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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 829 records · Page 46
All sourcesNASA NTRSDOE OSTI
DOE OSTI2018

Design, Development, and Operation of an Integrated Fluidized Carbon Capture Unit Using Polyethylenimine Sorbents

In this paper, we present the design, development, and operation of a reactor system for CO 2 capture. Modifications were implemented to address differences in sorbent from 180 μm Geldart group B to 115 μm Geldart group A material; operational issues were discovered during experimental trials. The major obstacle in system operation was the ability to maintain a constant circulation of a solid sorbent stemming from this change in sorbent material. The system consisted of four fluid beds, through which a polyamine impregnated sorbent was circulated and adsorption, preheat, regeneration, and cooling processes occurred. Pressure transducers, thermocouples, gas flow meters, and gas composition instrumentation were used to characterize thermal, hydrodynamic, and gas adsorption performance in this integrated unit. A series of shakedown tests were performed and the configuration altered to meet the needs of the sorbent performance and achieve desired target capture efficiencies. Methods were identified, tested, and applied to continuously monitor critical operating parameters including solids circulation rate, adsorbed and desorbed CO 2 , solids inventories, and pressures. The working capacity and CO 2 capture efficiency were used to assess sorbent performance while CO 2 closure was used to define data quality and approach to steady-state. Testing demonstrated >90% capture efficiencies and identified the regenerator to be the process step limiting throughput. Sorbent performance was found to be related to the reactant stoichiometry. Finally, a stochastic model with an exponential dependence on the relative CO 2 /amine concentration was used to describe 90% of the variance in the data.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2022

Module-Level Thermal Interface Material Degradation in HALT

Abstract In this study, thermal interface material (TIM) degradation is driven through highly accelerated life test (HALT) using temperature cycling with a prescribed vibrational acceleration for two commercially available materials having thermal conductivities of 6.0 and 8.5 W/m K. HALT specimens were prepared by applying TIM through a 4-mil stencil over AlSiC baseplates in the shape of those used in Wolfspeed CAS325M12HM2 power electronics modules. Baseplates were mounted onto aluminum carrier blocks with embedded thermocouples to characterize the thermal resistance across the baseplate and TIM layer. Thermal dissipation into the top of the baseplates was provided by a custom heating block, which mimics the size and placement of the die junctions in CAS325 modules, applying power loads of 200, 300, and 400 W. After initial characterization, samples were transferred to the HALT chamber with one set of samples exposed to temperature cycling only (TCO) and the other temperature cycling and vibration (TCV). Both sample sets were cycled between temperature extremes of −40 °C and 180 °C with vibrations applied at a peak acceleration of 3.21 Grms. After hundreds of cycles, samples were reevaluated to assess changes in thermal resistance to provide an accelerated measure of TIM degradation. This allows for reliability prediction of useful lifetime (illustrated in a solar inverter case study herein), as well as to provide a basis for developing an accelerated testing method to related temperature cycling to faster methods of degradation. Such techniques provide a means to develop maintenance schedules for power modules for ensuring sufficient thermal performance over the operating lifetime.

Engineering↗
DOE OSTI2023

Experimental and Computational Heat Transfer Study of sCO 2 Single-Jet Impingement

This study experimentally and computationally investigates the heat transfer capability of supercritical carbon dioxide (sCO 2 ) single jet impingement. The evaluated jet Reynolds number range is between 80,000 and 600,000, with a nondimensional jet-to-target surface spacing of 2.8. CO 2 -impinging jet stagnation conditions were maintained at approximately 200 bar and a temperature of ∼400 °C for most experiments. The goal is to understand how changes in the aforementioned parameters influence heat transfer between the working fluid and the heated surface. Additionally, due to the elevated Reynolds numbers and difference in thermodynamic properties between air and CO 2 , air-derived impingement correlations may not be appropriate for CO 2 impingement; these correlations will be evaluated against experimental sCO 2 impingement data. At the time of this study, no sCO 2 impingement data was available relevant to sCO 2 power cycles. The target surface is a 1.5-in. diameter copper block centered on the 3 mm jet orifice. A mica heating element bolted to the bottom of the copper block provides a uniform heat flux. Thermocouples embedded in the copper block are used to determine the surface temperature. Nusselt numbers obtained from experimental sCO 2 test data are compared to area-averaged Nusselt numbers from air-derived correlations. The comparisons showed that air correlations drastically underpredict the heat transfer when sCO 2 is used as the working fluid. A modified sCO 2 correlation using experimental data at discussed conditions is derived based on an existing air correlation. A CFD study is also performed to further investigate sCO 2 heat transfer characteristics, and assess the numerical model applicability to this problem type.

