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All sourcesNASA NTRSDOE OSTI
DOE OSTI2023

A Hybrid Domain Overlapping Method for Coupling System Thermal Hydraulics and CFD Codes

A hybrid multiscale coupling methodology based on a domain overlapping approach has been developed for coupling System Thermal Hydraulics (STH) and Computational Fluid Dynamics (CFD) codes. The method has been implemented between the modern STH code SAM and the CFD code NekRS, using the coupling tool Cardinal. The coupling aims to extend the STH code's applicability to scenarios where local momentum and energy transfers are important yet difficult for STH codes to capture, such as three-dimensional mixing. Two coupling strategies are implemented and compared: a hybrid domain overlapping method and the conventional domain decomposition method. Here, the strategies are applied to two closed-loop applications, and the present method shows superior stability behavior when compared to the domain decomposition method. Then, the present coupling method is validated against experimental data from a double T-junction experiment. The present STH/CFD coupling shows improved agreement with experimental data when compared to STH standalone simulations.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2018

Residual service life of carbonated structures based on site non-destructive tests

Assessing the residual service life of carbonated reinforced concrete structures is typically conducted by measuring cover depths and carbonation of drilled cores, assuming the ''square root law'' for the progress of the carbonation front. Given the large spatial variability of carbonation depths, the required number of cores becomes prohibitive. A model is presented, based on numerous experimental data, by which the carbonation rate can be estimated by means of non-destructive site measurements of the air-permeability kT. A Weibull distribution of the carbonation rate K{sub c} is fitted to the results, which is a function of kT. Hence, for each kT value measured on site coupled with the cover depth x{sub d}, expected, optimistic and pessimistic values of the corrosion initiation time can be obtained without the need of drilling cores. The method is validated on 111 paired results of kT and x{sub d}, obtained on the emblematic Tokyo's Museum of Western Art.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Influence of sizing concentration on strength, stiffness, and porosity in textile grade carbon fiber (TCF)-Epoxy composites: Revealing inverse trends

The effect of fiber sizing (i.e., surface treatment) concentration (0 %, 1.36 %, 1.52 %, 1.94 %, and 2.13 %) on the mechanical properties (tensile, flexural, interlaminar shear strength (ILSS), and low velocity impact) of textile grade carbon fiber (TCF)-epoxy composite is examined. An inverse relationship between the strength and stiffness of the composite is observed with increased sizing concentration. The root mean square (RMS) roughness of the fiber surface increased from 17.8 nm (unsized) to 22.7 nm with 2.13 % sizing concentration. It was found that the tensile strength increased by 131 % from 221.4 ± 18.5 MPa (unsized) to 510.8 ± 28.05 MPa (for 1.36 % sizing) and further by 155 %–563.7 ± 14.95 MPa at 2.13 % sizing. On the contrary, the stiffness is initially increased by 126 % from 33.52 ± 7.80 GPa (unsized) to 75.9 ± 3.21 GPa (for 1.36 % sizing) but reduced with further increase in the sizing concentration. A single fiber pull-out test is simulated using the finite element method to validate the reverse trend in strength and stiffness. The varying sizing concentration is simulated by introducing an interface of varying thickness between fibers and matrix. Simulation results confirm that a thicker interface, corresponding to a higher sizing concentration, decreases interfacial shear stress, enhancing material strength while decreasing stiffness. The reverse trend in strength and stiffness with the sizing concentration aligns with experimental observations. In conclusion, the present study emphasizes the importance of sizing concentration for mechanical properties and provide a design criterion for customized high-strength and high-stiffness applications.

