Engineering Papers⌕ Search

SEARCH · Engineering Papers

Results for “power engineering computing”

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.

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 865 records · Page 48
All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

Wholesale Electricity Analysis via Simulation & Learning Experiments (WEASLE): Platform Development and Pilot Competition

This document reports the development of the Wholesale Electricity Analysis via Simulation and Learning Experiments (WEASLE) platform and the pilot competition that was conducted to test the platform. Due to the increasing reliance on variable renewable energy resources for bulk power, the pilot competition, called the Energy Storage Participation Algorithm Competition (ESPA-Comp), was used to test the effect of various market designs on storage utilization and market efficiency. Basic details of the platform are provided, including an overview of the market clearing engine, the battery dispatch and degradation models, electric grid topology and resource mix, and software architecture. Two market designs were tested: a two-settlement market analogous to typical ISO design today, and a multi-settlement market that allows additional forward-trading periods during the real-time market. Results from the pilot competition show that the storage bidding problem is nontrivial and is well suited for future challenges. We find that: 1) all four teams utilized different approaches to the bidding problem, 2) different methodological approaches led to substantially different offer behaviors, 3) resource profits are clustered by team and methodological approach, 4) simulated offers reduced market surplus by about 0.5%, 5) substantially different prices between two-settlement and multi-settlement markets albeit minimal difference in overall market surplus.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2021

Comprehensive framework for data-driven model form discovery of the closure laws in thermal-hydraulics codes

The two-phase two-fluid model is a basis of many thermal-hydraulics codes used in design, licensing, and safety considerations of nuclear power plants. Thermal-hydraulics codes rely on the closure laws to close the system of conservation equations and describe the interactions between phases. These laws, derived from years of experimental investigations, are semi-empirical correlations that lack generality and have a limited range of applicability. Increase of computational power, availability of new experiments, and development of high-fidelity simulations has increased the number of validation data. The discrepancies between the code predictions and the validation data are a great source of knowledge. Missing physics that are not included in the model but are important for the considered phenomena can be discovered by propagating the information from the experimental results through the model. Furthermore, physics-discovered data-driven model form (P3DM) methodology integrates available integral effect tests and separate effects tests to determine the necessary corrections to the model form of the closure laws. In contrast to existing calibration techniques, the methodology modifies the functional form of the closure laws. Based on the functional form of the correction, the missing physics that were not included in the original model can be discovered. The methodology provides the alternative to the machine learning approach, in which the model is discovered in the form of the intractable black-box relation. In this work, the methodology was applied to the CTF subchannel code to improve the prediction of the two-phase flow phenomena.

42 ENGINEERING↗
DOE OSTI2021

SD-WAN Evaluation Criteria for a Defense Information Systems Network Expeditionary Customer Edge

The Defense Information Systems Agency (DISA) has identified a service provision gap midway between the capacity and capability of a Defense Information Systems Network (DISN) transport Edge Points of Presence (POP) and U.S. Department of Defense (DoD) Enterprise Classified Travel Kit (DECTK). Some deployed force 100-user Tactical Operations Centers are in field locations far removed from the DISN transport core, in challenging environmental conditions with limitations on space, weight, power, and cooling for network equipment. As part of a multi-phase project, Pacific Northwest National Laboratory (PNNL) will gather and analyze requirements, design, develop, prototype, and test a miniaturized and ruggedized DISN Customer Edge POP scaled to support approximately 100 users in a field Tactical Operations Center. An Expeditionary Customer Edge (ECE) will be more suitable for field deployment than a DISN transport Edge POP, using ruggedized hardware and network function virtualization (NFV) to operate in challenging field environmental conditions, plus reduce weight, power, and cooling requirements. A key enabling technology for ECE is Software Defined Wide Area Networking (SD-WAN). This document provides: • A brief overview of SD-WAN use cases and how they apply to ECE • How SD-WAN technology compares to existing networks like DISN that use Optical Transport Networking (OTN) and Multiprotocol Label Switching (MPLS) • SD-WAN functional requirements relevant to ECE • A description of an ECE Virtual Prototype, including simulated wide area network paths and a DISN-representative implementation of MPLS, in Cisco Modeling Labs • Detailed network flow walkthroughs • Evaluation criteria based on ECE-relevant SD-WAN functional requirements Finally, an appendix provides an informal evaluation of Speedify—a commercial retail Virtual Private Network service—against the ECE SD-WAN evaluation criteria.