42 ENGINEERING↗
DOE OSTI2024

Band Heater Heat Flux Characterization Using Inverse Heat Conduction Problem Models

Abstract An experimental apparatus was constructed to correlate water flowrate and temperature rise under an external band heater. Due to the physical characteristics of the band heater, its transient heating behavior is unknown. This paper investigates the application of inverse heat conduction problem (IHCP) methods to characterize the heat flux from the band heater. Three experiments with different heating times (5, 10, and 20 s) and no flowrate were conducted to measure the transient temperature under the 400 W band heater. Type-T thermocouples measure surface temperature at the centerline of the band heater. The experimental results are computed with five different heat conduction models. The models are chosen to identify how the heat flux response varies from a simplified to a realistic model. Additionally, the results of the experimental heat flux are compared to the manufacturer band heater data (58.9 kW/m2) for each model. The minimum time needed for the heater to fully energize the system is from 10 to 12 s. The residuals for each model are analyzed and used to evaluate the appropriateness of the five different models. The results show that the use of simpler models can achieve results similar to those of complex models, with less time and computational cost.

Engineering↗
DOE OSTI2019

Experimental Evaluation of Heat Transfer in a High Temperature High Pressure Test Facility

Performance of film cooling holes is generally evaluated near ambient conditions, so scaling the film cooling performance from ambient to engine conditions is important. These performance metrics can be reported in terms of net heat flux reduction, heat transfer enhancement, and effectiveness. There are several challenges and penalties in conducting experiments on a real engine or even on a stationary flat plate test article at near engine conditions. In this study, an experimental methodology capable of delivering film cooling performance for the experiments conducted in the high-temperature high-pressure test facility at NETL will be explored. More specifically, this study focuses on various challenges that are present and how these concerns are addressed to evaluate the heat transfer coefficient on the test article. Steady state experiments were conducted on a flat plate test article whose surface temperature distribution was obtained using an IR camera calibrated with a combination of bench top experiments and in-situ calibrations based on embedded thermocouple measurements. A detailed radiation analysis is conducted to enable differentiation of heat transfer by convection from heat transfer by radiation. The estimated surface heat flux and heat transfer coefficient were found to be higher than the one obtained from flat plate correlation.

Ramesh, Sridharan↗
DOE OSTI2020

Calculation of Critical Heat Flux Using an Inverse Heat Transfer Method to Support TREAT Experiment Analysis

Heat transfer between cladding and coolant during transient scenarios remains a critical area of uncertainty in understanding nuclear reactor safety. To advance the understanding of transient and accident scenarios involving critical heat flux (CHF), an in-pile experiment for the Transient Reactor Test (TREAT) facility at Idaho National Laboratory was developed. The experiment named CHF-Static Environment Rodlet Transient Test Apparatus (CHF-SERTTA), consists of a hollow borated stainless steel heater rod submerged in a static water pool which is heated via the (n, a) reaction in boron-10. This paper presents a novel inverse heat transfer method to determine CHF by using the optimization and uncertainty software DAKOTA to calibrate a RELAP5-3D model of CHF-SERTTA to temperature measurements obtained from a thermocouple welded to the surface of the rod.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2019

Welding Process Development for Spent Nuclear Fuel Canister Repair

The potential for stress corrosion cracking (SCC) of welded stainless-steel interim storage containers for spent nuclear fuel (SNF) has been identified as a high priority data gap. This paper presents a fusion welding process that was developed for SNF canister repair. Submerged arc welding (SAW) was developed to weld 12.7 mm (0.5 in.) thick 304L stainless steel plates to simulate the initial welds on SNF canisters. The SAW procedure was qualified following ASME Boiler and Pressure Vessel Code requirements. During SAW, the welding temperature was recorded at various locations by using thermocouples. After SAW, weld microstructures were characterized, joint mechanical properties were tested, and the maximum tensile residual stress direction was identified. After SAW procedure qualification, artificial cracks were excavated perpendicular to the maximum tensile residual stress direction in the SAW heat affected zone. Machine cold-wire gas tungsten arc welding (CW-GTAW) was developed and used for repair welding at cracked locations.

