Instability of electromagnetically driven shock.
Theory demonstrating stability of current sheets of different shapes in coaxial accelerators
MAGNETIC FIELD↗
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Pretest Simulations of a Supersonic Mixing and Combustion Validation Experiment to Assess Sensitivities
The reliance on CFD simulations to develop, design, and optimize scramjet systems (or components) has become commonplace. This reliance inevitably hinges on the ability of the computational analyst to quantify the level of confidence in their computational results. Unfortunately, nearly all the measured data available for this assessment comes from antiquated experimental datasets, or from tests that focused on the extraction of scramjet system (or component) performance. The objective of a CFD validation experiment is to quantify the predictive accuracy of one or more of the CFD physics submodels, implying that other uncertainties related to replicating the facility flow environment (e.g., knowledge of boundary conditions) must be minimized to the extent possible. This inevitably places stringent requirements on the quality and quantity of measurements taken to accurately specify inflow, outflow, and surface conditions for the CFD simulations; in addition to the measurements taken for the validation of physics submodels. This places additional demands on the experimental process above and beyond those for test article performance assessment. A recent high speed code credibility workshop series sponsored by AFRL identified a gap in existing validation data for fundamental assessments of turbulent mixing and combustion CFD closure models at scramjet engine relevant conditions. To address this gap, engineers at AFRL have designed a coaxial jet flame configuration that will be tested at two facilities (Research Cell 19 at the Air Force Research Lab, and at Purdue University). The effort described here documents pretest simulations of this validation experiment with the goal of fleshing out the extent of the facility flowpath that must be included to adequately reproduce the facility test section flow environment. The findings indicate that the flow around the support structure for the fuel injection centerbody upstream of the facility nozzle generates disturbances that persist throughout the nozzle expansion process; corrupting the azimuthal symmetry that was desired in the fuel/air mixing region of the test section. Simulations without this support structure maintained a high degree of azimuthal symmetry up until the fuel injection plane. However, even in this scenario the azimuthal symmetry was not maintained once the centerbody boundary layer transitioned to a wake flow downstream of the fuel injection plane.
CFD↗
Pretest Simulations of a Supersonic Mixing and Combustion Validation Experiment to Assess Sensitivities
The reliance on CFD simulations to develop, design, and optimize scramjet systems (or components) has become commonplace. This reliance inevitably hinges on the ability of the computational analyst to quantify the level of confidence in their computational results. Unfortunately, nearly all the measured data available for this assessment comes from antiquated experimental datasets, or from tests that focused on the extraction of scramjet system (or component) performance. The objective of a CFD validation experiment is to quantify the predictive accuracy of one or more of the CFD physics submodels, implying that other uncertainties related to replicating the facility flow environment (e.g., knowledge of boundary conditions) must be minimized to the extent possible. This inevitably places stringent requirements on the quality and quantity of measurements taken to accurately specify inflow, outflow, and surface conditions for the CFD simulations; in addition to the measurements taken for the validation of physics submodels. This places additional demands on the experimental process above and beyond those for test article performance assessment. A recent high speed code credibility workshop series sponsored by AFRL identified a gap in existing validation data for fundamental assessments of turbulent mixing and combustion CFD closure models at scramjet engine relevant conditions. To address this gap, engineers at AFRL have designed a coaxial jet flame configuration that will be tested at two facilities (Research Cell 19 at the Air Force Research Lab, and at Purdue University). The effort described here documents pretest simulations of this validation experiment with the goal of fleshing out the extent of the facility flowpath that must be included to adequately reproduce the facility test section flow environment. The findings indicate that the flow around the support structure for the fuel injection centerbody upstream of the facility nozzle generates disturbances that persist throughout the nozzle expansion process; corrupting the azimuthal symmetry that was desired in the fuel/air mixing region of the test section. Simulations without this support structure maintained a high degree of azimuthal symmetry up until the fuel injection plane. However, even in this scenario the azimuthal symmetry was not maintained once the centerbody boundary layer transitioned to a wake flow downstream of the fuel injection plane.