Porosity↗
DOE OSTI2019

A comprehensive modeling procedure for estimating statistical properties of forced ignition

In this work, a comprehensive modeling procedure for estimating the probability of ignition with application to high altitude relights of aircraft combustors is developed. In these configurations, an ignitor is used to introduce high-enthalpy discharge into a fuel-laden but stratified flow. Because of the inherent variabilities inflow conditions, kernel discharge process, and the chaotic turbulent flow, ignition cannot be described deterministically, but only as a probabilistic measure. The proposed modeling framework consists of three components. The turbulent flow is represented using the large eddy simulation (LES) framework. The ignition process is modeled using a manifold approach, where the initial kernel evolution is represented using a homogeneous reactor while the latter part of the evolution is represented as a competition between diffusion and chemical reactions using a flamelet-type mapping. A combined lookup table that can track the evolution of the kernel through these two distinct reaction stages is developed. The table lookup variables are solved within the LES framework. The resulting simulation tool is then embedded within an uncertainty quantification approach, where variations in the turbulent flow, as well as operating and kernel properties, are simulated using a Monte-Carlo-based sampling approach. Techniques to reduce computational cost are used to obtain a robust, numerically accurate, and physically representative model for engine relight. The method is validated using experimental data for ignition of methane/air mixtures. Due to the comprehensive nature of the modeling procedure, it is found that the simulation tool reproduces experimentally observed ignition probabilities over a wide range of operating conditions.

42 ENGINEERING↗
DOE OSTI2019

A sharp interface model for deterministic simulation of dendrite growth

A high order level set model is developed for deterministic simulation of dendritic growth in unstable solidifying systems. The model captures motion of the front implicitly on a structured finite difference grid, enables calculation of its geometric properties and also applies boundary conditions on the immersed interface. Interfacial capillary effect is incorporated in the model through the Gibbs-Thomson condition. Canonical problems for evaluating grid convergence of the numerical method and validation tests for stability of a growing nucleus in the presence of isotropic surface tension are presented. The growth morphology of solidifying nuclei in undercooled metallic melts is quantitatively analyzed. Effects of crystal anisotropy and melt undercooling on the front geometry, propagation speed and formation of branched dendritic structures are examined. In conclusion, the complex morphological changes, such as remelting of secondary perturbations under specific conditions of undercooling, are also captured during the quantitative analysis.

36 MATERIALS SCIENCE↗
DOE OSTI2025

RLGBS: Reinforcement Learning-Guided Beam Search for process optimization in a paper machine dryer section

Paper drying is responsible for over two-thirds of energy consumption in the U.S. pulp and paper industry, presenting significant potential for energy savings through optimization of process parameters. Current approaches often assume fixed operating conditions, neglecting dynamic ambient and process variations that limit achievable savings and real-world applicability. To this end, we develop a physics-based simulation environment for a paper machine dryer section and propose a reinforcement learning (RL) framework to minimize overall energy consumption by optimizing drying process parameters under diverse operating conditions. To mitigate overdrying and numerical instabilities caused by suboptimal local RL actions, we introduce Reinforcement Learning-Guided Beam Search (RLGBS), which explores multiple action sequences in parallel using beam search. Instead of making step-by-step decisions, RLGBS prioritizes solutions based on cumulative probability, reducing the impact of individual suboptimal actions. Experiments demonstrate that RLGBS achieves consistent energy savings under unseen operating conditions not encountered during training, outperforming conventional RL methods. While validated in drying optimization, this framework is broadly applicable to other RL-based industrial process control problems.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2021

Validation of process simulation workflow for thermosetting prepreg platelet molding compounds

Continuous carbon fiber prepreg slit and cut into rectangular platelets has proven to be a useful material for net shape molding of semi-structural and structural components in the aerospace and automotive industries. Furthermore, to assist the designer in use of these prepreg platelet molding compounds, sometimes called carbon fiber sheet molding compounds, simulation tools are required that can predict the as-manufactured fiber orientation state which has a significant impact on the resulting performance. Herein, an analysis workflow for design-enabling predictions is demonstrated for a double dome geometry with two different initial charge configurations. Here, the workflow is validated through comparison with experimental short shots, orientation state, and stiffness trends. Significantly, to complete the validation, a method is proposed for determining the confidence bounds on measured orientation state enhancing the results of optical microscopy which can only produce a small sample of platelet orientations.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Designing a drone delivery network with automated battery swapping machines

Drones are projected to alter last-mile delivery, but their short travel range is a concern. In this study, we propose a drone delivery network design using automated battery swapping machines (ABSMs) to extend ranges. The design minimizes the long-term delivery costs, including ABSM investment, drone ownership, and cost of the delivery time, and locates ABSMs to serve a set of customers. We build a mixed-integer nonlinear program that captures the nonlinear waiting time of drones at ABSMs. To solve the problem, we create an exact solution algorithm that finds the globally optimal solution using a derivative-supported cutting-plane method. To validate the applicability of our program, we conduct a case study on the Chicago Metropolitan area using cost data from leading ABSM manufacturer and geographical data from the planning and operations language for agent-based regional integrated simulation (more commonly known as POLARIS). A sensitivity analysis identifies that ABSM service times and costs are the key parameters impacting the long-term adoption of drone delivery.

