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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 811 records · Page 45
All sourcesNASA NTRSDOE OSTI
DOE OSTI2018

Design of Circular, Square, Single, and Multi-layer Induction Coils for Electromagnetic Priming Using Inductance Estimates

Special induction coils used for electro magnetic priming of ceramic foam filters in liquid metal filtration have been designed using a combination of analytical and finite element modeling. Relatively simple empirical equations published by Wheeler in 1928 and 1982 have been used during the design process. The equations were found to accurately predict the z-component of the magnetic flux densities of both single- and multi-layer coils as verified both experimentally and by using COMSOL{sup ®} 5.1 multiphysics simulations.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Experimental and Mathematical Simulation Study on the Granulation of a Modified Basic Oxygen Furnace Steel Slag

Basic oxygen furnace (BOF) steel slag is a major waste of the steelmaking industry. Utilization of BOF slag contributes to the sustainability of the steel industry by alleviating its environmental impact. Vitrification during cooling is an effective method to promote the cementitious activity of slags with the aim to apply slags in high value-added applications. In the present study, an Al{sub 2}O{sub 3}- and SiO{sub 2}-modified BOF slag was water granulated at a pilot scale. The amorphous and mineral fractions were measured quantitatively. The critical cooling rate to vitrify the modified slag was calculated through the Time-Temperature-Transformation diagrams constructed using in situ confocal scanning laser microscopy. To provide an insight into the crystallization behavior during the granulation process, a mathematical model was developed. The model was validated by comparing the amorphous fraction obtained from experiments with that from simulation. Temperature profiles of the slag particles with varied sizes were calculated with the aid of COMSOL Multiphysics software. The effect of particle size on the vitrified fraction was discussed in detail and the temperature gradient from surface to center of the particle was identified. The results provide novel fundamental understanding of the vitrification process regarding to the slag valorization, which will help the industrial implementation of granulation for pollution remediation and other engineered environmental systems such as chemical industry and pharmaceutical industry.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Modeling of Powder Bed Manufacturing Defects

Powder bed additive manufacturing offers unmatched capabilities. The deposition resolution achieved is extremely high enabling the production of innovative functional products and materials. Achieving the desired final quality is, however, hampered by many potential defects that have to be managed in due course of the manufacturing process. Defects observed in products manufactured via powder bed fusion have been studied experimentally. In this effort we have relied on experiments reported in the literature and—when experimental data were not sufficient—we have performed additional experiments providing an extended foundation for defect analysis. There is large interest in reducing the effort and cost of additive manufacturing process qualification and certification using integrated computational material engineering. A prerequisite is, however, that numerical methods can indeed capture defects. A multiscale multiphysics platform is developed and applied to predict and explain the origin of several defects that have been observed experimentally during laser-based powder bed fusion processes. The models utilized are briefly introduced. The ability of the models to capture the observed defects is verified. The root cause of the defects is explained by analyzing the numerical results thus confirming the ability of numerical methods to provide a foundation for rapid process qualification.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Research on the Corrosion Behavior of X70 Pipeline Steel Under Coupling Effect of AC + DC and Stress

The coupling effect of stray AC (alternating current) + DC (direct current) and tensile stress-induced X70 pipeline corrosion is complicated with its mechanism uncovered. In this work, the corrosion behavior of X70 pipeline steel under three different corrosion (including an individual AC corrosion, mixed AC + 150 MPa tensile stress corrosion, coupling effect of AC + a 30 A/m{sup 2} DC interference and 150 MPa tensile stress corrosion) conditions in Dagang soil simulated solution was investigated by COMSOL Multiphysics software simulation, electrochemical tests, scanning electron microscope and other techniques. The results indicated that with the increase in AC density, the open-circuit potential of the X70 steel samples was negatively shifted and corrosion rate increased in three different corrosion conditions. The corrosion rates of X70 steel samples under individual AC interference were almost unchanged when 150.9 MPa tensile stress was applied. When applying 30 A/m{sup 2} DC interference, the corrosion rate of X70 steel increases significantly. Therefore, the factors affecting corrosion performance of X70 pipeline steel were DC > AC > stress. Under individual AC interference, uniform corrosion occurred on the X70 steel at an AC current density of less than 30 A/m{sup 2}, while the pitting corrosion occurred at an AC current density of greater than 100 A/m{sup 2}. The application of tensile stress and DC had a certain inhibitory effect on pitting corrosion.

