta version was essentially completed in June 1998. Technical details of the NCC elements are given in the Reference List. Elements such as the baseline flow solver, turbulence module, and the chemistry module, have been extensively validated; and their parallel performance on large-scale parallel systems has been evaluated and optimized. However the scalar PDF module and the Spray module, as well as their coupling with the baseline flow solver, were developed in a small-scale distributed computing environment. As a result, the validation of the NCC beta version as a whole was quite limited. Current effort has been focused on the validation of the integrated code and the evaluation/optimization of its overall performance on large-scale parallel systems.

Liu, Nan-Suey↗

DOE OSTI2022

Enabling Parallel Execution of System-level Simulations in SAM

This report summarizes the recent code updates related to “element ghosting” in SAM to enable the parallel execution of system-level simulations using multiple processors/cores. Unlike typical MOOSE-based applications, for system-level simulations, SAM mostly deals with a collection of discrete small pieces of meshes, and the connection of physics on these meshes are realized by using “connector” types of components/code structures, such as conjugate heat transfer and flow junctions. The required code implementation is to correctly mark the necessary ghost elements for each type of such components/code structures; thus, the lower-level libraries can correctly perform the necessary data transfer between processors (CPUs) when executed in parallel mode. After the code updates, SAM can now run system-level simulations in the parallel mode. The parallel execution capability was then tested with an ABTR input model with 23k DOFs. Significant speedup was demonstrated when the optimal number of CPUs were used in parallel mode. Future systematic studies on parallelization performance using additional test cases covering different physics/scenarios will be needed to provide additional insights into the scalability of SAM parallelization.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗

DOE OSTI2025

Transfer learning of neural surrogates on multifidelity groundwater simulations

Multifidelity data used in the paper published in Advances in Water Resources 206 (2025) 105140, https://doi.org/10.1016/j.advwatres.2025.105140 The code used to process the data is openly available on GitHub at https://github.com/Model-Reduction-and-UQ-Group/Transfer_Learning_K_reconstruction Computationally inexpensive surrogates of process-based models, such as deep neural networks, enable ensemble-based computations used in risk assessment, data assimilation, etc. However, generation of large datasets required to train a neural network can be as expensive as the ensemble simulations themselves. We ameliorate this challenge by using data from multifidelity (MF) groundwater simulations and transfer learning (TL) to reduce data generation costs while maintaining model accuracy. As a computational example, we train a deep convolutional neural network (CNN) to reconstruct permeability fields from saturation maps derived from a multiphase flow model. Starting with very low- and low-fidelity data generated on increasingly coarse meshes, we pretrain the CNN, followed by output-layer training and fine-tuning using only a limited number of high-fidelity samples. We demonstrate the surrogate’s robustness when interpreting low-quality inputs—such as interpolated maps or data affected by noise—which has strong implications for the applicability in practical hydrogeological scenarios. This multilevel MF-TL strategy achieves a favorable trade-off between computational efficiency and predictive accuracy, significantly outperforming high-fidelity-only approaches under the same computational budget.

Chiofalo, Alessia [University of Bologna] (ORCID:0↗

NASA NTRS1985

A computer analysis program for interfacing thermal and structural codes

A software package has been developed to transfer three-dimensional transient thermal information accurately, efficiently, and automatically from a heat transfer analysis code to a structural analysis code. The code is called three-dimensional TRansfer ANalysis Code to Interface Thermal and Structural codes, or 3D TRANCITS. TRANCITS has the capability to couple finite difference and finite element heat transfer analysis codes to linear and nonlinear finite element structural analysis codes. TRANCITS currently supports the output of SINDA and MARC heat transfer codes directly. It will also format the thermal data output directly so that it is compatible with the input requirements of the NASTRAN and MARC structural analysis codes. Other thermal and structural codes can be interfaced using the transfer module with the neutral heat transfer input file and the neutral temperature output file. The transfer module can handle different elemental mesh densities for the heat transfer analysis and the structural analysis.

Thompson, R. L.↗

NASA NTRS1985

A computer analysis program for interfacing thermal and structural codes

Thompson, R. L.↗

DOE OSTI2025

High-Fidelity CFD Simulation of Mixed Convection and Forced Convection in a Pebble Bed Test Reactor Core

