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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 OSTI2023

Development of experimental and computational frameworks to predict subcooled flow boiling in the LANL Isotope Production Facility

Cooling is crucial to maintain the integrity of target systems in isotope production facilities. At Los Alamos National Laboratory (LANL)’s Isotope Production Facility (IPF), multiple encapsulated targets are stacked and irradiated in tandem with a 100 MeV, ~250μA proton beam. To facilitate effective heat removal, these stacked targets are separated and cooled via a series of water channels. At these beam currents, this high-energy proton beam heats the target system, likely initiating subcooled flow boiling in the cooling channels. However, in-beam monitoring of the IPF target system is not possible due to the extreme radiation environment, and the necessarily significant shielding. To better understand high-power target performance, we developed ex-situ experimental and computational frameworks to predict the behavior of subcooled flow boiling at IPF. Subcooled flow boiling experiments on Inconel 625 samples under IPF conditions (2 bar pressure, 10 GPM flow rate (i.e., 2249 kg/m 2 /s), 85 K subcooling) revealed that IPF's average operating power is at the early stage of boiling with a heat transfer coefficient of 48,000 W/m 2 /s. The proposed modeling framework enables us to predict a complete boiling curve, i.e., single-phase heat transfer, onset of nucleate boiling, two-phase heat transfer, and critical heat flux (CHF), with specification of input boiling parameters up to intermediate heat flux levels. The estimated CHF under IPF conditions is 5.2 MW/m 2 . Experimental data under reduced conditions (2 bar pressure, 1.5 GPM flow rate (i.e., 337 kg/m 2 /s), 45 K subcooling) served as validation cases for the computational modeling. This computational model can be further extended to more complicated systems replicating the real IPF configuration, for instance, to study void distribution as a function of the incident proton beam profile and coolant velocity profile of multiple cooling channels. Finally, the proposed experimental and computational frameworks provide a means to better understand cooling systems in the isotope production facilities at different accelerators, where in-beam monitoring of the cooling process is not available.

07 ISOTOPE AND RADIATION SOURCES↗
DOE OSTI2024

Reliability of Copper Inverse Opal Surfaces for Extreme-Heat-Flux Micro-Coolers in Low-Global-Warming-Potential Refrigerant R-1233zd Pool Boiling Experiments

This presentation provides a brief snapshot of the InterPACK paper InterPACK2023-113781. The paper explores copper inverse opal (CIO) surface reliability in pool boiling experiments in water and a new, low-global-warming-potential (GWP = 1) hydrofluoroolefin (HFO) refrigerant R-1233zd. The CIO-based structure is intended to develop enhanced two-phase heat transfer surfaces for extreme-heat-flux (approximately 1 kW/cm2) micro-coolers. In this study, a limited number of pool boiling experiments were performed using water and HFO-1233zd fluid, and the reliability of the CIO-based surfaces was evaluated. Critical heat flux (CHF) values in HFO-1233zd at 40 Degrees Celsius to 45 Degrees Celsius saturation temperatures and the corresponding saturation pressures were also measured. The CHF values with the refrigerant are significantly lower compared to those with water, but the refrigerant allows for a wider usable temperature range in the end application of the micro-coolers and is not limited to data centers with controlled ambient conditions. Reliability experiments with CIO surface samples - involving pool boiling with water on the CIO surfaces for approximately 48 hours and with HFO-1233zd for 144 hours - showed no structural degradation of the enhanced surface or any significant performance drop in heat transfer coefficients. The CIO surface samples in water were oxidized, most likely due to the presence of air in water and in the experimental vessel.

critical heat flux↗
DOE OSTI2026

Two-Phase Cooling for High Packaging Density Planar Inverter: Cooperative Research and Development Final Report, CRADA Number CRD-15-00592