CFD↗
Epoxy IR Filters for Superconducting Resonators
Infrared radiation leakage through dielectrics in coaxial cabling can create unwanted quasiparticles in superconducting resonators if allowed to reach devices unattenuated. Modern experimental setups commonly incorporate epoxy-based filter blocks on readout and control lines in order to mitigate this effect; however, most of these multi-channel designs require specialized mounting hardware. Here, this investigation details the design and construction of single-channel inline infrared filters, and finds that their installation in the readout system for an aluminum resonator increased its quality factor by an average of 12% across a range of operating temperatures and powers. The option to incorporate general-purpose inline filters instead of designing custom filter blocks and mounts should prove more convenient for many newer experiments.
75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
Design and validation of a gamma-ray scanning system for measuring irradiated nuclear fuel
We report a prototype gamma-ray scanning system was designed to perform post-irradiation measurements of nuclear fuel at Idaho National Laboratory (INL). The system is composed of a coaxial high-purity germanium (HPGe) detector, a collimator, and mechanical positioning stages that translate the fuel sample across the front of the collimator. This paper documents the design process, modeling and the laboratory characterization performed to validate the system. The modeling of the system was done using the Monte Carlo N-Particle code with vendor-supplied design specifications, dimensional measurements, and x-ray radiographs of the HPGe detector. The characterization included measurements of calibrated radiation sources in different geometries, and calculations for absolute efficiency and dead time. Benchmark measurements were performed scanning an irradiated fuel rodlet containing ten pellets of 4.9% enriched UO2 in zirconium alloy. These results were compared to simulated spectra to further help characterize the detector model. One goal of the system is to determine the number of fissions per gram of UO2 in the fuel; comparison of the results from this prototype system's assay of the irradiated fuel rodlet are in agreement with previously estimated results.
98 NUCLEAR DISARMAMENT, SAFEGUARDS, AND PHYSICAL P↗
Non-Oxidative Ethane Dehydrogenation in a Packed-Bed DBD Plasma Reactor
Abstract Plasma-assisted conversion of ethane (C 2 H 6 ) can produce value-added chemical building blocks using green electricity. Here we employ a simple packed-bed coaxial dielectric barrier discharge (DBD) reactor to convert C 2 H 6 at mild operating conditions unattainable by conventional thermocatalysis. Ethylene (C 2 H 4 ), acetylene (C 2 H 2 ), and methane (CH 4 ) are the main products along with small fractions of C 3 and C 4 hydrocarbons. Interestingly, the C 2 H 4 selectivity is primarily correlated to C 2 H 6 conversion, dominated by electron dissociation and recombination reactions irrespective of the dielectric properties of the packed bed material (SiO 2 , Al 2 O 3 , ZrO 2 , TiO 2 , and BaTiO 3 ), packing material size, supplied power, and C 2 H 6 concentration. While a distortion of the electric field and discharge propagation results in varying dissipated power as materials change, the C 2 H 4 energy yield remains constant. The particle size appears to affect conversion mainly due to pressure alterations. Pd/SiO 2 catalyst can change the selectivity, favoring saturated species by expending hydrogen.