36 MATERIALS SCIENCE↗
DOE OSTI2016

Multi-Dimensional Simulation of LWR Fuel Behavior in the BISON Fuel Performance Code

Nuclear fuel operates in an extreme environment that induces complex multiphysics phenomena occurring over distances ranging from inter-atomic spacing to meters, and times scales ranging from microseconds to years. To simulate this behavior requires a wide variety of material models that are often complex and nonlinear. The recently developed BISON code represents a powerful fuel performance simulation tool based on its material and physical behavior capabilities, finite-element versatility of spatial representation, and use of parallel computing. The code can operate in full three dimensional (3D) mode, as well as in reduced two dimensional (2D) modes, e.g., axisymmetric radial-axial (R-Z) or plane radial-circumferential (R-θ), to suit the application and to allow treatment of global and local effects. A BISON case study was used in this paper to illustrate analysis of Pellet Clad Mechanical Interaction failures from manufacturing defects using combined 2D and 3D analyses. The analysis involved commercial fuel rods and demonstrated successful computation of metrics of interest to fuel failures, including cladding peak hoop stress and strain energy density. Finally, in comparison with a failure threshold derived from power ramp tests, results corroborate industry analyses of the root cause of the pellet-clad interaction failures and illustrate the importance of modeling 3D local effects around fuel pellet defects, which can produce complex effects including cold spots in the cladding, stress concentrations, and hot spots in the fuel that can lead to enhanced cladding degradation such as hydriding, oxidation, CRUD formation, and stress corrosion cracking.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2019

Integrated Simulation Framework for Additively Manufactured Ti-6Al-4V: Melt Pool Dynamics, Microstructure, Solid-State Phase Transformation, and Microelastic Response

In this work, to accelerate the establishment of fundamental understanding of the additive manufacturing (AM) process and its influence on microstructural evolution and related properties, we develop a multiphysics and multiscale modeling framework that integrates: (1) a high-fidelity powder-scale three-dimensional simulation of transient heat transfer and melt flow dynamics, (2) cellular automaton simulation of solidification grain structure and texture, (3) phase-field modeling of precipitation and dissolution of second-phase precipitate during repeated thermal cycles, and (4) microstructure-based micro- and mesoscopic elastic response calculation. Using Ti-6Al-4V as a model system, we demonstrate the application of the integrated framework to simulate complex microstructure evolution during a single-track laser powder bed fusion process and the associated mechanical response. Our modeling framework successfully captures the solidification β grain structure as a function of laser power and scanning speed, α precipitation upon subsequent cooling with different rates, and elastic response of the resulting (α + β) two-phase microstructure. The key features of solidification and second-phase precipitate microstructures, and their dependence on processing parameters, agree well with existing experimental observations. Finally, the established modeling framework is generally applicable to other metallic materials fabricated by AM.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Solving macroscopic and microscopic pin-fin heat sink problems by adapted spectral method

In this paper, simulation of heat transfer in a heat sink with macroscopic and microscopic scales when one pin-fin is added to the system is investigated by the proposed spectral method. In the microscopic problems, heat transfer model uses dual-phase lag formulas in contrast with macroscopic problems when Fourier law is used to formulate the governing equation. In macroscopic problem, the results are compared with COMSOL multiphysics software results and a good agreement between the results are shown. In microscopic problems, 3D Gaussian heat source is used and boundary conditions obey the Newton law. Comparisons show the efficiency of the current method, while the results are compared with existed literature. It is shown that: by adding one pin fin to the heat sink problem, temperature of the system will decrease. Numerical results are given and graphs of the temperature for various kinds of pin-fin heat sink problems are depicted.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2021

Additive Manufacturing in the Nuclear Reactor Industry

This article discusses the application of additive manufacturing in the nuclear reactor industry.Additive manufacturing for nuclear applications increased significantly in the late 2010s due to rapid progress in technology, particularly with methods using metals and ceramics.Because these manufacturing technologies are uniquely data-rich, they allow for an advanced understanding of materials, and they offer the potential to predict part performance based on build data. The inherent characteristics of additive manufacturing technologies allow for rapid prototyping and geometric freedom, making it possible to implement an accelerated agile design process for advanced nuclear reactor applications. Predictive high-fidelity multiphysics simulations are crucial to fully leverage this geometric flexibility. Qualification and regulator acceptance ultimately determine the breadth and scope of applications for these technologies. The US Department of Energy Office of Nuclear Energy Transformational Challenge Reactor program integrates many of these elements to accelerate the deployment of additive manufacturing technologies to industry.

