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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 OSTI2020

Towards improved speed and accuracy of laser powder bed fusion simulations via multiscale spatial representations

Due to the growing popularity of laser powder bed fusion (LPBF) as a metal additive manufacturing technique, there is a strong need to be able to accurately predict build outcomes. Full fidelity simulations of this process are not feasible due to the vast range of length and time scales inherent to it. While part-scale codes for simulating residual stress and distortion have shown reasonable predictive capability, they often neglect many aspects of the process occurring over smaller length/time scales, and thus are unable to capture effects of process parameter adjustments or the behavior of fine features. One way of capturing aspects at more refined length scales is through the use of adaptive mesh refinement (AMR). AMR allows for the process to be simulated at scales approaching the physical spatial dimensions without drastically increasing the total degrees of freedom in the simulation. This manuscript describes the implementation of an AMR algorithm within a multiphysics, parallelized finite element code, and its application to the LPBF problem. In this work, part-scale examples are provided where the use of AMR has allowed for higher fidelity thermal and thermomechanical simulations, as compared to experimental measurements. Results from these higher resolution simulations show that while AMR is a necessary component for increased accuracy in a computationally efficient manner, other improvements are also necessary, including handling of the multiple time scales inherent to the problem and the need for improved AM-specific material models.

42 ENGINEERING↗
DOE OSTI2024

Comparison of excess free energy at an interface according to the applied interpolation scheme for elasticity: A phase-field method

Phase-field modeling is an effective simulation technique for modeling microstructure evolution of elastically anisotropic systems. To introduce the elastic energy contribution in a phase field model, an interpolation scheme is used to define the mechanical properties within the phases and across the continuous interface. Several existing interpolation schemes introduce a potential excess elastic energy at the interface, which undesirable effect on microstructure evolution needs to be evaluated. In this study, we focused on three interpolation schemes including Khachaturyan’ scheme (KHS), Voigt–Taylor’s scheme (VTS), and Steinbach–Apel’s scheme (SAS). Comparisons of these schemes’ performances were performed in three configuration types using the MOOSE (Multiphysics Object-Oriented Simulation Environment) framework: bi-crystal, isotropic particle-matrix and anisotropic particle-matrix. The contribution of excess elastic energy on the interface energy as a function of interface width and the computational time to steady-state were evaluated in these three configurations. SAS introduces the lowest excess elastic energy contribution and the VTS has the biggest contribution amongst the considered schemes. Moreover, when modeling precipitation in an anisotropic elastic material, the SAS approach seems to predict more physical convex shapes during growth, making it preferable to KHS and VTS. Finally, as currently implemented, SAS requires the largest computational time and KHS requires the smallest time to reach steady-state amongst the considered schemes.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Optimization of direct air capture processes using reactive transport models of adsorption-desorption cycles

In this study, we develop and implement a reactive transport model in COMSOL Multiphysics® to address the challenges of direct air carbon capture. The model is validated against experimental data and used to simulate the cyclic steady state of the adsorption-desorption process. The optimization of this model is achieved through advanced trust-region methods integrated with Gaussian Processes. Key decision variables, including adsorption and desorption times, desorption temperature and pressure, input velocity, bed porosity, column length, and radius were optimized to minimize the capture cost. After optimization, a sensitivity analysis revealed the complex interplay between the decision variables and their effect on the specific energy and cost of removing the CO 2 . We optimized the capture cost while taking into account the trade-off between energy consumption and productivity. The resulting minimum capture cost was determined to be 265.2 $/t-CO 2 , which aligns with expected values reported in the literature. Numerical results suggest the effectiveness of the optimization strategies applied, and underscore the importance of simultaneous decision variable selection in improving the performance in direct air capture processes. We also extend the modeling approach to a 2D axisymmetric model to better visualize CO₂ uptake and temperature profiles, revealing significant radial gradients during the regeneration step. As a main drawback, this enhanced model comes with a computational cost approximately 40 times higher than that of the 1D model.