The project objective was to utilize two-phase heat transfer to enable compact and power-dense inverters. The high heat transfer capacity and near isothermal characteristics of two-phase cooling can enable higher power densities, reducing the size and cost of the power electronics system. This project focused on developing efficient, passive (no pump or compressor) two-phase cooling strategies that consist of an air-cooled condenser and evaporator. This report describes the modeling work conducted to design the evaporator and air-cooled condenser for a prototype inverter development work underway in the John Deere. Prototypes of the final evaporator and condenser designs were then fabricated via 3D printing for testing. Experiments on the evaporator confirmed that this component can meet the heat load and junction temperatures requirements for Si IGBT (insulated-gate bipolar transistor) inverter. Experiments with the air-cooled condenser were not possible due to leaks through the condenser walls.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2021

Study of the film boiling heat transfer and two-phase flow interface behavior using image processing

Here, in this study, based on a small-scale quench test facility, the two-phase flow interface behavior during quench transients is visualized and analyzed utilizing an image processing framework. The high-fidelity experimental results obtained for two-phase flow in the current framework can support various studies both in the time domain and in the frequency domain. In particular, visualization of the data obtained from different heating surfaces under different test conditions are used to perform a full-scale transient 2-D vapor film reconstruction. The liquid-vapor interface variations in various heat transfer regimes as well as at the initial film breakup point can be directly obtained through the processed data. Moreover, the temporal variation of the interfacial wave frequency approaching quench is investigated in detail. Based on the high-resolution data obtained for the liquid-vapor interface, the detailed phase velocity and temperature profiles are obtained through theoretic analysis, based on which the film boiling heat transfer coefficient (HTC) can be determined. In addition, an improved film boiling HTC model is developed considering the effects of wall superheat, liquid subcooling temperature, vapor film thickness as well as fluid properties. The model is found to predict film boiling HTC well within 15% error.

42 ENGINEERING↗
DOE OSTI2024

Development of Modified Perturbation Solutions to the One-Phase Stefan Problems With a Convective Boundary

The classical Stefan problem is used to track the moving solid-liquid interface during the freezing process. Perturbation theory has often been applied to find an approximate analytical solution due to the nonlinearity of the moving interface. However, the Stefan number (i.e., the sensible over latent heat) must be small and usually less than 0.01 to assume the perturbation expansion, which in turn limits the thermal engineering applications. In this study, a modified perturbation solution is developed by adding a correction term after the leading-order solution to be valid for a much wider range of Stefan numbers (i.e., 0.01 less than or equal to Ste less than or equal to 1). Specifically, a one-phase Stefan problem is first formulated subjected to a convective boundary in the Cartesian, cylindrical, and spherical coordinate systems for inward solidification. The leading-order solution is calculated based on the regular perturbation theory, while the correction term is obtained using the Monte-Carlo method and a multi-variant regression. Results show that the correction term has a linear relationship with the Stefan number and is not significantly influenced by the Biot number. The proposed modified perturbation solution can accurately and rapidly predict the nonlinear moving interface motion for the freezing process.

DIRECT ENERGY CONVERSION,MATHEMATICS AND COMPUTING↗
DOE OSTI2026

Beyond Contrast Transfer: Spectral SNR as a Finite-Dose Metric for STEM Phase Retrieval

The contrast transfer function (CTF) is widely used to evaluate phase retrieval methods in scanning transmission electron microscopy (STEM), including center-of-mass imaging, parallax imaging, direct ptychography, and iterative ptychography. However, the CTF reflects only the maximum usable signal, neglecting the effects of finite electron fluence and the Poisson-limited nature of detection. As a result, it can significantly overestimate practical performance, especially in low-dose regimes. Here, we employ the spectral signal-to-noise ratio (SSNR), as a finite-dose statistical framework to evaluate the recoverable signal as a function of spatial frequency. Using numerical reconstructions of white-noise objects, we show that center-of-mass, parallax, and direct ptychography exhibit dose-independent SSNRs, with close-form analytic expressions. In contrast, iterative ptychography exhibits a surprising dose dependence: at low fluence, its SSNR converges to that of direct ptychography; at high fluence, it saturates at a value consistent with the maximum detective quantum efficiency predicted by recent quantum Fisher information bounds. The results highlight the limitations of CTF-based evaluation and motivate SSNR as a more accurate, finite-dose metric for assessing STEM phase retrieval methods.