Tang, Wei↗
DOE OSTI2021

TRANSIENT THERMAL MODELING OF THE HIGH BURNUP DEMONSTRATION RESEARCH PROJECT CASK USING STAR-CCM+ AND COBRA-SFS

The Department of Energy in collaboration with the Electric Power Research Institute is in the process of conducting the High Burnup Demonstration Project. Where the objective is to characterize the performance of high-burnup fuel in long term storage. As part of this demonstration, a TN-32B dry storage cask was instrumented and loaded with spent nuclear fuel at North Anna Nuclear Generating Station in November 2017. The project cask provides a unique opportunity to gain information on spent fuel and cask performance from an in-service operational system. The cask was instrumented with thermocouples inside of the fuel assemblies, then loaded and dried using normal procedures. After the drying process a thermal soak period where the cask was left indoors was used to obtain steady temperatures for model comparison along with surface temperatures. This paper details thermal modeling validation work that was done to model both the steady state and transient cases. Two modeling tools were used to predict temperatures in the cask. The general purpose CFD and heat transfer code STAR-CCM+ was used with both a detailed pin-by-pin model was used along with a more efficient k-effective simplification. The other code is COBRA-SFS, a purpose-built detailed thermal modeling tool developed and maintained at PNNL. Results from all the modeling tools were compared blind to the test data. Each model utilized general design information and compared reasonably well to the blind steady state data using convection and surface temperature boundary conditions. Post-test adjustments were later made to better reflect the “as built” conditions of the cask. Based on lessons learned from the steady state analysis the vacuum drying process was modeled in both codes. Utilizing the measured loading conditions the transient models were able to compare very well with the measured data. Overall the project showed an ability to model spent fuel storage conditions very well and future work is planned to generalize the methodology used for vacuum drying.

Thermal Analysis, Spent Fuel, Dry Storage↗
DOE OSTI2014

JOHNSON NOISE THERMOMETRY FOR DRIFT-FREE MEASUREMENTS

In order for Johnson Noise Thermometry (JNT) to be beneficial to SMR designers, it must offer advantages beyond the current state-of-the-art technology. Comparisons to traditional RTDs and thermocouples will involve life-cycle costs, installation footprint, reliability, and accuracy. With JNT, there is additional equipment beyond what is required for the traditional RTD measurement. Therefore, the JNT-RTD system will involve additional complexity and this additional complexity must be justified. Operators will want to know that the measurement is reliable and trustworthy. It is also important that the sensor involve little, if any, additional ongoing maintenance work and that it has a low probability of causing any malfunction of the primary measurement channel. If these features can be successfully demonstrated, the JNT-RTD system could potentially save money and increase plant reliability.

Britton, Jr, Charles L↗
DOE OSTI2017

Polarization effects associated with thermal processing of HY-80 structural steel using high-power laser diode array

Localized heating of roughened steel surfaces using disperse laser light emitted from high power laser diode arrays was experimentally demonstrated and compared with theoretical predictions. The Fresnel equations were used to analyze the optical absorptivity in terms of the angle of incidence and polarization state to understand the laser-induced temperature rise of HY-80 steel plates under 383-612 W laser irradiation. Laser-induced, transient temperature distributions were directly measured using bulk thermocouple probes and thermal imaging. Finite element analysis yielded quantitative assessment of energy deposition and heat transport in HY-80 steel using absorptivity as a tuning parameter. The extracted absorptivity values ranged from 0.62 to 0.75 for S-polarized and 0.63 to 0.85 for P-polarized light, in agreement with partially oxidized iron surfaces. Microstructural analysis using electron backscatter diffraction revealed a heat affected zone for the highest temperature conditions (612 W, P-polarized) as evidence of rapid quenching and an austenite to martensite transformation. In conclusion, the efficient use of diode arrays for laser-assisted advanced manufacturing technologies such as hybrid friction stir welding is discussed.

36 MATERIALS SCIENCE↗
DOE OSTI2021

In Situ Measurement of Temperature Distributions in a Li-ion Cell during Internal Short Circuit and Thermal Runaway

Here we report in situ measurement of temperature distributions in a 2.5-Ah pouch format Li-ion cell during internal short circuit (ISC) and thermal runaway. The ISC and thermal runaway were triggered by nail penetration. The local temperatures were measured by embedded K type micro thermocouples in the middle layer of the experimental Li-ion cell. Highly non-uniform temperature distributions were observed during ISC and thermal runaway as compared with those during constant current discharging and external short circuit. The in situ measurement also captured details of how thermal runaway started from the ISC location and spread to the entire cell in a few seconds. Moreover, the comparison between ISC without thermal runaway and ISC with thermal runaway suggests that internal short circuit resistance plays a critical role in the risk of thermal runaway.