42 ENGINEERING↗
DOE OSTI2023

Visual Style Elements in Human–System Interface Design for Nuclear Power Operations: Does Style Affect Performance and Preference?

As the world increasingly adopts renewable and sustainable energy systems, transitionary solutions include nuclear power, which currently provides 20% of the United States’ electricity and is the largest single source of carbon-free electricity generation. Advanced reactors are a critical component of a carbon-free mixed energy portfolio that require careful design of first-of-a-kind control rooms. The application of Human Factors Engineering (HFE) is essential for scientific and iterative testing of novel human–system interface (HSI) concepts to ensure effective, efficient, and safe plant operations. Microworlds are simulators that use simplified physics models and control systems to distill nuclear power operations into essential functions. HFE scientists used the Rancor Microworld Simulator to obtain preference and performance metrics for novel and traditional static HSI design styles. Participants comprised advanced reactor company employees and nuclear industry consultants. A mixture of quantitative and qualitative data was captured. There was a preference for the basic graphical style that included high contrast and traditional color scheme elements. No single HSI design outperformed the others, and the participants did not perform better using their preferred HSI style. We report this experiment is the first in a series of HFE testing for HSIs in advanced reactor control room development. Clear user preferences emerged for elements within static displays. The cutting-edge neumorphic style was the least preferred. Future directions include tests of dynamic displays. HFE is used in evaluating and designing HSI devices that will improve the efficiency and safety of advanced nuclear power operations.

99 GENERAL AND MISCELLANEOUS↗
DOE OSTI2025

XFEM Development for Modeling Crack Growth in Prototypical Welded Components

Nuclear power plant components are subjected to harsh operating environments that can lead to multiple degradation mechanisms in which fracture can play a prominent role. Predicting crack growth is important for assessing the integrity of welded components. The extended finite element method (XFEM) is an important tool for modeling such crack growth, and XFEM capabilities have been developed within the MOOSE framework. This report documents work in the MOOSE XFEM module to model fractures in three-dimensional representations of components using a topologically two-dimensional mesh to define cutting planes. Crack growth algorithms have been implemented to evolve the cutting mesh based on equations for stress corrosion cracking. Additionally, several usability and robustness improvements have been developed to enable three-dimensional fracture simulations. The cutting algorithms were demonstrated on a three-dimensional model of a prototypical reactor component undergoing stress corrosion cracking driven by idealized weld residual stresses. This is an incremental step toward using this capability to model more complex components with residual stresses computed through welding process simulations.

42 - ENGINEERING↗
DOE OSTI2023

CoolPINNs: A physics-informed neural network modeling of active cooling in vascular systems

Emerging technologies like hypersonic aircraft, space exploration vehicles, and batteries avail fluid circulation in embedded microvasculatures for efficient thermal regulation. Modeling is vital during the design and operational phases of these engineered systems. However, many challenges exist in developing a modeling framework. What is lacking is an accurate framework that (i) captures sharp jumps in the thermal flux across complex vasculature layouts, (ii) deals with oblique derivatives (involving tangential and normal components), (iii) handles nonlinearity because of radiative heat transfer, (iv) provides a high-speed forecast for real-time monitoring, and (v) facilitates robust inverse modeling. Here, this paper addresses these challenges by availing the power of physics-informed neural networks (PINNs). We develop a fast, reliable, and accurate Scientific Machine Learning (SciML) framework for vascular-based thermal regulation—called CoolPINNs: a PINNs-based modeling framework for active cooling. The proposed mesh-less framework elegantly overcomes all the mentioned challenges. The significance of the reported research is multi-fold. First, the framework is valuable for real-time monitoring of thermal regulatory systems because of rapid forecasting. Second, researchers can address complex thermoregulation designs since the approach is meshless. Finally, the framework facilitates systematic parameter identification and inverse modeling studies, perhaps the most significant utility of the current framework.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2020