Engineering↗
Registration and fusion of large-scale melt pool temperature and morphology monitoring data demonstrated for surface topography prediction in LPBF
In-situ monitoring technologies for laser powder bed fusion (LPBF) additive manufacturing often face one key challenge, extracting the ultrafast melt pool (MP) signatures for understanding the localized part properties. Further, the spatial information of each monitored MP signature is essential for correlating the MP – part property. This spatial information is often unavailable especially from commercial LPBF printers. Many MP monitoring methods have been reported and utilized. However, very few of these have the MP’s spatial information. To overcome this challenge, in this work we report a method for spatially registering the key MP signatures (MP intensity, temperature, and area) to the monitored print parts. The MP signatures are obtained from our coaxial high-speed single-camera based two-wavelength imaging pyrometry (STWIP) system and the MP spatial information is obtained from an off-axis camera system. A machine learning aided image analysis method is employed to retrieve the spatial distribution of MPs within the corresponding part’s coordinates system. Then, the MP signature maps (MPSMs) are reconstructed by mapping the STWIP measured MP signatures to the registered MP coordinates. Further, a long short-term memory (LSTM) neural network is developed for estimating the layer surface topography from the registered MPSMs. The obtained results indicate that the layer surface topography can be more accurately estimated by using MP temperature signature rather than MP intensity and/or area signatures as in common practice. Finally, our developed methods for MP monitoring, registration, and MP-surface topography prediction offer advanced capabilities for the online detection of process anomalies and part defects.
36 MATERIALS SCIENCE↗
Localized keyhole pore prediction during laser powder bed fusion via multimodal process monitoring and X-ray radiography
Systematic fault detection and control during laser powder bed fusion (L-PBF) has been a long-standing objective for system manufacturers and researchers in the additive manufacturing (AM) industry. This manuscript investigates a data fusion approach for detection of keyhole porosity formation during laser irradiation of Ti-6Al-4V substrates by concurrent recording of thermally induced optical emission measured using both off-axis and coaxial photodiode sensors, and acoustic emission. Subsurface defect formation was monitored via high-speed synchrotron X-ray imaging at 20,000 frames per second, enabling temporal registration of keyhole pore formation events to the monitoring signals at a resolution of 50 µs. We developed data fusion machine learning (ML) models for localized prediction of keyhole pore formation at various time scales ranging from 0.5 ms to 2 ms. The signal segments were featurized using two independent approaches: (1) power spectral density (PSD) and (2) highly comparative time series analysis (HCTSA) framework. The extracted features from different sensor modalities were fused together to construct a multimodal feature space and sequential feature selection was used to determine the most informative features for training the ML models. The predictive performance was evaluated for three classifying algorithms: Support Vector Machine (SVM), K-Nearest Neighbor (KNN), and Gaussian Naive Bayes (GNB). As a result, pore formation events were predicted with up to 0.95 F1-score, 1.0 recall and 0.94 accuracy. The most heavily weighted features indicate that model performance is chiefly governed by the acoustic monitoring signal, with a secondary contribution from the optical emission sensors.
36 MATERIALS SCIENCE↗
Multimodal sensor fusion for real-time standoff estimation in directed energy deposition
In Laser Powder-based Direct Energy Deposition (LP-DED) systems, achieving consistency, precision and quality of produced parts requires tight control over printing parameters. One of the critical parameters is the standoff distance. Maintaining an optimal standoff height is crucial for achieving correct laser power density and powder catchment efficiency, as both laser and powder streams are focused at this distance. Here, this study introduces a novel approach using multimodal sensor fusion to predict standoff height in real-time. The proposed system integrates two low-profile, cost-effective sensors: an RGB coaxial camera and a high frequency and high dynamic range microphone. By utilizing a simple fully connected neural network, trained on a limited dataset, data fusion of these sensors allowed for the real-time prediction of the standoff height. The results demonstrate high resolution and accuracy of the predictions across multiple geometries and a wide range of standoff heights. This approach offers a simple, and cost-effective solution for real-time standoff height monitoring and lays the groundwork for future integration into commercial LP-DED systems.