25 ENERGY STORAGE↗
DOE OSTI2024

Specifying angular reference for robust three-phase state estimation

While the phase angle of any of the bus voltages can be chosen as the angular reference in the state estimation formulation of positive sequence networks, the same approach does not readily extend to three-phase network state estimation problem. It is commonly assumed that there is at least one bus where the bus voltages are perfectly balanced with phase angles displaced ±120° and these balanced three phase voltages are used as the three-phase reference in solving the three-phase state estimation problem. This assumption may be quite realistic in transmission networks, and for distribution networks with a strong transmission system connection. However, it might not be realistic to assume existence of a perfectly balanced reference bus in today’s distribution systems with ever increasing penetration of renewable sources or for isolated operation of microgrids. In this paper, a novel state estimation formulation will be presented which facilitates correct solution irrespective of the existence of buses with perfectly balanced voltages. The new formulation is general, and lends itself to bad data processing. It yields accurate results in any three-phase power system irrespective of its operating conditions (balanced or highly unbalanced), configuration (isolated microgrid, connected to transmission system, etc.) and whether or not it contains any synchronous generators. The performance of the method is validated using the IEEE 123 bus three-phase system.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2021

A hierarchical gray-box dynamic modeling methodology for direct-expansion cooling systems to support control stability analysis; Méthodologie de modélisation dynamique hiérarchique de type boîte grise pour les systèmes de refroidissement à détente directe afin de soutenir l'analyse de stabilité de la commande

In this paper, a gray-box dynamic modeling approach for direct-expansion cooling systems is presented. The overall approach incorporates a multi-stage training procedure that consists of 1) identification of component sub-models from quasi-steady-state performance data, 2) system model integration with estimation of refrigerant charge and 3) fine tuning of thermal capacitances of the evaporator and condenser to capture the system dynamic responses. Compared to traditional physics-based models, the proposed modeling approach has advantages including reduced engineering efforts in the model development phase, improved computational efficiency and enhanced prediction accuracy. The modeling method was validated using a 3-ton variable-speed heat pump and proved to be capable of accurately predicting the system transient behaviors over a wide range of operating conditions. The established dynamic model was then applied for control stability analysis, with a specific goal of determining a proper control execution time step. The case study results showed that the stable control execution time step could change significantly, from 3 sec to 19 sec, as the operating conditions and control settings vary, and a proper selection of the execution time step is critical to ensure stable and reliable operations.

42 ENGINEERING↗
DOE OSTI2022

Lattice dynamics of high-pressure hydrides studied by inelastic neutron scattering

Due to the small mass and anomalously large neutron scattering cross-section of proton (about 80 barns compared to a few barns for other nuclei), inelastic neutron scattering is considered as one of the most effective tools in studying optical vibrations of hydrogen atoms in metal hydrides. The current review is focused on the binary hydrides of 3d- and 4d-metals of groups VI–VIII, which were produced at high hydrogen pressures of several gigapascals in relatively large quantities of hundreds of mg, quenched to low temperature and studied by INS ex situ at ambient pressure with high statistical accuracy. One of the unusual effects revealed by INS is a strong increase in the strength of the metal-hydrogen interactions with decreasing atomic number of the d-metal accompanied by an increase in the Me-H distance. Based on the available experimental results, the spectra g(E) of the phonon density of states and temperature dependencies CV(T) of the heat capacity at constant volume at T up to 1000 K have been derived in this paper and presented both in the figures and in digital form. This provides the reference data for the theoretical investigations of the crystal structures and compositions of new practically important hydrides giving the opportunity to validate calculation methods by comparing the calculated g(E) and CV(T) with the accurate experimental dependencies for the binary hydrides. Recent INS studies showed [R.A. Klein et al., J. Alloy. Compd. 894 (2022) 162381] that the fingerprints of anomalously short H-H separations of 1.6 Å violating the “2 Å rule” can be easily and unambiguously identified in the complex INS spectra of quaternary hydrides (La,Ce)NiInH 1+x . This makes neutron spectroscopy an attractive means for obtaining valuable data in the search for novel hydrides with a record high hydrogen capacity.