Betzler, Benjamin↗
DOE OSTI2023

High fidelity model of directed energy deposition: Laser-powder-melt pool interaction and effect of laser beam profile on solidification microstructure

Metal additive manufacturing technologies keep receiving a great deal of interest as well as strong requests to develop methods to link the process science to printed parts performance and understand how to overcome inherent limitations. Here, a high-fidelity model based on the multiphysics ALE3D code was developed to reproduce the directed energy deposition process down to the powder scale. This includes resolving the laser-powder-melt pool interactions (powder impingement and incorporation into melt pool, hydrodynamics flow condition and laser absorption inefficiencies) as well as the resulting solidification microstructure. This micrometer scale digital twin captured the effect of powder incorporation process and powder flow rate on porosity. Furthermore, it was used to explore how a ring laser beam profile instead of the standard Gaussian laser profile could decrease the thermal gradient along the solidification front in the melt pool, which in turn can increase propensity for more desirable equiaxed grains.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Non-intrusive reduced order modeling of natural convection in porous media using convolutional autoencoders: Comparison with linear subspace techniques

Natural convection in porous media is a highly nonlinear multiphysical problem relevant to many engineering applications (e.g., the process of CO 2 sequestration). Here, we extend and present a non-intrusive reduced order model of natural convection in porous media employing deep convolutional autoencoders for the compression and reconstruction and either radial basis function (RBF) interpolation or artificial neural networks (ANNs) for mapping parameters of partial differential equations (PDEs) on the corresponding nonlinear manifolds. To benchmark our approach, we also describe linear compression and reconstruction processes relying on proper orthogonal decomposition (POD) and ANNs. Further, we present comprehensive comparisons among different models through three benchmark problems. The reduced order models, linear and nonlinear approaches, are much faster than the finite element model, obtaining a maximum speed-up of 7 × 10 6 because our framework is not bound by the Courant–Friedrichs–Lewy condition; hence, it could deliver quantities of interest at any given time contrary to the finite element model. Our model’s accuracy still lies within a relative error of 7% in the worst-case scenario. We illustrate that, in specific settings, the nonlinear approach outperforms its linear counterpart and vice versa. We hypothesize that a visual comparison between principal component analysis (PCA) and t-Distributed Stochastic Neighbor Embedding (t-SNE) could indicate which method will perform better prior to employing any specific compression strategy.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2018

Measurement of acoustic properties of microalgae and implications for the performance of ultrasonic harvesting systems

Microalgae are a promising feedstock for biofuel production, but difficulties associated with harvesting suspended cultures contribute to the high costs of algal feedstock production. Ultrasonic harvesting has been identified as a potential low-cost technique, but limited data are available on the response of microalgae cells in the presence of an acoustic field. The acoustic radiation force acting on a cell depends upon cell size and the acoustic contrast factor (ACF) of the cell in the media. The ACF depends upon the density and compressibility of the cell and the media. Cell size and ACF were measured for Microchloropsis gaditana, Nannochloropsis oculata, Phaeodactylum tricornutum, and Chlamydomonas reinhardtii. The average ACFs, which were determined by measuring the densities and sound velocities of suspensions containing varying concentrations of cells in growth media, were 0.04 (range = 0.03–0.05) for M. gaditana, 0.02 (range = 0.01–0.04) for N. oculata, 0.05 (range = 0.04–0.07) for P. tricornutum, and 0.05 (range = 0.049–0.053) for C. reinhardtii. The ratio of the acoustic radiation force to the drag force would be highest for C. reinhardtii cells due to their larger effective radius (5.6 μm compared to 1.9–2.7 μm for the other species). The effective ACF of C. reinhardtii was also evaluated by recording the motion of cells in the presence of an acoustic field, using particle tracking velocimetry, and then modeling the recorded motion using COMSOL Multiphysics software. The result (ACF = 0.04) demonstrated agreement with the density/sound velocity meter method. Experiments with starch null sta6 mutant C. reinhardtii cells demonstrated that the effective ACF can transition from positive to zero and eventually become negative as microalgae cells accumulate lipids. Furthermore, the dynamic nature of the ACF represents an opportunity and a challenge for acoustic harvesting of algal cells.