Adsorption-desorption process↗
DOE OSTI2020

A matrix-free hyperviscosity formulation for high-order ALE hydrodynamics

The numerical approximation of compressible hydrodynamics is at the core of high-energy density (HED) multiphysics simulations as shocks are the driving force in experiments like inertial confinement fusion (ICF). In this work, we describe our extension of the hyperviscosity technique, originally developed for shock treatment in finite difference simulations, for use in arbitrarily high-order finite element methods for Lagrangian hydrodynamics. Hyperviscosity enables shock capturing while preserving the high-order properties of the underlying discretization away from the shock region. Specifically, we compute a high-order term based on a product of the mesh length scale to a high power scaled by a hyper-Laplacian operator applied to a scalar field. We then form the total artificial viscosity by taking a non-linear blend of this term and a traditional artificial viscosity term. We also present a matrix-free formulation for computing the finite element based hyper-Laplacian operator. Such matrix-free methods have superior performance characteristics compared to traditional full matrix assembly approaches and offer advantages for GPU based HPC hardware. We demonstrate the numerical convergence of our method and its application to complex, multi-material ALE simulations on high-order (curved) meshes.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2019

A heuristic model inversion for coupled thermo-hydro-mechanical modelling of triaxial experiments

As multiphysics geomechanical models get developed, their increasing complexity and number of parameters make it particularly difficult to calibrate against experimental data. In this contribution, we present a heuristic workflow to invert for parameters of a coupled Thermo-Hydro-Mechanical (THM) model in a way that helps the theoretical modellers refine their definition of the underlying elasto-visco-plastic model itself. We apply this workflow to the calibration of deviatoric and volumetric data for two sets of triaxial experiments on mudstone and sandstone. Here, we show that beyond the calibration of well-defined parameters of the THM model, one or two scaling factors of the experimentally obtained yield surface and two more factors to capture the confinement and pore pressure dependency of the flow law lead to the satisfactory matching of series of experiments at varying confinements for two different rock types. Using this physical model, we also show that tracking the volumetric component of the mechanical power in the numerical simulations might allow reducing the number of experiments required to calibrate the model.

58 GEOSCIENCES↗
DOE OSTI2021

Effects of fiber dosage, loading orientation and stress on frequency response of enhanced Carbon Nano-Fiber Aggregates

Nanomaterial additives have been broadly used in cement and concrete-based sensors to measure the stress and strain in the structure. Most of the studies focused on measuring the resistivity of sensors with Direct Current (DC) or relatively low-frequency. Here in this work, the impedance responses of enhanced Carbon Nano-Fiber Aggregates (CNFAs) at different frequencies are rigorously studied and utilized as a tool for real-time structural health monitoring (SHM). The CNFA impedance measurements at different measurement frequencies provide an extra dimension (frequency dimension) to allow the characterization of different phenomena and multimodal measurements simultaneously. First, a comprehensive physical model is established to understand the frequency responses of the CNFA impedance. Second, COMSOL Multiphysics is used to simulate the frequency responses of the CNFA impedance, which provides more insights into the electric field and current density distribution. The impedance of CNFAs decreased with the increased dosage of carbon nanofibers (CNFs). Third, experimental studies are reported in detail. The electrical impedance variation (EZV) of the CNFA in parallel orientation is 151% higher than that of perpendicular orientation at the frequency of 2612 Hz and uniaxial compression stress of 4.65 MPa. The strain-EZV curve obtained from the response spectrum is linear for frequencies ranging from 98 Hz to 463.9 kHz. The strain-EZV curve for 5625 Hz has a linear fit with the gauge factor of 147.78. At 1000 Hz, the CNFA exhibited a repeatable behavior up to 9.35 MPa and detection limit up to the stress of 18.62 MPa.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Thermo4PFM: Facilitating Phase-field simulations of alloys with thermodynamic driving forces