38 RADIATION CHEMISTRY, RADIOCHEMISTRY, AND NUCLEA↗
DOE OSTI2024

Weak boundary conditions for Lagrangian shock hydrodynamics: A high-order finite element implementation on curved boundaries

Here, we propose a new Nitsche-type approach for weak enforcement of normal velocity boundary conditions for a Lagrangian discretization of the compressible shock-hydrodynamics equations using high-order finite elements on curved boundaries. Specifically, the variational formulation is appropriately modified to enforce free-slip wall boundary conditions, without perturbing the structure of the function spaces used to represent the solution, with a considerable simplification with respect to traditional approaches. Total energy is conserved and the resulting mass matrices are constant in time. The robustness and accuracy of the proposed method are validated with an extensive set of tests involving nontrivial curved boundaries.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2025

In situ high-temperature Raman spectroscopy for online EAF slag analysis

Real-time monitoring of slag chemistry is critical for optimizing Electric Arc Furnace (EAF) steelmaking operations, where dynamic variations in slag composition directly influence slag foaming, refractory degradation, and thermal efficiency. Conventional techniques such as X-ray fluorescence (XRF), Fourier-transform infrared (FTIR), and scanning electron microscopy coupled with energy-dispersive X-ray spectroscopy (SEM-EDS) are commonly used to analyze slag composition, but their offline nature and equipment constraints limit their applicability for online monitoring in harsh industrial environments. To address this challenge, we present an in situ, high-temperature analytical approach that integrates Raman spectroscopy with a custom designed fiber-optic probe for real-time slag characterization at 1550 °C. The system enables non destructive spectral acquisition from molten slags, providing molecular-level insights into silicate polymerization and iron oxidation states. Eight synthetic slag samples were evaluated, and key Raman features—such as Q n silicate units and FeO₄/FeO₆ coordination environments—were identified and quantitatively correlated with slag basicity and Fe₂O₃ content. The results demonstrate agreement between Raman spectral ratios and bulk slag chemistry, validating the method’s capability to track compositional and structural changes under molten temperature. This work establishes the feasibility of deploying fiber-optic Raman probe for online EAF slag monitoring and highlights their potential to support closed-loop control strategies, thereby enhancing process stability, refractory protection, and steel quality in industrial steelmaking applications.

47 OTHER INSTRUMENTATION↗
DOE OSTI2022

Method to account for natural fracture induced elastic anisotropy in geomechanical characterization of shale gas reservoirs

Shale has been usually recognized as a transverse isotropic (TI) medium in conventional geomechanical log interpretation due to its laminated nature. However, when natural fractures exist in the shale rock, additional elastic anisotropy is introduced, converting laminated Shale to an orthorhombic (OB) medium. Previous studies illustrate that neglecting the natural fracture induced anisotropy in shale geomechanical log interpretation could lead to inaccurate evaluations of elastic moduli and in-situ stresses. In this paper, a new method is developed to account for the natural fracture induced anisotropy in geomechanical log interpretation based upon the TI acoustic model developed by the author and a characterization technique of elastic wave anisotropy (Sayers, 1991). The new OB model incorporates the four acoustic log data inputs and five modeling constraints in a nonlinear optimization algorithm to solve for the nine independent stiffness coefficients of an OB rock, and further to solve for the geomechanical properties and in-situ stress profiles in an OB formation. The new method was validated with a Marcellus Gas Shale field case. Both the new OB model and the conventional TI model were applied to interpret the minimum horizontal stress profile for the same formation. By comparing the results, the OB model is more robust than the TI from two aspects. First, the average stress magnitude predicted by the OB model is closer to the one measured by the Diagnostic Fracture Injection Test (DFIT). Second, the OB model predicts a more obvious stress barrier between the lower Marcellus and upper Onondaga Limestone than the TI model does. Finally, the predicted stress barrier is consistent with the observation of the microseismic events of a horizontal well drilled and completed nearby, which reveals that no hydraulic fracture propagates downward through the bottom boundary of Marcellus Shale into the underlying Onondaga Limestone.