STEM phase retrieval↗
DOE OSTI2024

Correlation Between Microscopic Current Fluctuations Observed at Ultra-Microelectrodes and Macroscopic Bulk Electrolysis Performance in Redox-Active Microemulsions

Microemulsions (μEs) have been proposed as redox flow battery (RFB) electrolytes that maximize ionic conductivity and charge capacity by synergizing two immiscible phases. However, charge transfer during electrolysis in μEs is poorly understood. Here, we show that ultramicroelectrode electrolysis of ferrocene-loaded μEs –20%, 60%, and 90% water - reveals stochastic current fluctuations. These are differentiated in the scanning electrochemical microscopy (SECM) geometry, where power spectral density analysis showed distinct changes in the frequency contributions. SECM in the substrate generation-tip collection mode showed that fluctuations arise under mass-transfer control. Significant differences in the diffusion coefficient of ferrocene species were deducted from SECM approach curves, suggesting phase transfer behavior. Using bulk electrolysis, we calculated the charge accessibility and cycling behavior in the μEs. A decrease in the stochastic behavior of the μEs seems to correlate to a higher accessibility and cycling performance, with the 90% water μE displaying the best reversibility and the 60% the lowest. Altogether, these results suggest that Marangoni-type convection driven by concentration gradients and/or μE restructuring during charge transfer play a role in the electrochemical performance of μEs. This presents opportunities for screening and diagnosing the performance of these emerging RFB electrolytes.

25 ENERGY STORAGE↗
DOE OSTI2023

Pressure modulated charge transfer and phonon interactions drive phase transitions in uranium–aluminum laves phases

Lanthanide AB 2 intermetallic compounds known as Laves phases have itinerant 3d and localized 4f electrons, which lead to interesting physical properties such as magnetic anisotropy and high Curie temperatures. Actinide Laves phases can display physical properties that are similarly intriguing. However, at reduced A–A spacing the C14 and C15 polytypes may exhibit larger wavefunction overlap for their 5f electron states and distinct characteristics for phases with more delocalized chemical bonding. The C36 polytype, on the other hand, is extraordinarily rare (<5% of known Laves phases). UAl 2 is the only known actinide Laves phase to show a pressure-controllable C15 → C36 transition. Here, we apply first principles calculations to determine the origin of the C15 → C36 phase transition and reveal the differences between the corresponding properties of each phase. Pressure increases lead to bond compression–induced electron transfer from Al to U, which drives dynamic instability in the C15 phonon modes because of the uniform U–U bonding environment. Further, the opposite phenomena is observed in C36: varied U–U bonding environments are vibronically more stable after charge transfer. We find that the interplay between charge transfer, chemical bonding, and phononic stability are central to predicting phase transitions and corresponding changes in physical properties for both C15 and C36 UAl 2 .

36 MATERIALS SCIENCE↗
DOE OSTI2025

Super-resolution imaging reveals resistance to mass transfer in functionalized stationary phases

Chemical separations are costly in terms of energy, time, and money. Separation methods are optimized with inefficient trial-and-error approaches that lack insight into the molecular dynamics that lead to the success or failure of a separation and, hence, ways to improve the process. We perform super-resolution imaging of fluorescent analytes in five different commercial liquid chromatography materials. Unexpectedly, we observe that chemical functionalization can block more than 50% of the material’s porous interior, rendering it inaccessible to small-molecule analytes. Only in situ imaging unveils the inaccessibility when compared to the industry-accepted ex situ characterization methods. Selectively removing some of the functionalization with solvent restores pore access without substantially altering the single-molecule kinetics that underlie the separation and agree with bulk chromatography measurements. Our molecular results determine that commercial “fully porous” stationary phases are over-functionalized and provide an alternative avenue to characterize and direct separation material design from the bottom-up.