Phase-field modeling is a popular front-tracking approach used to model solidification. Its time-evolution equations are often coupled to alloy composition and/or thermal diffusion in high-resolution multiphysics approaches. Materials thermodynamic properties tabulated in CALPHAD databases can be used for phase-field modeling to parameterize bulk energies of alloys. In addition, they can be naturally integrated into models such as the Kim-Kim-Suzuki (KKS) model where driving forces depend on the differences between chemical potentials of co-existing phases. In that case, a small system of coupled nonlinear equations needs to be solved at every point in space where the phase-field order parameter is to be updated and evolved in time. Here we present Thermo4PFM, a solver for the KKS equations for binary and ternary alloys, with two or three phases, and parameterized with CALPHAD models. Thermo4PFM is open source, written in C++, and can take advantage of Graphics Processing Units (GPU) accelerators. Using OpenMP offload capabilities for C++ classes, an excellent performance is demonstrated on GPU using the LLVM compiler. CALPHAD data is read from simple JSON files using an open source parser from the boost library.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Verification and validation of the open-source plasma fluid code: Zapdos

Zapdos is an open-source finite element plasma fluid solver based on the MOOSE multiphysics framework. This paper outlines Zapdos verification, benchmarking, and validation efforts for 1D and 2D RF capacitively coupled plasma discharge models for mid-range pressures (0.1 - 1 Torr). The verification process involved using the method of manufactured solutions to assess Zapdos spatial and temporal error convergence. L2 errors ranged from 10 -2 to 10 -4 , while the convergence’s slope were in agreement with the predicted slopes for the tested variable and time integration orders. The benchmarking process involved comparisons to previously results from the validated finite element code, LSODI. These works included 1D and 2D simulations for a range of plasma parameters (densities, temperatures, voltage, etc.). For the 1D cases, Zapdos and LSODI results were in very good agreement. In the 2D cases, variable behaviors matched, with slight discrepancies in peak values. The validation process involved comparisons to experimental works including electron density measurements by microwave interferometry and metastable density measurements by planar laser-induced fluorescence imaging. Results shown reasonable agreement at higher pressure, with results starting to diverge at low pressures. Furthermore, probable causes for this diverges are the limitation of the fluid assumption for plasmas at low pressure, or the need for more robust boundary conditions. Overall, Zapdos shown reasonable results for the verification, benchmarking, and validation efforts, and Zapdos can be downloaded at https://github.com/shannon-lab/zapdos.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2024

The MOOSE fluid properties module

The Fluid Properties module within the Multiphysics Object-Oriented Simulation Environment (MOOSE) is used to compute fluid properties for numerous applications, ranging from nuclear reactor thermal hydraulics to geothermal energy. Those applications drove the development of the module to enable numerous different fluid equations of states, property lookups with primitive and conserved flow variable to cater to pressure and density-driven solvers, and an object-oriented design facilitating expansion and maintenance. Each fluid property is implemented in its own class but inherits capabilities such as automatic differentiation, automated out-of-bounds handling or variable conversion capabilities. Here, this paper presents the module, its design, its user and developer interface, its content in terms of fluids and properties, and several of its applications showing its major role in the MOOSE simulation ecosystem.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2025

A computational investigation of high-flux, plate-and-frame membrane modules for industrial carbon capture

In this work, we study the application of membrane-based separation systems for carbon capture, considering plate-and-frame membrane modules. The successful deployment of membrane CO 2 capture system relies on high-performing membranes as well as effective membrane modules that can fully exploit the developed membranes. A plate-and-frame membrane module is especially attractive for CO 2 capture from industrial flue gas due to its lower pressure drop compared to its counterparts such as spiral wound modules and hollow fiber modules. To design better plate-and-frame modules, we investigate their basic unit - a single membrane stack through a combination of computational modeling and experimental investigations. The modeling approach is based on Computational Fluid Dynamics (CFD) to represent a multiphysics problem, including the fluid flow and diffusion processes within a membrane module. We use experimental data collected under different operating conditions to validate the CFD model. Numerical results suggest a good agreement between experiments and model outputs for the CO 2 recovery, CO 2 mole fraction in the retentate and permeate, and stage-cut. The CFD model is able to predict accurately the flow behavior, providing valuable insights on the effects of fluid dynamics on mass transfer of CO 2 . We also carry out a sensitivity analysis to identify the effect of key parameters on the CO 2 recovery and the CO 2 purity of the outlet streams.