The Hermes low-power [35-MW(thermal)] reactor will be built and operated by Kairos Power LLC (KP) to demonstrate its fluoride salt-cooled high-temperature reactor (FHR) technology. In the KP FHR, the reactor core is composed of randomly packed pebbles with TRISO fuel particles inside with FLiBe flow upward through the core acting as a coolant. Previous numerical and experimental studies have been limited to either a small-size bed or to a lack of detailed measurements for heat transfer. Here, to address the lack of high-fidelity heat transfer data in a real-size FHR core, in this study, we simulated a pebble bed core with 34 374 pebbles randomly packed, similar to the Hermes reactor's size. The core radius was 14 times that of the pebble diameter, while the core height was 45 times. In this work, we were particularly interested in a mixed convection regime, where buoyancy is important. Therefore, we performed several large-eddy simulations at different Reynolds numbers (160 to 1000) with gravitational force included. The spectral element computational fluid dynamics code NekRS with graphics processing unit acceleration was used for this study. The low-Mach number approximation was applied to address property changes in the FLiBe and to account for buoyancy. A pure hexahedral mesh with 60 million elements was generated by the Voronoi cell method. At the polynomial order of 5, the total degrees of freedom was 7.5 billion. The developed case in this work is the first of its kind in terms of size and complexity. The local numerical data across the domain were obtained and compared with empirical correlations. After examining the data, we found the following conclusions. For pressure drop, the Reger correlation predicted less than a 5% error. On the other hand, for heat transfer, the Wakao correlation outperformed the others. Based on our findings, we recommend the use of the Wakao correlation for the Nusselt number calculation, and for pressure drop, the KTA (Kerntechnischer Ausschuss) correclation, among the available experimental correlations. In conclusion, the Reger direct numerical simulation-driven correlation for pressure drops should also be considered, given its best agreement with our calculations.

Mixed Convection↗

NASA NTRS2011

Test-Anchored Vibration Response Predictions for an Acoustically Energized Curved Orthogrid Panel with Mounted Components

rich body of vibroacoustic test data was recently generated at Marshall Space Flight Center for component-loaded curved orthogrid panels typical of launch vehicle skin structures. The test data were used to anchor computational predictions of a variety of spatially distributed responses including acceleration, strain and component interface force. Transfer functions relating the responses to the input pressure field were generated from finite element based modal solutions and test-derived damping estimates. A diffuse acoustic field model was applied to correlate the measured input sound pressures across the energized panel. This application quantifies the ability to quickly and accurately predict a variety of responses to acoustically energized skin panels with mounted components. Favorable comparisons between the measured and predicted responses were established. The validated models were used to examine vibration response sensitivities to relevant modeling parameters such as pressure patch density, mesh density, weight of the mounted component and model form. Convergence metrics include spectral densities and cumulative root-mean squared (RMS) functions for acceleration, velocity, displacement, strain and interface force. Minimum frequencies for response convergence were established as well as recommendations for modeling techniques, particularly in the early stages of a component design when accurate structural vibration requirements are needed relatively quickly. The results were compared with long-established guidelines for modeling accuracy of component-loaded panels. A theoretical basis for the Response/Pressure Transfer Function (RPTF) approach provides insight into trends observed in the response predictions and confirmed in the test data. The software developed for the RPTF method allows easy replacement of the diffuse acoustic field with other pressure fields such as a turbulent boundary layer (TBL) model suitable for vehicle ascent. Structural responses using a TBL model were demonstrated, and wind tunnel tests have been proposed to anchor the predictions and provide new insight into modeling approaches for this environment. Finally, design load factors were developed from the measured and predicted responses and compared with those derived from traditional techniques such as historical Mass Acceleration Curves and Barrett scaling methods for acreage and component-loaded panels.

Frady, Gregory P.↗

NASA NTRS2011

Test-Anchored Vibration Response Predictions for an Acoustically Energized Curved Orthogrid Panel with Mounted Components

A rich body of vibroacoustic test data was recently generated at Marshall Space Flight Center for a curved orthogrid panel typical of launch vehicle skin structures. Several test article configurations were produced by adding component equipment of differing weights to the flight-like vehicle panel. The test data were used to anchor computational predictions of a variety of spatially distributed responses including acceleration, strain and component interface force. Transfer functions relating the responses to the input pressure field were generated from finite element based modal solutions and test-derived damping estimates. A diffuse acoustic field model was employed to describe the assumed correlation of phased input sound pressures across the energized panel. This application demonstrates the ability to quickly and accurately predict a variety of responses to acoustically energized skin panels with mounted components. Favorable comparisons between the measured and predicted responses were established. The validated models were used to examine vibration response sensitivities to relevant modeling parameters such as pressure patch density, mesh density, weight of the mounted component and model form. Convergence metrics include spectral densities and cumulative root-mean squared (RMS) functions for acceleration, velocity, displacement, strain and interface force. Minimum frequencies for response convergence were established as well as recommendations for modeling techniques, particularly in the early stages of a component design when accurate structural vibration requirements are needed relatively quickly. The results were compared with long-established guidelines for modeling accuracy of component-loaded panels. A theoretical basis for the Response/Pressure Transfer Function (RPTF) approach provides insight into trends observed in the response predictions and confirmed in the test data. The software modules developed for the RPTF method can be easily adapted for quick replacement of the diffuse acoustic field with other pressure field models; for example a turbulent boundary layer (TBL) model suitable for vehicle ascent. Wind tunnel tests have been proposed to anchor the predictions and provide new insight into modeling approaches for this type of environment. Finally, component vibration environments for design were developed from the measured and predicted responses and compared with those derived from traditional techniques such as Barrett scaling methods for unloaded and component-loaded panels.