Science & Technology - Other Topics↗
DOE OSTI2021

Review of heat transfer enhancement techniques in two-phase flows for highly efficient and sustainable cooling

We show that two-phase internal flow is ubiquitous to many systems due to its ability to transfer large amounts of heat effectively. Recent advances motivated by sustainability have pushed towards augmenting the heat transfer between the tube and the two-phase working fluid. Augmenting heat transfer in two-phase flows enables process intensification, and compactness leading to reduced cost and material consumption. This review investigates the effect of heat transfer enhancement techniques on different fluids including R134a, R407C, R22, etc … The techniques are categorized into passive and active and focus on durable enhancement methods which do not include surface structuring or coating. Passive techniques utilize geometrical and surface modifications to induce better mixing. Several passive techniques are analyzed including fins, inserts, and more. In analyzing these techniques, the effect of changing geometric parameters is studied, and the limitations are highlighted. Further, active techniques that enable heat transfer enhancement through applying power are also investigated. Electrohydrodynamic approaches are analyzed and compared to passive techniques. Additionally, the implications of heat exchange enhancement in the context of global energy are discussed. An energy analysis discretized by the use sector is conducted, with an emphasis on predicting the future potential for renewable and sustainable development. Moreover, although active approaches provide the highest heat transfer enhancement, due to implementation difficulties, passive techniques are more frequently adopted. The review ends with discussion of next-generation heat exchangers which will rely more on additive manufacturing due to its flexibility and reduced cost per part as the technology matures.

Nusselt number↗
DOE OSTI2025

Nonlinear Alfvén instability simulation and EP transport for ITER reversed shear (steady-state) and monotonic q-profile regimes *

The nonlinear evolution and dynamics of energetic particle (EP) driven instabilities in both steady-state (reversed shear q-profile) and monotonic q-profile regimes of ITER are examined using the global gyro-Landau closure model FAR3d. Both neutral beam and alpha components are included, leading to synergistic effects between the two populations. In order to maintain computational feasibility, the present nonlinear simulation includes all toroidal mode numbers ranging from n = 0 to 15. It cannot be excluded that n’s above this range could introduce larger linear growth rates; however, as indicated from the results, the n = 0 to 15 range is sufficient to provide a strong linear drive and significant nonlinear transport effects. While the toroidal mode numbers n = 6,13 dominate the linear instability growth phase, nonlinear energy transfers in the saturated phase reverse this trend, leading to the dominance of lower n’s in the saturated phase of the simulation. Zonal flow structure generation and EP density flattening are further consequences of the nonlinear phase. The density profile flattening is caused by collectively driven EP radial transport fluxes, which have non-local characteristics. Instantaneous alpha particle transport fluxes are significant (Γ α ~ 2 x 10 20 m –2 s –1 ) for the reversed shear regime and lower (Γ α ~ 1.1 x 10 20 m –2 s –1 ) for the monotonic q-profile case.

AE↗
DOE OSTI2026

Phase change material-to-refrigerant heat exchangers: Experimental validation and uneven melting analysis

Thermal energy storage (TES) using phase change materials (PCMs) enables load shifting and reduces mismatches between the building's thermal demand and the heat pump (HP) system's thermal capacity. While most TES studies have focused on single-phase heat transfer fluids, PCM-to-refrigerant heat exchangers (PRHX), in which the refrigerant undergoes liquid-vapor phase change, remain largely underexplored. Here, to address this gap, this study systematically investigates a shell-and-tube PRHX operating as the condenser in an HP through experiments and simulations. A two-dimensional enthalpy-based finite-volume PRHX model was developed and validated against experimental data, including refrigerant and PCM temperature profiles, PRHX capacity, and system-level performance. Results show three characteristic stages: Stage I, the condenser temperature rapidly increases with PCM in the solid state absorbing sensible heat; Stage II, stable operation during PCM phase change; and Stage III, performance decline once part of the PCM becomes fully melted. Heat transfer analysis revealed that uneven PCM melting along the condenser length was driven primarily by variations in the refrigerant-side heat transfer coefficient, rather than local approach temperature differences. Further study demonstrated that minimizing refrigerant outlet subcooling led to more uniform PCM melting and extended Stages I and II by up to 89%. This paper provides a validated PRHX model, clarifies the mechanisms of uneven PCM melting, and highlights subcooling control as an effective strategy to improve TES performance in HP systems without requiring secondary loops.