03 NATURAL GAS↗
DOE OSTI2023

Customizable adaptive regularization techniques for B-spline modeling

B-spline models are a powerful way to represent scientific data sets with a functional approximation. However, these models can suffer from spurious oscillations when the data to be approximated are not uniformly distributed. Model regularization (i.e., smoothing) has traditionally been used to minimize these oscillations; unfortunately, it is sometimes impossible to sufficiently remove unwanted artifacts without smoothing away key features of the data set. In this article, we present a method of model regularization that preserves significant features of a data set while minimizing artificial oscillations. Our method varies the strength of a smoothing parameter throughout the domain automatically, removing artifacts in poorly-constrained regions while leaving other regions unchanged. Further, the proposed method selectively incorporates regularization terms based on first and second derivatives to maintain model accuracy while minimizing numerical artifacts. The behavior of our method is validated on a collection of two- and three-dimensional data sets produced by scientific simulations. In addition, a key tuning parameter is highlighted and the effects of this parameter are presented in detail. This paper is an extension of our previous conference paper at the 2022 International Conference on Computational Science (ICCS) (Lenz et al., 2022).

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2018

Control of donor-like effect in V2VI3 polycrystalline thermoelectric materials

Highlights: • Thermal control of donor-like effect for V{sub 2}VI{sub 3} polycrystalline materials is proposed. • Low-temperature sintering or hot deforming facilitates the donor-like effect. • Recovery role by high-temperature sintering/deforming enhances the Seebeck coefficient. • Temperature should be strictly selected for each V{sub 2}VI{sub 3} polycrystalline material. - Abstract: Intrinsic point defect plays a core role in improving thermoelectric performance of V{sub 2}VI{sub 3} polycrystalline materials. However, the control of intrinsic point defect is challenging during powder refinement due to the donor-like effect. This paper shows a systematic approach to thermal control the donor-like effect via engineering spark plasma sintering and hot deformation temperature. Bi{sub 2}Te{sub 2.85}Se{sub 0.15} polycrystalline alloy with high electron concentration was chosen as example to validate the method. The low Seebeck coefficient of n-type Bi{sub 2}Te{sub 2.85}Se{sub 0.15} polycrystalline, arising from strong donor-like effect after powder refinement, was enhanced by recovery role induced reduction in electron concentration through proper tuning sintering or deforming temperature. Repetitive hot deformation was applied to further improve the Seebeck coefficient via the recovery role and a maximum zT of 1.0 is obtained at 410 K. The present results give insights into developing higher performance V{sub 2}VI{sub 3} polycrystalline materials through thermal control the donor-like effect.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2024

At-power subcritical multiplication in the Advanced Test Reactor during nuclear requalification testing

Power division information during nuclear requalification of the Advanced Test Reactor (ATR) is of considerable interest as an importance function for observed changes to core reactivity. The degree to which a given physical subdivision of a critical reactor acts as a neutron source for other lobes is not analytically characterized for general application. When ATR operates at power, individual power-producing lobes rely on each other as neutron sources in order to maintain constant power, which in general requires either exactly critical multiplication within a reactor or an external neutron source. Here, this work shows that fuel element and lobe powers in ATR can be related with subcritical multiplication theory. Subcritical multiplication factors are computed with a physically validated analytical method based on actual at-power operation, quantifying for each lobe its dependence on other lobes as an external neutron source. This explanation is significant for ATR due to the desire to irradiate a large variety of experiments simultaneously, each having its impact on the core neutron population. For any physical subdivision of any other critical reactor, it is likewise true that the subdivision undergoes only subcritical multiplication.

21 - SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLAN↗