Huang, Shan↗
DOE OSTI2017

Tracking Internal Temperature and Structural Dynamics during Nail Penetration of Lithium-Ion Cells

Mechanical abuse of lithium-ion batteries is widely used during testing to induce thermal runaway, characterize associated risks, and expose cell and module vulnerabilities. But, the repeatability of puncture or 'nail penetration' tests is a key issue as there is often a high degree of variability in the resulting thermal runaway process. Here, the failure mechanisms of 18650 cells punctured at different locations and orientations are characterized with respect to their internal structural degradation, and both their internal and surface temperature, all of which are monitored in real time. The initiation and propagation of thermal runaway is visualized via high-speed synchrotron X-ray radiography at 2000 frames per second, and the surface and internal temperatures are recorded via infrared imaging and a thermocouple embedded in the tip of the penetrating nail, respectively. The influence of the nail, as well as how and where it penetrates the cell, on the initiation and propagation of thermal runaway is described and the suitability of this test method for representing in-field failures is discussed.

25 ENERGY STORAGE↗
DOE OSTI2022

sCO2 heat exchanger control software

SAND2022-6992 O The sCO2 Heat Exchanger Control Software was written for control and operation of high temperature, high pressure supercritical CO2 systems designed for use as heat exchangers. The software was written using the basic LabVIEW package with LabVIEW modules added to it. The software controls valves and actuators, displays data from pressure transducers and thermocouples, and is able to record data at different storage rates. Sandia National Laboratories is a multimission laboratory managed and operated by National Technology & Engineering Solutions of Sandia, LLC, a wholly owned subsidiary of Honeywell International Inc., for the U.S. Department of Energy’s National Nuclear Security Administration under contract DE-NA0003525.

Garcia Maldonado, Luis↗
DOE OSTI2017

Characterization of the pyroelectric coefficient of a high-temperature sensor

Temperature is one of the most important thermodynamic properties measured and controlled in energy generation systems. To operate the energy system at optimum operating conditions for lower emission and higher efficiency, it is important to measure real-time temperatures. Furthermore, temperature sensing in intense environments is necessary since most sensors in energy systems get exposed to elevated temperatures, corrosive environments, and elevated pressures. One of the solutions for developing harsh environment sensors is to use ceramic materials, especially functional ceramics such as pyroelectrics. Pyroelectric ceramics could be used to develop active sensors for both temperature and pressure due to their capabilities in coupling energy among mechanical, thermal, and electrical domains. In this study, Lithium niobate (LiNbO 3 ) pyroelectric ceramic material was used to develop a temperature sensor for high-temperature applications. LiNbO 3 has high Curie temperature (1210°C) compared to other pyroelectric ceramic materials. A high Curie temperature material is important since the polarization properties of the material break down above the Curie temperature. Hence, the use of a material with a higher Curie temperature, such as LiNbO 3 , makes it promising to be used as a sensing material for high-temperature applications. A study was performed to actively measure the temperature up to 500°C using a pyroelectric ceramic lithium niobate (LiNbO 3 ) as a sensor material. Due to the non-linear pyroelectric response of LiNbO 3 , the temperature-dependent pyroelectric coefficient of LiNbO 3 was measured with a dynamic pyroelectric coefficient technique in temperature ranges up to 500°C. Temperature-dependent pyroelectric coefficient of LiNbO 3 was found to increase from −0.5 × 10 −5 to −3.70 × 10 −5 C/m 2 °C from room temperature to 500°C. The LiNbO 3 sensor was then tested for higher temperature sensing at 220°C, 280°C, 410°C, and 500°C and has shown 4.31%, 2.1%, 0.4%, and 0.6% deviation, respectively, compared with thermocouple measurements.

Sarker, Md Rashedul H.↗
DOE OSTI2022

Characterization and repair of core gap manufacturing defects for wind turbine blades

Various wind turbine blade components, such as shear webs and skins, commonly use fiber-reinforced composite sandwich structures with a core material like balsa or foam. During manufacturing, core gap defects may result from the misalignment of adjacent foam or balsa core sheets in the blade mold. It is important to understand the influence that core gaps have on the structural integrity of wind turbine blades and how to mitigate their influence. This research characterized the effects of core gap defects at the manufacturing and mechanical levels for both epoxy and next-generation thermoplastic composites. Common repair methods were assessed and compared. Multiple defect sizes were compared using temperature data gathered with thermocouples embedded during manufacturing to core gap defect characteristics obtained using image-mapping techniques, optical microscopy, and mechanical characterization by long beam flexure. Results showed that peak exothermic temperatures during curing were closely related to core gap size. The long beam flexure tests determined that transverse core gaps under pure bending loads can have a substantial effect on the ultimate facesheet strength of both epoxy and thermoplastic composite sandwich structures (up to 25% strength reduction), although the size of the defect itself had less of an influence on the magnitude of the strength reduction. The supporting image-mapping techniques indicated that the distortion of the composite facesheets by the core gaps contributed to the premature failures. The repair methods used in this study did very little to improve the ultimate strength of the sandwich panels that previously had core gap defects. The repair of the thermoplastic panel resulted in a further loss in ultimate facesheet strength. This research demonstrated that there is a vital need for the development of a compatible thermoplastic polymer repair resin system and appropriate resin specific repair procedures for the next generation of recyclable thermoplastic wind blades.