Graphite matrix↗
DOE OSTI2024

Experimentation on Finned-Tube Microchannel Heat Exchanger Incorporating Phase Change Material and R-410A

Integrating latent heat thermal energy storage, particularly phase change materials (PCM), in building heating, ventilation, air conditioning, and refrigeration (HVAC&R) systems, offers substantial benefits for peak load shifting and energy efficiency. While numerous studies explore PCM-embedded heat exchangers (PCM-HX) using single-phase heat transfer fluids, there needs to be more investigation regarding PCM-HX utilizing two-phase refrigerant flow. This gap is even more pronounced for microchannel heat exchanger (MCHX) configurations. In this study, an MCHX-based PCM-HX was built and tested to analyze and evaluate the performance of a PCM-HX operating with a two-phase refrigerant as the working fluid. A commercially available MCHX condenser unit was embedded with 2.6 kg of RT35 PCM and tested using R-410A as the working fluid, using an in-house test loop to control the refrigerant inlet conditions precisely. Thin and minimally invasive T-type thermocouples traced the temperature evolution along MCHX channels and tube banks. Additional larger T-type thermocouple probes at the refrigerant inlet and outlet measured the average power of the PCM-HX during condensing tests, ranging from 0.7 kW to 1.6 kW based on mass flow rates varying from 3.5 g/s to 8 g/s. This experimental study on MCHX-based PCM-HX with a two-phase refrigerant has the potential to offer practical design guidelines for the direct integration of PCM-TES in HVAC&R systems without the use of a secondary loop, while caution is advised to avoid a substantial increase in the refrigerant charge amount.

42 ENGINEERING↗
DOE OSTI2025

A Multiscale Approach to Simulate Non‐Isothermal Multiphase Flow in Deformable Porous Materials

Coupled thermal, hydraulic, and mechanical processes in porous materials play important roles in several energy and environmental technologies. The Darcy-Brinkman-Biot (DBB) framework has proven effective in modeling multiphase fluid flow in deformable porous solids across both pore and Darcy scales, including in systems where fractures coexist with a porous matrix. In this study, we extend the DBB framework, originally designed for isothermal conditions, to address non-isothermal problems by incorporating an energy conservation equation. The resulting solver, hybridBiotThermalInterFoam, enables simulations of coupled multiphase fluid flow, heat transfer, and solid deformation in hybrid-scale systems containing both solid-free regions and ductile porous domains. The new solver is validated through comparisons with analytical solutions and, also, against established heat transfer solvers chtMultiRegionFoam and compressibleInterFoam. Further, a series of 2D and 3D case studies, including two-phase heat transfer in solid-free, static, or deformable porous media, highlights the solver's capacity to simulate complex flow dynamics and heat transport in systems involving high mobility ratios, viscous fingering, and fracture propagation. Our results establish the feasibility of incorporating thermal effects in simulations of a wide variety of energy geotechnics and environmental applications, including enhanced hydrocarbon recovery, soil remediation, and enhanced geothermal energy systems.