42 ENGINEERING↗
Assessment of multi-stage telescopic control rods in a pebble bed reactor. Part II: corrosion and wear performance
To support High-Temperature Gas-Cooled Reactor designs, the effects of corrosion and wear on a SS316L telescopic control rod prototype were investigated in helium at 775 °C with up to 5 ppm oxygen for durations up to 500 h. Three deployment conditions were tested to assess their impact on wear and oxide formation: severe cycles, daily cycles, and gravity-driven deployments. Here, a chromium-rich oxide layer developed on regions exposed to the helium flow, reaching up to 2 µm in the most affected areas. No carburization or decarburization was observed. Oxide breakthrough occurred mainly at grooves and contact points during severe cycling of the telescopic rod, while in the other tests it was limited to contact points. Friction forces increased due to oxide growth and thermal expansion, the latter being the dominant factor, but never enough to hinder rod deployment significantly. Coaxial misalignment of stages was identified as the main potential risk to reliable operation under normal conditions.
Control rod↗
Insights into mixing of non-isothermal multi-polymer melts for complex plastics recycling
Catalytic recycling or upcycling of plastics is often limited not by catalyst performance, but by transport, arising from highly viscous, non-Newtonian polymer melts. In this work, we develop a reactor-scale framework that integrates rheological measurements, constitutive modeling, computational fluid dynamics (CFD), and experiments to quantify mixing, heat transfer, and dispersion in surrogate hydrocarbon melts representing mixed plastics systems. Temperature- and shear rate-dependent viscosity of low-density polyethylene (LDPE) and high-density polyethylene (HDPE) is measured to create two surrogate polymers (PLD and PHD) that capture the dominant shear-thinning flow behavior while neglecting strong elastic effects, enabling tractable simulation of non-isothermal, polymer-melt mixing using a Carreau-Arrhenius generalized Newtonian framework. Three-dimensional CFD simulations are employed to evaluate impeller performance in PLD using mixing time, cavern volume, thermal uniformity, and interfacial area for regimes in which viscoelastic effects are not dominant. We show that magnetic stir bars commonly used in lab-scale studies produce large thermal gradients (~60 °C) and poor mixing, even under idealized power delivery and polymer flow conditions. In contrast, close-clearance anchor impellers achieve near-isothermal operation, reduce mixing times by up to 5×, and provide >90% active circulation volume. We further demonstrate that, at low pseudo-Deborah number (De*), motor power requirements can be predicted directly from shear rate-dependent rheology using the Carreau-Arrhenius framework, enabling rational selection of operating conditions. Extension to surrogate immiscible multi-polymer systems based on PLD and PHD shows that interfacial area is highly sensitive to operating conditions and impeller design, with coaxial anchor-turbine configurations enhancing dispersion by up to 4 × .
Close-clearance impellers↗
Imogolite in water: Simulating the effects of nanotube curvature on structure and dynamics
Imogolite is a fascinating inorganic nanotube that is found in nature or synthesized in a laboratory. The synthesis process is carried out in liquid media, and leads to the formation of almost monodisperse diameter nanotubes. Here we investigate, employing classical molecular dynamics simulations, the interaction of water and imogolite for nanotubes of several radii. We established that water penetrates the pores of N = 9 and larger nanotubes, and adopts a coaxial arrangement in it. Also, while water molecules can diffuse along the center of the nanotube, the molecules next to the inner imogolite walls have very low mobility. At the outer nanotube wall, an increase of water density is observed, this effect extends up to 1 nm, beyond which water properties are bulk-like. Both phenomena are affected by the imogolite curvature.