Frady, Gregory P.↗

NASA NTRS2001

Metal Mesh Fabrication and Testing for Infrared Astronomy and ISO Science Programs; ISO GO Data Analysis and LWS Instrument Team Activities

This research program addresses astrophysics research with the Infrared Space Observatory's Long Wavelength Spectrometer (ISO-LWS), including efforts to supply ISO-LWS with superior metal mesh filters. This grant has, over the years, enabled Dr. Smith in his role as a Co-Investigator on the satellite, the PI (Principal Investigator) on the Extragalactic Science Team, and a member of the Calibration and performance working groups. The emphasis of the budget in this proposal is in support of Dr. Smith's Infrared Space Observatory research. This program began (under a different grant number) while Dr. Smith was at the Smithsonian's National Air and Space Museum, and was transferred to SAO with a change in number. While Dr. Smith was a visiting Discipline Scientist at NASA HQ the program was in abeyance, but it has resumed in full since his return to SAO. The Infrared Space Observatory mission was launched in November, 1996, and since then has successfully completed its planned lifetime mission. Data are currently being calibrated to the 2% level.

Smith, Howard A.↗

NASA NTRS1995

Thermal behavior spiral bevel gears

An experimental and analytical study of the thermal behavior of spiral bevel gears is presented. Experimental data were taken using thermocoupled test hardware and an infrared microscope. Many operational parameters were varied to investigate their effects on the thermal behavior. The data taken were also used to validate the boundary conditions applied to the analytical model. A finite element-based solution sequence was developed. The three-dimensional model was developed based on the manufacturing process for these gears. Contact between the meshing gears was found using tooth contact analysis to describe the location, curvatures, orientations, and surface velocities. This information was then used in a three-dimensional Hertzian contact analysis to predict contact ellipse size and maximum pressure. From these results, an estimate of the heat flux magnitude and the location on the finite element model was made. The finite element model used time-averaged boundary conditions to permit the solution to attain steady state in a computationally efficient manner.Then time- and position-varying boundary conditions were applied to the model to analyze the cyclic heating and cooling due to the gears meshing and transferring heat to the surroundings, respectively. The model was run in this mode until the temperature behavior stabilized. The transient flash temperature on the surface was therefore described. The analysis can be used to predict the overall expected thermal behavior of spiral bevel gears. The experimental and analytical results were compared for this study and also with a limited number of other studies. The experimental and analytical results attained in the current study were basically within 10% of each other for the cases compared. The experimental comparison was for bulk thermocouple locations and data taken with an infrared microscope. The results of a limited number of other studies were compared with those obtained herein and predicted the same basic behavior.

Handschuh, Robert F.↗

NASA NTRS1990

Prediction of the ullage gas thermal stratification in a NASP vehicle propellant tank experimental simulation using FLOW-3D

As part of the National Aero-Space Plane (NASP) project, the multi-dimensional effects of gravitational force, initial tank pressure, initial ullage temperature, and heat transfer rate on the 2-D temperature profiles were studied. FLOW-3D, a commercial finite difference fluid flow model, was used for the evaluation. These effects were examined on the basis of previous liquid hydrogen experimental data with gaseous hydrogen pressurant. FLOW-3D results were compared against an existing 1-D model. In addition, the effects of mesh size and convergence criteria on the analytical results were investigated. Suggestions for future modifications and uses of FLOW-3D for modeling of a NASP tank are also presented.

Hardy, Terry L.↗

NASA NTRS1994

Measurements of the Influence of Integral Length Scale on Stagnation Region Heat Transfer

The purpose was twofold: first, to determine if a length scale existed that would cause the greatest augmentation in stagnation region heat transfer for a given turbulence intensity and second, to develop a prediction tool for stagnation heat transfer in the presence of free stream turbulence. Toward this end, a model with a circular leading edge was fabricated with heat transfer gages in the stagnation region. The model was qualified in a low turbulence wind tunnel by comparing measurements with Frossling's solution for stagnation region heat transfer in a laminar free stream. Five turbulence generating grids were fabricated; four were square mesh, biplane grids made from square bars. Each had identical mesh to bar width ratio but different bar widths. The fifth grid was an array of fine parallel wires that were perpendicular to the axis of the cylindrical leading edge. Turbulence intensity and integral length scale were measured as a function of distance from the grids. Stagnation region heat transfer was measured at various distances downstream of each grid. Data were taken at cylinder Reynolds numbers ranging from 42,000 to 193,000. Turbulence intensities were in the range 1.1 to 15.9 percent while the ratio of integral length scale to cylinder diameter ranged from 0.05 to 0.30. Stagnation region heat transfer augmentation increased with decreasing length scale. An optimum scale was not found. A correlation was developed that fit heat transfer data for the square bar grids to within +4 percent. The data from the array of wires were not predicted by the correlation; augmentation was higher for this case indicating that the degree of isotropy in the turbulent flow field has a large effect on stagnation heat transfer. The data of other researchers are also compared with the correlation.

Vanfossen, G. James↗