04 OIL SHALES AND TAR SANDS↗
DOE OSTI2021

A molecular dynamics study of collisional heat transfer to nanoclusters in the gas phase

Nanoclusters in the gas phase grow by condensation and coagulation, which heat up nanoclusters, creating thermal non-equilibrium with the surrounding gas. The extent of non-equilibrium for nanoclusters is dependent upon the rate of heating relative to the rate of cooling brought about by nanocluster-gas molecule collisions, hence the latter process plays an important role in nanocluster energy evolution during growth. We apply molecular dynamics simulations to investigate heat transfer between metal nanoclusters and gas molecules relevant to high temperature aerosol systems. In analysis, we first define a thermal reemission coefficient (TRC), which is a correction factor for the portion of energy possessed by reemitted gas molecules after collision. Here, the TRC differs from the thermal accommodation coefficient (TAC), which is a correction factor for the maximum possible energy transfer rate from nanoclusters to gas molecules based on the diffusive collision model. We find the TRC is insensitive to nanocluster size but is affected by the nanocluster to gas temperature ratio and the nanocluster to gas atomic mass ratio. Comparison to the traditionally-defined TAC shows that the TAC is insensitive to temperature, a phenomenon that has been widely indicated in literature but not quantitatively explained. We show how the temperature insensitivity of the TAC arises because of the manner in which TRCs vary with both nanocluster and gas temperature, i.e. the manner in which the reemitted gas molecule energy from a surface varies with the temperature of that surface relative to that of the gas. In addition, while calculations ultimately reveal temperature insensitive TACs and justify their continued use in modeling gas-phase heat transfer, we argue that the TRC is more appropriate to calculate a priori in analyzing simulations; it is physically more realistic to first introduce a correction factor solely for the energy of reemitted gas molecules after a collision (as TRCs) instead of a correction factor applying to both the reemission energy and the initial energy (as TACs), as the latter is exactly calculable and independent of nanocluster properties. In line with prior work, for monoatomic gases we find the TAC decreases as the nanocluster to gas atomic mass increases, approaching 0.08 for gold nanoclusters in helium.

77 NANOSCIENCE AND NANOTECHNOLOGY↗
DOE OSTI2025

Characterization of Fuel-to-Coolant Heat Transfer During Reactivity-Initiated Accidents Using Tightly Coupled Thermal Hydraulics and Fuel Thermomechanics

The reactivity-initiated accident (RIA) is a complex scenario with several tightly interacting physical phenomena. Accurately predicting fuel behavior during these transients is difficult due to limitations in the modeling of fuel-to-coolant heat transfer. Common approaches to simulate RIAs involve standalone calculations using either a fuel performance code or a thermal-hydraulic code. The complex interdependencies of thermal-hydraulic and fuel mechanical behavior suggest that a tight coupling between these codes may provide more accurate predictions of fuel-to-coolant heat transfer and cladding mechanical response. Here, RELAP5-3D and BISON are coupled in this paper to simulate RIAs, and a sensitivity analysis is performed to rank key thermal properties and two-phase heat transfer parameters relevant for fuel-to-coolant heat transfer and cladding failure mechanisms in UO 2 –Zircaloy-4 systems. Gas gap conductance, film boiling heat transfer uncertainty, pulse width, fuel-specific heat capacity, and cladding-specific heat capacity were identified as important parameters. Variations in figures of merit resulting from changes to pulse width and the material thermal properties indicate that time-dependent heat transfer rates are significant for safety-relevant mechanical parameters due to the time dependence of cladding ductility and pellet-cladding mechanical interaction loading. The results suggest that the thermal-hydraulic factors have a nonnegligible influence on the thermomechanical solution and vice versa. Tight coupling of both sets of physics is recommended to improve prediction of fuel behavior during RIAs. Highlights include the following: 1. The RELAP5-3D thermal-hydraulic code and the BISON fuel performance code are tightly coupled for simulation of RIA transients with energy depositions at the Zircaloy-4 cladding failure threshold. 2. Departure from nucleate boiling occurred for all simulated cases. Due to the ductility of fresh fuel, substantial ballooning occurred in most cases. 3. Gas gap conductance, fuel-specific heat capacity, cladding-specific heat capacity, transient pulse width, and film boiling heat transfer were the dominant thermal factors impacting the safety figures of merit at energy depositions.

Critical Heat Flux (CHF)↗