CFD simulation↗
DOE OSTI2025

Geologic hydrogen: From natural occurrences to anthropogenic generation – A review of fundamentals, potential, challenges and prospects

Growing demand for hydrogen is exposing the environmental and economic limits of reforming-based and carbon-managed supply chains, while the scale-up of electrolytic capacity remains capital-constrained. Geologic hydrogen, defined as molecular H₂ generated and stored within the Earth's crust offers a complementary, potentially lower-cost resource, yet exploration is still ad hoc. This review (1) revisits a global inventory of confirmed hydrogen seeps and subsurface occurrences; (2) analyzes the controlling reactions, migration pathways, and trapping conditions governing these occurrences; (3) proposes a process-based geologic hydrogen system concept analogous to, yet distinct from, the petroleum system; and (4) evaluates potential geologic hydrogen systems within the United States as a representative case study. Here, we contrast natural systems powered by serpentinization, mantle degassing or radiolysis with anthropogenic systems that stimulate the same reactions or convert in-situ hydrocarbons. Stable hydrogen accumulations require generation rates that outpace combined physical, chemical and microbial losses; the Bourakébougou field (Mali) exemplifies a self-recharging, free-gas reservoir sustained by meteoric-water serpentinization beneath an efficient caprock. Prospective geologic hydrogen resources are likely to occur in regions where iron-rich lithologies, deep-seated faults, and low-permeability sealing formations coexist. Applying this principle, we highlight three promising hydrogen play types in U.S. geological terrains: ophiolite belts (Appalachian and Californian regions), the Midcontinent Rift and the Lake Superior banded‑iron formations. Multiphysics numerical models and positive-unlabeled machine-learning workflows help to accelerate play screening and de-risk future production; yet, reaction kinetics, stimulation strategies, and full techno-economic and life-cycle assessments remain pivotal knowledge gaps.

Anthropogenic hydrogen generation↗
DOE OSTI2024

Coupling thermal energy storage with a thermally anisotropic building envelope for building demand-side management across various US climate conditions

Here, the thermally anisotropic building envelope (TABE) is a novel active building envelope that enhances energy efficiency and thermal comfort in buildings by transferring heat and cold between building envelopes and hydronic loops. When coupled with thermal energy storage (TES) units, the TABE + TES enables the storage of both heat and cold energy captured by the TABE roof or exterior walls. This stored energy can be later released by the TABE floor for indoor heating and cooling, benefiting both the grid and the end user. This paper evaluates the merits of TABE + TES for building demand-side management across various US climate conditions, focusing on peak load shaving, annual energy savings, and cost savings under time-of-use (TOU) electric rate schedules. Simulations were conducted by integrating time-of-day–informed, rule-based control strategies in MATLAB, TABE components and TES units in COMSOL Multiphysics, and whole-building energy analysis in EnergyPlus. A case study using the US Department of Energy’s prototype single-family detached house model in Birmingham, Alabama; Los Angeles, California; Oak Ridge, Tennessee; and Denver, Colorado, showed that the TABE + TES system achieved (1) 70 % peak load shaving in Los Angeles and Denver and 20 % in Birmingham and Oak Ridge; (2) significant peak electricity savings of 351–497 kWh, reducing peak energy consumption by 38 %–78 %; and (3) annual heating cost savings of 0.79 $\$$/m2–1.17 $\$$/m 2 and cooling cost savings of 0.60 $\$$/m 2 –1.17 $\$$/m 2 using a normal utility rate or low-TOU rate. The benefits of employing the TABE + TES system are even more significant under high TOU rates.

25 ENERGY STORAGE↗
DOE OSTI2025

Enhancing EnergyPlus capabilities to model dynamic building envelopes using python plugin