FALCON: Framework for Anomaly Detection in Industrial Control Systems

Industrial Control Systems (ICS) are used to control physical processes in critical infrastructure. These systems are used in a wide variety of operations such as water treatment, power generation and distribution, and manufacturing. While the safety and security of these systems are of serious concern, recent reports have shown an increase in targeted attacks aimed at manipulating physical processes to cause catastrophic consequences. This trend emphasizes the need for algorithms and tools that provide resilient and smart attack detection mechanisms to protect ICS. In this paper, we propose an anomaly detection framework for ICS based on a deep neural network. The proposed methodology uses dilated convolution and long short-term memory (LSTM) layers to learn temporal as well as long term dependencies within sensor and actuator data in an ICS. The sensor/actuator data are passed through a unique feature engineering pipeline where wavelet transformation is applied to the sensor signals to extract features that are fed into the model. Additionally, this paper explores four variations of supervised deep learning models, as well as an unsupervised support vector machine (SVM) model for this problem. The proposed framework is validated on Secure Water Treatment testbed results. This framework detects more attacks in a shorter period of time than previously published methods.

97 - MATHEMATICS AND COMPUTING↗
DOE OSTI2022

Tackling Climate Change with Machine Learning

Climate change is one of the greatest challenges facing humanity, and we, as machine learning (ML) experts, may wonder how we can help. Here we describe how ML can be a powerful tool in reducing greenhouse gas emissions and helping society adapt to a changing climate. From smart grids to disaster management, we identify high impact problems where existing gaps can be filled by ML, in collaboration with other fields. Our recommendations encompass exciting research questions as well as promising business opportunities. We call on the ML community to join the global effort against climate change.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2025

The Fluid Dynamics Uncertainty Quantification Challenge Problem: XFOIL vs. MFOIL

Uncertainty quantification (UQ) has become more critical in aerospace engineering due to the growing dependence on computational tools for design optimization and performance analyses of aerospace vehicles. Even though the significance of UQ in assessing the credibility of computational analyses is well recognized, its costs and complexity impede its integration into standard practices, particularly in computational fluid dynamics (CFD) and other fluid analyses. This paper presents a UQ study for low-fidelity computational aerodynamics analyses with XFOIL and mfoil (i.e., the MATLAB version of XFOIL with several implementation modifications); these tools are utilized widely in both research and education. The main contributions of this paper are as follows: 1) improved precision in quantifying the uncertainty of the baseline Monte Carlo results used to benchmark surrogate modeling techniques for UQ, 2) quantification of the effect of the implementation differences between XFOIL and mfoil on solution quantities of interest (QoIs), such as lift and pitching moment coefficients, and 3) development of an open-source UQ library for use with XFOIL and mfoil, which has educational values and helps promote UQ for fluid analyses with aerospace applications. Results and discussions revolve around cases 1-4 of the challenge problem posed by the AIAA Fluid Dynamics Technical Committee’s Uncertainty Quantification Discussion Group (UQDG). In case 3, this work employs CFDverify, an open-source solution verification software, to quantify the discretization error and evaluate the extrapolated QoIs based on the grid convergence index (GCI). This UQ study differentiates itself from previous studies in the rigor of handling baseline Monte Carlo uncertainty and in including mfoil, which is a more accessible alternative to XFOIL. Finally, despite the growing computing power, low-fidelity computational tools remain valuable, such as for aerodynamic shape optimization at Mach numbers below 0.65 and low-to-mid Reynolds numbers.

Lay, Aidan S [University of Tennessee, Knoxville (↗
DOE OSTI2022

Autonomous aerial flight path inspection using advanced manufacturing techniques

Robotic systems have shown capabilities to perform inspection tasks in dangerous and difficult-to-access environments, such as those found in different components of power plants. However, most of the current robotic inspection technology is designed for specific components. Aerial robots, commonly termed as Drones, have raised an option to inspect a wider range of structural components. Nevertheless, current aerial inspecting technology still relies on a human pilot with limited line of sight, field of view and a reduced perception as the drone flies away, which prevents performing close-quarter inspection in intricate, structurally complex and GPS-denied environments. This work introduces offline inspection path generation methods based on robotics-integrated to manufacturing techniques. One method uses computer-aided manufacturing (CAM) techniques and the other an additive manufacturing (AM) approach to generate the flight path. That is to say, the drone would fly along the path described by a 3D (Three Dimensional) printer’s extruder or a CNC (Computer Numerical Control) machining tool, enabling to fly very close the structure even in physical structures with a complex geometry. Once the trajectories are generated, they are introduced for its validation in the Gazebo robotics simulator. Simulation results demonstrate the proper performance of the method and confirm that this approach can be used for close inspection of structural components.