09 BIOMASS FUELS↗
DOE OSTI2016

Implementation and testing of the on-the-fly thermal scattering Monte Carlo sampling method for graphite and light water in MCNP6

Here, a proper treatment of thermal neutron scattering requires accounting for chemical binding through a scattering law S(α,β,T). Monte Carlo codes sample the secondary neutron energy and angle after a thermal scattering event from probability tables generated from S(α,β,T) tables at discrete temperatures, requiring a large amount of data for multiscale and multiphysics problems with detailed temperature gradients. We have previously developed a method to handle this temperature dependence on-the-fly during the Monte Carlo random walk using polynomial expansions in 1/T to directly sample the secondary energy and angle. In this paper, the on-the-fly method is implemented into MCNP6 and tested in both graphite-moderated and light water-moderated systems. The on-the-fly method is compared with the thermal ACE libraries that come standard with MCNP6, yielding good agreement with integral reactor quantities like k-eigenvalue and differential quantities like single-scatter secondary energy and angle distributions. The simulation runtimes are comparable between the two methods (on the order of 5–15% difference for the problems tested) and the on-the-fly fit coefficients only require 5–15 MB of total data storage.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2020

Global error analysis of the Chebyshev rational approximation method

The Chebyshev rational approximation method (CRAM) has become a widely adopted method for solving nuclear depletion problems. Therefore, understanding CRAM’s accuracy is important for the safe operation of nuclear power plants. This article performs a global error analysis of CRAM and finds that, as the length of the time step approaches zero, the relative error measured between the exact and CRAM solutions at a fixed end time approaches one and infinity for even and odd orders, respectively; for intermediate time step sizes, a minimum in relative error is observed. Finally, we show that the reason for CRAM’s behavior is that the method is inconsistent. Two best practices for using CRAM, derived from these results, are: (1) use CRAM order 16 or higher, (2) if necessary, increase the CRAM order when multiphysics coupling requires smaller time steps.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2023

A sensitivity analysis to predict the neutronics behavior of samples irradiated in the VTR rabbit system

We report a low-order neutronics model is developed to carry out hundreds of simulations efficiently and investigate the neutronics behavior of samples being irradiated in a test reactor setting under different geometrical constraints. The low-order model allowed for simulations that yield the expected neutronics behavior of any irradiated sample in any environment and allows for the calculation of highly accurate spatially averaged statistics and idealized spatial distributions in the neutron flux. Several benchmarks are performed to evaluate the performance and limitations of the low-order model revealing many important findings. The low-order model predicted the LHGR in the EBR-II driver fuel to within 2.34% by only simulating the fuel rod by itself, which served as a validation for the model. Sensitivity studies investigated 3% enriched UO 2 and U-10Zr being irradiated in the Versatile Test Reactor rabbit system. The analyses investigated a range of combinations of 15 radii and 5 heights for each sample in the rabbit system. Similar data sets are also provided for irradiations in the Advanced Test Reactor’s B-10 irradiation position, which is a thermal neutron spectrum environment. Generalized fits and fit coefficients are obtained for sample heating, reaction rate densities, and local multiplication rate characteristics, allowing the predictions of the neutronics behavior of the samples based on their geometrical constraints. The analyses and fits laid the groundwork for developing a user-end Multiphysics analysis framework to assist and accelerate irradiation experiment design and optimization.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2023

Effects of transient fission gas release on rod balloon burst behavior during a loss-of-coolant accident

The US nuclear energy industry is investigating strategies to increase the reactor operating cycle to 24 months, which would result in rod average burnups exceeding the current limit of 62 GWd/tU. To support this goal, multiphysics simulations tools and methodologies are being developed to predict the effects of this change during transient events such as loss-of-coolant accidents (LOCAs). In this work, two cladding burst correlations were used to predict cladding failure. Here, these were coupled with three transient fission gas release (tFGR) models and were implemented in the BISON fuel performance code to quantify any changes in cladding burst behavior during a large-break LOCA. First, a simple linear model was used to perform a sensitivity analysis of a single fuel rod. Second, a tFGR model available in BISON was applied to 281 fuel rods throughout the core. The third model examined was an empirical correlation based on data from the literature.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2024

The importance of delayed neutron precursors in gamma dose calculations for activated primary heat exchanger components in the Molten Salt Breeder Reactor