Nearly half of the energy consumption in the United States is related to buildings, resulting in an urgent need to develop innovative technologies to improve building energy efficiency. Dynamic building envelopes, comprising switchable insulation and thermal energy storage materials, have been proposed recently as a promising solution to reduce buildings' heating and cooling loads by thermally coupling the indoor environment with the ambient environment when beneficial while decoupling them when outdoor conditions are not favorable. Although various related technologies are still underway, the whole-building energy modeling tools, like EnergyPlus, do not have the capability to simulate the transient and dynamic nature of dynamic envelope materials and components to accurately predict their impact on building energy use. The objective of this study is to formulate a method in EnergyPlus simulation engine to model multilayer envelopes, comprising dynamic building materials with variable thermophysical properties, and discuss the changes made to the program using a Python plugin. Furthermore, the thermal performance of the dynamic envelopes using the proposed method is compared and verified with the results from a well-established commercial code, COMSOL Multiphysics. A parametric assessment is also conducted to evaluate the energy efficiency benefits of dynamic envelopes in a single-family residential building, demonstrating total annual energy savings up to 11.6 %, when a dynamic envelope operates alone, and up to 18.2 % when it is combined with a thin layer of phase change material as a thermal storage medium. Finally, a United States wide energy efficiency assessment is presented to showcase the geographical spread of the energy savings. The method designed and implemented in this study provides the researchers with the ability to implement their dynamic insulation methods in EnergyPlus and evaluate the whole building energy impact.

25 ENERGY STORAGE↗
DOE OSTI2019

Ceramic nuclear fuel fracture modeling with the extended finite element method

Ceramic fuel pellets used in nuclear light water reactors experience significant fracture due to the high thermal gradients experienced under normal operating conditions. This has important effects on the performance of the fuel system. Because of this, a realistic, physically based fracture modeling capability is essential to predict fuel behavior in a wide variety of normal and off-normal conditions. The extended finite element method (X-FEM) is a powerful method to represent arbitrary propagating discrete cracks in finite element models, and has many characteristics that make it attractive for nuclear fuel performance analysis. This paper describes the implementation of X-FEM in a multiphysics fuel performance code and presents applications of that capability. These applications include several thermal mechanics fracture benchmark problems, which demonstrate the accuracy of this approach. It also includes application of this capability to study nuclear fuel fracture, both on stationary and propagating cracks. The study on stationary cracks shows the effects that varying the number of radial cracks and the length of those cracks have on the energy release rate. Here, the propagating crack case demonstrates random initiation and subsequent propagation of interacting thermally induced cracks during an initial ramp to full power with fresh fuel.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2018

A distillation column for hydrogen isotope removal from liquid lithium

Recovery of tritium from plasma-facing components in fusion devices will be vital to future full-scale operation. Liquid, low-Z materials have demonstrated many inherent advantages over solid first wall materials. To this end, a thermal treatment method in the form of a distillation column for extraction of hydrogen isotopes from liquid lithium has been designed, developed, and constructed at the Center for Plasma-Material Interactions at the University of Illinois at Urbana-Champaign. Use of induction heating and lithium condensation stages are the two qualities that set this design apart from other thermal treatment systems. Induction heating capabilities were modeled using the COMSOL Multiphysics software, which were validated when commissioning the physical heater module. Proof-of-concept tests were performed in the prototype column, which were undertaken as batch processes to investigate the efficacy with which the column could remove hydrogen gas from lithium-rich and lithium hydride-rich samples. All of the tests reported used lithium hydride as a surrogate for lithium deuteride and lithium tritide. The design process and results from the initial tests will be discussed, along with the envisioned placement of this treatment scheme in a fully-functional lithium loop.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2024

Assessment of thermal and radiation induced creep in the dual cooled lead lithium blanket

The creep in recently designed blanket for the fusion nuclear science facility is described by decomposing it into thermal, irradiation and cavity swelling creep. Initial estimates of thermal creep using elastic high temperature rules showed that the recent heat transfer improvements at the first wall (FW) is feasible, and the FW can withstand heat flux of 0.35 MW/m 2 at 3000 hrs without rupture. A viscoplastic model that is based on Norton's power law and relies on Multiphysics coupling of solid mechanics and heat transfer modules is used to capture the inelastic deformation in the blanket. Results showed that the design peak heat flux of 0.25 MW/m 2 produced maximum thermal creep strain of 0.45 % and the relaxation of the thermal stress at the FW. Irradiation creep is prescribed to be proportional to the displacement damage dose and applied stress. The displacements from irradiation creep radially decrease from the FW to the back wall, but the maximum deformation is found at the back wall that is connected to the Helium manifold due to the high stresses at the region. In conclusion, cavity swelling creep is dominant at steady state and combined with radiation creep to produce displacement of about 8 mm at the FW.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