42 ENGINEERING↗
DOE OSTI2021

Validation of simulated wave energy converter responses to focused waves

Focused waves are increasingly used as a design method to predict extreme loads for offshore structures, such as wave energy converters (WECs). However, the ability of computational methods to accurately simulate the prescribed focused waves and resulting wave structure interactions is not well validated. This study uses two computational fluid dynamic methods, WEC-Sim and STAR-CCM+, to evaluate the responses of two taut-moored WEC-like buoys to three different focused waves. WEC-Sim is a computationally efficient, mid-fidelity model, based on linearised potential flow theory. In contrast, STAR-CCM+ is a high-fidelity, three-dimensional, unsteady, Reynolds-averaged Navier–Stokes-based model. The two buoy geometries considered are a hemispherical-bottom cylinder and a truncated cylinder with a cylindrical moon pool. Three prescribed focused waves are generated in both codes, and the simulated displacements and mooring loads are obtained for each of the hydrodynamic bodies. The resulting STAR-CCM+ generated focused waves have approximately the same accuracy, in comparison with the analytic solution, as experimentally generated focused waves. The WEC-Sim simulated responses, when using viscous coefficients tuned to the measured displacements, are, on average, within 11.5% of experimentally measured values, whereas the STAR-CCM+ simulated responses are, on average, within 14.2% of the experimental values.

16 TIDAL AND WAVE POWER↗
DOE OSTI2022

Smart Contract Architectures and Templates for Blockchain-based Energy Markets (V.1.0)

Within the field of Transactive Energy Systems (TES), there is an active need for tools that can support and accelerate the development of these new grid solutions. Among the many tools available, blockchain stands out as a viable instrument that can help researchers develop decentralized, autonomous, and tamper-resistant grid applications. In this work, we explore the use of smart contracts (SCs), a subset of blockchain technology, and analyze their applicability to facilitating the implementation of TES solutions. In particular, we focus on presenting areas of opportunity and potential drawbacks, along with use cases that can benefit from this technology building upon previous research developed by Pacific Northwest National Laboratory and other research organizations. This work builds upon the fundamentals of TES and smart contract technology to develop a series of software templates that can be used by industry to build TES-oriented grid solutions. These templates are intended to be platform agnostic and take into consideration the unique properties of SCs and distributed ledger storage mechanisms to ensure actual code implementations remain aware of the limitations of the technology. The proposed templates have the potential to enable software architects to mix and match components to satisfy their application requirements, thereby reducing the number of resources required to implement blockchain-based solutions. These templates are divided into two main components—data and behavioral models. The data models are intended to help software engineers represent the underlying grid objects along with their properties in a ledger-based storage system. The behavioral models are used to describe the processes and actions that actors within a system must perform to achieve a given outcome such as registering an asset, placing a bid, and performing bid clearances. These two components are documented in a Unified Modeling Language (UML) format and are intended for use in SC-based implementations, with special behavioral considerations to account for the asynchronous properties of the underlying ledger and the typical execution model of smart contracts. Finally, future research ideas and potential extensions to this work are discussed. In particular, known limitations and potential improvements of the developed product are identified and expected to be addressed in future revisions of the template model.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2025

Bridging Equipment Reliability Data and Risk Informed Decisions in a Plant Operation Context

Industry equipment reliability and asset management programs are essential elements that help ensure the safe and economical operation of nuclear power plants. The effectiveness of these programs is addressed in several industry-developed and regulatory programs. The Risk-Informed Asset Management (RIAM) project is tasked to develop tools in support of the equipment reliability and asset management programs at nuclear power plants. These tools are designed to create a direct bridge between component health/lifecycle data and decision making (e.g., maintenance scheduling and project prioritization). The goal of this article is to provide a guide for specific use cases that the RIAM project is targeting. We have grouped uses cases into three main areas. The first area focuses on the analysis of equipment reliability data with a particular emphasis on condition-based data, such as test/surveillance reports and component monitoring data. The second area focuses on the integration of equipment reliability into system/plant reliability models to determine system/plant health and identify the components that are critical to maintain an operational system. Lastly, the third area manages plant resources, such as maintenance activities and replacement scheduling using optimization methods. Here the primary focus is on supporting typical system engineer decisions regarding maintenance activity scheduling and component aging management. This is performed in a risk-informed context where the term “risk” is broadly constructed to include both plant reliability and economics. This framework combines data analytics tools to analyze equipment reliability data with risk-informed methods designed to support system engineer decisions (e.g., maintenance and replacement schedules, optimal maintenance posture) in a customizable workflow.