58 GEOSCIENCES↗
Preheating and premixing effects on NO x emissions in a high-pressure axially staged combustor
NO x emissions remain a primary concern for modern and future gas turbines, particularly as we progress towards a net-zero carbon future. It is critical to identify novel strategies to mitigate environmental pollutants for both modern turbines operated on natural gas and future turbines projected to use carbon-free fuels (such as hydrogen). In the current study, NO x emissions of a reacting methane-air jet in a vitiated crossflow are experimentally investigated in a model axially staged combustor at 5 atm. The combustion products from the main stage combustor flow into the axial stage at temperatures ranging from 1580 to 1650 °C. The axial stage contains a reacting jet in crossflow, which provides an overall temperature rise ranging from 50 to 220 °C to generate exit temperatures similar to gas turbine engines. The focus of this paper is to explore the effects of flame liftoff and ignition timescales on the NO x contribution of this secondary jet. This is done by varying the premixed level and preheat temperature of the axial jet. The effects are explored at different momentum flux ratios (J), jet equivalence ratios (φ jet ), exit temperatures (T exit ), and main stage (headend) temperatures (T HE ). High-speed CH* chemiluminescence imaging is employed for each test case to determine the flame stabilization point. For a given temperature rise and combustor exit temperature, an increase in ignition delay was observed with a decrease in jet temperature. This provided a NO x benefit, particularly for jets that are injected at or close to an ignitable mixture fraction. Similarly, the coaxial injector caused a significant ignition delay compared to the fully premixed injector; this also led to a NO x benefit. Overall, the results show that a thermally driven delay in the axial stage provides a greater NO x reduction than a mixing delay.
03 NATURAL GAS↗
Droplet-Gas Interactions in Nanoelectrospray Multiphase Flow
Electrospray (ES) is production of a charged droplet plume that transits from an electrically biased supply capillary to a counter electrode under the influence of an electric field. Drag interactions with the surrounding gas decelerate the droplets while transferring the momentum from droplets to accelerate the surrounding gas, resulting in an induced gas flow. This work seeks to characterize the structure of the resulting gas jet and identify the key mechanisms defining the flow structure. The phenomenon of gas jets produced by momentum transfer from nano-electrospray (nES) plumes is explored with schlieren visualization, thermal anemometry, and numerical simulations. Schlieren visualization experiments provide information on the flow structure in support of simulation predictions, and the hot thermistor anemometry measurements of gas velocities outside the spray demonstrate quantitatively validated simulation results. The study reveals the formation of a moderately high velocity coaxial gas jet within the nES plume and provides insight into the overall flow structure of the induced flow. The multiphase electrohydrodynamic simulations enable numerical experimentation to explore the fundamental physics of coupled droplet-gas transport and the resulting flow structure. The simulations, confirmed by the experiments, reveal gas jetting induced by nES with a narrow (sub hundred micrometers in diameter) core originating from the nES liquid-jet breakup region and a surrounding larger-in-extent zone (several hundred micrometers in diameter) of lower velocity gas flow within the electrospray plume. This behavior is due to nES ejecting a stream of droplets from the tip of a narrow liquid cone-jet, where the combined effect of many small droplets transferring momentum to a confined region of gas yields a narrow but high-velocity gas stream. Furthermore, the micro-jets produced by nES have practical utility for mass spectrometry, 3D printing and fabrication, and thermal management.
77 NANOSCIENCE AND NANOTECHNOLOGY↗
Atomic Layer Thermopiles: Comprehensive static calibration, comparison and application in subsonic and supersonic flows
Here, this paper compares the calibration of different heat flux sensors in radiation- and convection-based sub- and supersonic operation. First, four heat flux sensors based on different principles: ALTP (Transverse Seebeck Effect), HFM-8E (differential-layer device), coaxial Thermocouple and a TG-2000 (circular-foil gage) are calibrated in a laser-based radiation setup. In a second step, all heat flux sensors are compared with a slug-calorimeter within a subsonic convection-dominated facility based on stagnation-point measurements of an impinging hot air jet. The obtained results indicate that a sensitivity transfer between a radiative calibrated sensor used in a mainly convective environment is not always possible and can lead to significant, systematic errors. Calibration in a subsonic shear flow with thermocouple readings demonstrate small divergence from the manufacturer provided sensitivity. Finally, supersonic testing with high frequency shock-boundary layer interactions highlight the need for ALTP rather than the conventional use of thermocouple arrays to resolve the high frequency phenomena associated with shock boundary layer interactions.