The Molten Salt Reactor (MSR) Multiphysics Applications technical area in the Nuclear Energy Advanced Modeling and Simulation program has supported the development of 3D Monte Carlo models of the Molten Salt Breeder Reactor (MSBR) over the last couple of years. This MSBR model was previously run with the Shift Monte Carlo code to perform radiation shielding calculations in the reactor cell area. The MSBR is a 2250 MWth (1000 MWe) liquid-fueled molten salt reactor design developed at Oak Ridge National Laboratory in the 1970s. Determining the source terms from activated primary heat exchanger (HX) components is important because delayed and prompt neutron fluxes incident on these components affect the dose rate in the primary HX maintenance areas. This information can be used in the development of remote handling procedures required during shutdown for maintenance. A methodology has been developed and is proposed in this paper to quantify the activated source term from the primary HX components as a result of the movement of the delayed neutron precursors in flowing primary fuel salt through the primary HXs in the MSBR. The goal of this research is to evaluate the gamma dose rates in the maintenance hatches above the primary HX using the activated HX source terms. The study showed that the gamma dose rates are approximately two orders of magnitudes higher when accounting for the neutron activation from the movement of delayed neutron precursors through the HXs than when flowing fuel is not considered. Thus, the movement of delayed neutron precursors must be taken into account for accurately predicting the neutron activation of primary loop components.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2024

A study on the impact of using a subchannel resolution for modeling of large break loss of coolant accidents

The nuclear industry is investigating the feasibility of transitioning from 18- to 24-month fuel cycles because of the positive impact it would have on the operational costs for the current fleet of light-water reactors. A challenge to making this change is the increased risk of fuel fragmentation, relocation, and dispersal (FFRD) due to the known potential for ceramic fuel to pulverize into fine particles at the higher discharge burnups. Previous work has been performed by the Nuclear Energy Advanced Modeling and Simulation program to assess FFRD risk in high-burnup cores using the BISON fuel performance code and a coarse mesh thermal hydraulics (T/H) solution for a loss-of-coolant accident (LOCA) using the TRACE system T/H code. Because of the importance of the T/H solution for FFRD assessment, this study seeks to investigate the impact of using higher-fidelity subchannel techniques for modeling of the LOCA transient. CTF was used to model a subregion of a high-burnup core that was depleted by the Virtual Environment for Reactor Applications (VERA) multiphysics core simulator. Both coarse-mesh and pin-resolved models were created in CTF, and a consistent coarse-mesh TRACE model was also developed to allow for benchmarking the code results. Further, a large-break loss-of-coolant accident (LBLOCA) reflood transient was simulated using these three models, and results were compared. Results showed some consistent differences between the CTF and TRACE coarse models, including a higher peak cladding temperature (PCT) prediction in CTF and later quenching in CTF; however, the transient clad temperature behavior was similar, and these differences are likely due to post-critical heat flux heat transfer modeling differences and minimum film boiling temperature model differences. The pin-resolved results indicate that the PCT in the lumped model is often under-predicted by as much as 70 °C and that PCT occurs at a different location than the high-power pin in the assembly. The lumped model predicts a difference of 10 °C or less between the average and hot pins in the assembly, whereas the pin-resolved model predicts a range of over 100 °C. These results indicate that higher-fidelity T/H results may have an impact on predicted core behavior during LOCA, which may be important to consider when assessing FFRD risk.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2021

High spatial resolution temperature profile measurements of solid-oxide fuel cells

Temperature gradients resulting from local electrochemical reactions, current distribution and geometry of gas flow channels in solid oxide fuel cells (SOFCs) create thermal stresses, localized thermophysical property gradients and uneven property evolution, contributing to SOFC degradation. This paper presents a new method to perform temperature measurements (up to 800°C) at high spatial resolutions to monitor the operation of SOFCs. Using femtosecond laser irradiation, distributed fiber sensors were hardened for high temperature environment applications. Distributed fiber sensors were embedded in interconnected plates using an additive manufacturing method to perform temperature measurements with 4-mm spatial resolution during the operation of a planar fuel cell. The measurement revealed the impact of various H 2 fuel concentrations and current loads have on temperature profiles of the SOFC tested. Temperature variation on the anode side was found to be less than 5°C, and 3°C on the cathode side. The measurements were compared to results from a multiphysics fuel cell performance model simulating similar conditions. These simulations predicted similar temperature gradients, indicating the experimental data obtained is reasonable. The model also predicts that the effect of the embedded sensor has on the local temperature will be minimal and that the gradient of temperature in the gas channels will be captured despite the separation between the sensor and the gas flow. Finally, the high spatial resolution data harnessed by these distributed fiber sensors provides experimental support for model-based design and optimization to improve the operational efficiency and longevity of solid oxide fuel cells and fuel cell assemblies.

25 ENERGY STORAGE↗