97 - MATHEMATICS AND COMPUTING↗
DOE OSTI2025

Computational Modeling of Graphite Degradation due to Molten Salt Infiltration and Wear

Molten-salt reactors (MSRs) represent a promising next-generation reactor design, with graphite serving as a moderator and/or reflector in several designs. However, due to limited experimental data and operational experience, a technical understanding of the structural integrity of graphite in molten salt environments remains incomplete. This report presents a modeling-based evaluation of graphite degradation in MSR environments, focusing on the effects of salt infiltration in fuel salt-based designs and surface wear in pebble bed reactor designs. The objective of this study is to enhance understanding of the structural integrity challenges posed by these degradation mechanisms and to provide a framework for assessing graphite behavior in MSRs. The first part of the report investigates the phenomenon of molten salt infiltration into graphite. This infiltration occurs when molten salt permeates the interconnected pore structure of the graphite moderator, driven by factors such as pressure differentials and the physical properties of both the salt and graphite. The infiltration process is influenced by characteristics of the pore structure, viscosity of the molten salt, and the interfacial energies between the graphite, salt, and the atmosphere within the graphite pore. Utilizing a coupled multiphysics modeling approach with Grizzly software, the study evaluates the stress induced by internal heat sources due to infiltration, which can lead to structural concerns. This evaluation is crucial for understanding how infiltration affects the mechanical integrity of graphite components in MSRs. The study considers the Molten-Salt Reactor Experiment (MSRE) graphite stringer geometry due to the availability of relevant data. Through detailed finite element analysis, the study examines stress distributions at varying infiltration percentages, revealing that stress levels increase with higher amounts of infiltration. Rare-event simulations, using the parallel subset simulation (PSS) framework, further quantify the failure probabilities under input uncertainties, with a user-specified failure metric. The PSS framework also identifies critical input parameters that significantly affect the stress values, including infiltration amount, thermal conductivity, and power density. Additionally, considering realistic reactor scenarios, the analysis was performed to account for the combined effects of radiation and infiltration, and modeling strategies on how to analyze new reactor designs or new graphite grades are discussed. The second part of the report focuses on wear mechanisms in pebble bed-based MSRs. As graphite fuel pebbles interact with the graphite reflector block, wear can result in material loss and the formation of surface defects, which may act as stress concentrators. A similar multiphysics modeling framework is employed to assess the impact of wear on the structural integrity of graphite components. This study considers a generic fluoride-cooled high-temperature reactor (gFHR) design due to the availability of comprehensive data. Worst-case scenario dimensions of the reflector blocks were analyzed under thermal and radiation conditions. Subsequently, wear in the form of idealized pits and grooves is modeled on the inner surface of the graphite block, with the maximum stress from previous simulations. The simulations show that groove-type defects are more detrimental than pits, leading to higher stress concentrations. Considering worst-case simulation scenarios and experimental wear rates, it was determined that the formation of a surface defect critical enough to affect the stress may not be possible in a gFHR design. Overall, the findings of this research contribute to the development of robust modeling tools for predicting graphite behavior under various operational conditions in MSRs.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2021

Simulation of enhanced light extraction from periodic, disordered, and quasi-periodic OLED structures

Here we have developed a rigorous scattering matrix theory of light emission from periodically structured media using a Green’s function approach. We computationally simulate the spectral power inside the structure, incorporating Purcell factor enhancements, and find internal waveguiding modes and plasmonic losses. We simulate the light-outcoupling factor η out and describe how corrugations and structured media can enhance η out . We have extended our framework to describe non-periodic disordered arrays as well as aperiodic quasi-crystalline arrays. Flat organic light-emitting diodes (OLEDs) have low outcoupling with η out ~20% since most of the light is trapped in waveguided modes in higher index layers or lost to plasmonic excitations at the metal cathode. Periodically corrugated OLEDs can achieve highly enhanced η out ~65%-70% for pitch values between 1000 and 2000 nm, representing an enhancement factor >3 over planar structures. Periodic corrugations strongly diffract trapped waveguided and plasmonic modes to the emissive air cone. Disordered templates also can cause significant enhanced outcoupling with η out ~50%-55% for smaller nearest-neighbor separations of 300–400 nm. Quasi-crystalline tilings can also lead to enhancements of η out ~50%-55%. This framework can be utilized to design novel structured media that can generate high light extraction.