42 ENGINEERING↗
Variational, stable, and self-consistent coupling of 3D electromagnetics to 1D transmission lines in the time domain
This work presents a new multiscale method for coupling the 3D Maxwell's equations to the 1D telegrapher's equations. While Maxwell's equations are appropriate for modeling complex electromagnetics in arbitrary-geometry domains, simulation cost for many applications (e.g. pulsed power) can be dramatically reduced by representing less complex transmission line regions of the domain with a 1D model. By assuming a transverse electromagnetic (TEM) ansatz for the solution in a transmission line region, we reduce the Maxwell's equations to the telegrapher's equations. Here, we propose a self-consistent finite element formulation of the fully coupled system that uses boundary integrals to couple between the 3D and 1D domains and supports arbitrary unstructured 3D meshes. Additionally, by using a Lagrange multiplier to enforce continuity at the coupling interface, we allow for an absorbing boundary condition to also be applied to non-TEM modes on this boundary. We demonstrate that this feature reduces non-physical reflection and ringing of non-TEM modes off of the coupling boundary. By employing implicit time integration, we ensure a stable coupling, and we introduce an efficient method for solving the resulting linear systems. We demonstrate the accuracy of the new method on two verification problems, a transient O-wave in a rectilinear prism and a steady-state problem in a coaxial geometry, and show the efficiency and weak scalability of our implementation on a cold test of the Z-machine MITL and post-hole convolute.
71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
Closed-loop control of meltpool temperature in directed energy deposition
The objective of this work is to mitigate flaw formation in powder and laser-based directed energy deposition (DED) additive manufacturing process through close-loop control of the meltpool temperature. In this work, the meltpool temperature was controlled by modulating the laser power based on feedback signals from a coaxial two-wavelength imaging pyrometer. The utility of closed-loop control in DED is demonstrated in the context of practically inspired trapezoid-shaped stainlesssteel parts (SS 316L). We demonstrate that parts built under closed-loop control have reduced variation in porosity and uniform microstructure compared to parts built under open-loop conditions. For example, post-process characterization showed that closed-loop processed parts had a volume percent porosity ranging from 0.036% to 0.043%. In comparison, open-loop processed parts had a larger variation in volume percent porosity ranging from 0.032% to 0.068%. Further, parts built with closed-loop processing depicted consistent dendritic microstructure. By contrast, parts built with open-loop processing showed microstructure heterogeneity with the presence of both dendritic and planar grains, which in turn translated to large variation in microhardness
36 MATERIALS SCIENCE↗
Multi phenomena melt pool sensor data fusion for enhanced process monitoring of laser powder bed fusion additive manufacturing
Finding actionable trends in laser-based metal additive manufacturing process monitoring data is challenging owing to the diversity and complexity of the underlying physical interactions. A single monitoring solution that captures a particular process phenomenon, such as a photodiode that tracks melt pool intensity, is not alone capable of evaluating process stability or detecting flaw formation with sufficient precision for routine application in industry. In this work, to improve flaw detection performance, we adopted a data fusion approach that captures multiple process phenomena. To demonstrate this, we acquired data from laser powder bed fusion (LPBF) builds of cylindrical specimens produced with different laser spot sizes, emulating defocusing due to process faults such as thermal lensing. The resulting specimens had porosity of varying types and severity, quantified by post-build non-destructive X-ray computed tomography, Archimedes density measurements, and destructive metallographic characterization. During the build, the melt pool state was monitored with two coaxial high-speed video cameras and a temperature field imaging system. Physically intuitive low-level melt pool signatures, such as melt pool temperature, shape and size, and spatter intensity were extracted from this high-dimensional, image-based sensor data. These process signatures were subsequently used as input features in relatively simple machine learning models, such as a support vector machine, which were trained to detect laser defocusing, and in addition, predict porosity type and severity. The results show that the data fusion approach significantly enhanced system performance by reducing the overall false positive rate from ~ 0.1 to ~ 0.001 without sacrificing the true positive rate (~0.90). These results were at par with a black-box, deep machine learning approach (convolutional neural network).
36 MATERIALS SCIENCE↗