17 WIND ENERGY↗
DOE OSTI2022

In-situ thermomechanical measurements during burst testing of Zr claddings using digital image correlation and infrared thermography techniques

Burst testing has long been a relied-on method for assessing fuel cladding materials in light-water reactoraccident scenarios. However, burst testing historically provided minimal in-situ observations beyond a few thermocouple readings, pressure from transducers, and post-test deformation measurements. Acquisition of full cladding thermomechanical data throughout a burst test would be invaluable to fuel system qualification, material model development and fuel performance code validation, such as the BISON fuel performance code. Recently, methodologies for simultaneously applying 2-dimensional digital image correlation and infrared thermography techniques to quantify the relationship between temperature, internal cladding pressure, and deformation during burst testing were developed. This work details results from the application of these techniques to burst testing of Zircaloy-4 cladding segments subjected to loss-of-coolant accident transients in an air environment. Two types of tests were performed with: (a) cladding segments connected to a fixed pressure reservoir as well as (b) closed systems where internal pressure increased during transients. In-situ thermomechanical measurements including strain and thermal gradient data are presented, demonstrating the effectiveness of applying combined surface measurement techniques to burst testing

Bell, Sam↗
DOE OSTI2014

Spectroradiometric monitoring for open outdoor culturing of algae and cyanobacteria

We assess the measurement of hyperspectral reflectance for the outdoor monitoring of green algae and cyanobacteria cultures with a multi-channel, fiber-coupled spectroradiometer. Reflectance data acquired over a four-week period are interpreted via numerical inversion of a reflectance model, in which the above-water reflectance is expressed as a quadratic function of the single backscattering albedo, dependent on the absorption and backscatter coefficients. The absorption coefficient is treated as the sum of component spectra consisting of the cultured species (green algae or cyanobacteria), dissolved organic matter, and water (including the temperature dependence of the water absorption spectrum). The backscatter coefficient is approximated as the scaled Hilbert transform of the culture absorption spectrum with a wavelength-independent vertical offset. Additional terms in the reflectance model account for the pigment fluorescence features and the water surface reflection of sunlight and skylight. For both the green algae and cyanobacteria, the wavelength-independent vertical offset of the backscatter coefficient is found to scale linearly with daily dry weight measurements, providing the capability for a non-sampling measurement of biomass in outdoor ponds. Other fitting parameters in the reflectance model are compared to auxiliary measurements and physics-based calculations. The magnitudes of the sunlight and skylight water-surface contributions derived from the reflectance model compare favorably with Fresnel reflectance calculations, while the reflectance-derived quantum efficiency of Chl-a fluorescence is found to be in agreement with literature values. To conlclude, the water temperature derived from the reflectance model exhibits excellent agreement with thermocouple measurements during the morning hours and highlights significantly elevated temperatures in the afternoon hours.

47 OTHER INSTRUMENTATION↗
DOE OSTI2026

Dual-mode fiber-optic refractive-index gas thermometry with primary anchoring and continuous temperature tracking

Extending fiber-optic refractive-index gas thermometry beyond primary-only operation, we report a dual-mode argon-filled Fabry-Perot thermometer in which the same cavity first establishes a primary temperature anchor and then performs continuous secondary-mode tracking. The primary anchor is obtained from two-pressure fringe shifts using a virial-coefficient refractivity model. During secondary operation, pressure cycling is stopped, and temperature is recovered from the monitored fringe wavelength and gas pressure using a model that includes argon refractivity, pressure-induced cavity strain, and fused-silica thermal expansion. From 310 to 1013 K, secondary-mode temperatures agreed with a reference thermocouple with 0.21 K RMSE and 0.47 K maximum error; 45-min natural furnace cooldowns were also tracked from nearby anchors with close agreement. The dual-mode method retains the empirical-calibration-free primary measurement as an in-situ reference while enabling simpler continuous tracking between anchors, addressing a practical limitation of primary-only fiberoptic refractive-index gas thermometry for hightemperature applications.

Syed, Musaddeque [Michigan State University, East ↗