42 ENGINEERING↗
DOE OSTI2022

Effect of coaxial nozzle wear on catchment efficiency in direct energy deposition built components

Laser based Direct Energy Deposition (DED) systems using metallic powder feedstock are recognized as a promising manufacturing method for their ability to shorten production cycles and create complex part geometries. Components are built by generating a melt pool with a high-power laser beam while material is coaxially injected and left to solidify. An impediment to large scale use of DED lies in poor powder catchment efficiency, the condition in which a portion of injected powder escapes the melt pool resulting in a ratio of decreased printed material mass to mass of supplied feedstock. The wear state of a coaxial nozzle on a DED system within a hybrid manufacturing machine tool has been observed to decrease catchment efficiency over time. Herein this study investigates this effect by adapting flow visualization techniques to an in-situ process monitoring format, the implementation of a Computational Fluid Dynamics (CFD) simulation, and deposition testing. Nozzle geometric defects due to wear are identified and categorized, and the impact of nozzle tip wear, resulting in axial tip reduction, on powder catchment efficiency is proven by multiple calculation methods. A linear correlation between catchment efficiency and powder stream diameter is identified, causing a 15–20% loss in efficiency sustained over incremental nozzle tip reduction up to − 1 mm. These results provide a foundation for further study of wear effects and Zero defect manufacturing solutions for powder fed DED systems.

42 ENGINEERING↗
DOE OSTI2021

OC6 Phase Ib: Validation of the CFD predictions of difference-frequency wave excitation on a FOWT semisubmersible

During the previous OC5 11 project, state-of-the-art mid-fidelity engineering tools for floating wind systems were found to consistently underpredict the nonlinear, low-frequency responses of semisubmersible offshore wind platforms, leading to substantial errors in the structural loads because of low-frequency surge and pitch resonance. To examine this underprediction, a coordinated investigation with computational fluid dynamics (CFD) simulations and model-basin experiments was carried out. Both investigations involved a fixed and simplified OC5-DeepCwind semisubmersible in bichromatic waves. The wave excitations - especially the nonlinear, difference-frequency excitation - on the structure from the CFD simulations were compared to the experimental measurements for validation, with uncertainty analyses for both the experimental and the CFD results. Furthermore, the wave excitations on each column of the semisubmersible were measured separately in the experiment, allowing the validation of the CFD results to be done on a per-column basis. Overall, the CFD predictions of the difference-frequency excitations agree with the experimental measurements, suggesting the CFD solutions can be used as a reference for tuning and improving the engineering-level tools and can provide a means to better understand the underprediction at low frequencies.

16 TIDAL AND WAVE POWER↗
DOE OSTI2023

Motorette Thermal Performance Testing and Modeling for an Electric Motor with Additively Manufactured Hollow Conductors with Integrated Heat Pipes

This paper discusses the design, build and test of a motorette to characterize the thermal performance of an additively manufactured coil integrated with heat pipes. The motorette is powered using a variable frequency AC power supply and cooled through two independent cooling systems. The first cooling system cools the stator core using forced convection of air flowing over a finned heat sink mounted on the stator outer diameter. The second cooling system cools the heat pipes using forced convection of 50-50 water ethylene glycol (WEG) mixture flowing through condenser chambers. A 3D thermal FEA model of the setup is built and heat transfer coefficients (HTC) of convective boundaries are computed using coolant flow rates from test data and empirical equations. Temperature at locations on the coil and heat sink are recorded and compared to thermal model predicted values. A maximum temperature error of 22.7% occurs at 180ARMS and 800 Hz operating point for the AM dual coil. The thermal model provides higher temperatures compared to test results and hence it is on the conservative side but in general, there is good correlation between test and model results. Lastly, opportunities for improvement to both test data measurement and 3D thermal FEA modeling are discussed.

additive manufacturing↗