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All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

Dynamics in a stellar convective layer and at its boundary: Comparison of five 3D hydrodynamics codes

Our ability to predict the structure and evolution of stars is in part limited by complex, 3D hydrodynamic processes such as convective boundary mixing. Hydrodynamic simulations help us understand the dynamics of stellar convection and convective boundaries. However, the codes used to compute such simulations are usually tested on extremely simple problems and the reliability and reproducibility of their predictions for turbulent flows is unclear. We define a test problem involving turbulent convection in a plane-parallel box, which leads to mass entrainment from, and internal-wave generation in, a stably stratified layer. We compare the outputs from the codes FLASH, MUSIC, PPMSTAR, PROMPI, and SLH, which have been widely employed to study hydrodynamic problems in stellar interiors. The convection is dominated by the largest scales that fit into the simulation box. All time-averaged profiles of velocity components, fluctuation amplitudes, and fluxes of enthalpy and kinetic energy are within ≲3σ of the mean of all simulations on a given grid (128 3 and 256 3 grid cells), where σ describes the statistical variation due to the flow’s time dependence. They also agree well with a 512 3 reference run. The 128 3 and 256 3 simulations agree within 9% and 4%, respectively, on the total mass entrained into the convective layer. The entrainment rate appears to be set by the amount of energy that can be converted to work in our setup and details of the small-scale flows in the boundary layer seem to be largely irrelevant. Our results lend credence to hydrodynamic simulations of flows in stellar interiors. We provide in electronic form all outputs of our simulations as well as all information needed to reproduce or extend our study.

79 ASTRONOMY AND ASTROPHYSICS↗
DOE OSTI2021

Experimental Study of Transport Behavior of Swellable Microgel Particles in Superpermeable Channels for Conformance Control

Summary Gel treatment is an effective way to attack excessive water production during oil development. The transport behavior of gel materials in reservoirs is of crucial importance to the effectiveness of gel treatments. The aim of this paper is investigating the transport behavior of swellable micrometer-sized preformed particle gels (PPGs, or microgels) through superpermeable (super-K) channels. Sandpacks with permeabilities ranging from 27 to 221 darcies were used to mimic the super-K channels. Multiple pressure sensors were applied along the sandpack models to monitor the propagation behavior of the microgels. The tested microgel particles could transport through the super-K channels, and a higher driving pressure gradient was required when the particle/pore size ratio was larger. The pressure gradient distribution along the super-K channels was relatively uniform when the particle/pore ratio was low (less than 1.3). However, the inlet section would show increasingly higher pressure gradients as the particle/pore ratio was increased, indicating increased difficulty in propagation. The propagation of the gel particles was significantly slower compared with the carrying fluid. The delayed propagation behavior was more pronounced when the particle/pore ratio was higher. The injection pressure was much less sensitive to the injection flow rate compared with a Newtonian fluid. The gel dispersion exhibited an apparent shear thinning (pseudoplastic) behavior when transporting through the porous channels. Breakage of the gel particles was observed especially at high superficial velocities. The particle breakage was partially responsible for the apparent shear thinning behavior. The breakage phenomenon was in favor of deep placement of the gel particles. The channel permeabilities were significantly reduced by the microgels, bringing sufficient resistance to subsequent waterflooding (more than 99.5%). At given matching size conditions, softer gels were more likely to establish in-depth placement and uniform water blocking capacity in the channels. The microgel particles exhibited salinity-responsive behavior to the post-brine flush. The gel particles could shrink and reswell according to the salinity of the injected water. Possibilities were discussed to use this salinity-responsive behavior. Also, the microgels exhibited a particular disproportionate permeability reduction (DPR) effect. After gel injection, the channel permeability to water flow was reduced by more than 20 to 92 times of the permeability to oil flow. This work provides important support to understand the transport behavior of gel particles in super-K channels. The achievements are helpful for gel product selection and gel treatment design.

Engineering↗
DOE OSTI2019

Validation of RELAP-7 for Forced Convective and Natural Circulation Reactor Flows

New reactor designs such as small modular reactors and newly proposed passive safety systems rely on natural circulation two-phase flow cooling of the reactor core under accident conditions. Without a pump to drive the flow, the circulation rate is a strong function of void fraction. Under these conditions where the flow rate, pressure drop, and heat transfer are all closely coupled through the mixture density, the accurate prediction of void fraction is pivotal. Furthermore, while these passive systems boast a more reliable cooling option, the sensitivity of the system to two-phase flow instabilities is more likely than in forced convective cooling and can result in dangerous density wave or flow excursion conditions. Improvement of one-dimensional system codes and further development of three-dimensional code capability are all important efforts in addressing these issues. The proposed work is a critical step towards providing confidence through validation of the capability of thermal-hydraulic tools to meet the emerging challenges in reactor simulation. Historically, system analysis codes develop a stiffness over time due to fine-tuning of adjustable code parameters that result in a reluctance or inability to adopt improved models. Therefore, a rigorous effort should be invested in preparation for RELAP-7 to identify required modeling improvements of constitutive relations and validation of the code applicability to the wide range of possible reactor flow conditions. Part of this validation involves the uncertainty quantification which is a critical step in the Code Scaling, Applicability, and Uncertainty (CSAU) methodology and Best-Estimate Plus Uncertainty (BEPU) licensing method. BEPU allows recovery of safety margins and potentially optimizing plant performance, resulting in economic benefit for the reactor operators. Beginning with the collection of past experimental data covering prototypic LWR conditions, this document reviews three critical datasets available for the validation of system codes. The experimental methods, procedures, facilities, instrumentation, and supplementary information are consolidated to aid the validation efforts of this work and future projects. These three datasets (824 conditions) are chosen due to their wide acceptance and demonstrated application for code validation. Two experimental datasets from the Nuclear Power Engineering Corporation (NUPEC) span prototypic conditions of Boiling Water Reactors (BWR) and Pressurized Water Reactors (PWR). These datasets are labeled as the BFBT (BWR Full-size Fine-mesh Bundle Test) and the PSBT (PWR Subchannel and Bundle Test) datasets respectively. The third dataset is taken in an internally heated annulus that is scaled based on a BWR subassembly and includes two-phase flows important to post-blowdown analysis. Together, the datasets consider the full range of pressure and mass flux expected in LWR forced convective flows from steady-state to long term cooling conditions. Recognizing the deficiency of available data under low-pressure, low-flow, a new natural circulation dataset consisting of 107 conditions is obtained. With system pressures ranging between 145 and 950 kPa, natural circulation is driven by a heat flux up to 275 kW/m2 in a 3 m long heated region of the annulus test section which is followed by a 2 m long unheated region before entering a condenser. Stable natural circulation flow rates in this facility were measured to be between 182 and 590 kg/m2-s. Pressure and temperature are measured at ten locations in the facility. In addition, measurements of void fraction, interfacial area concentration, and gas velocity are obtained at five axial locations in the annulus test section. The RELAP5-3D code demonstrates good accuracy for void fraction predictions in BFBT and PSBT benchmarks, but shows relatively large discrepancy in the annulus experiments at lower pressures. In two-phase natural circulation, large oscillations are observed in many system parameters during the simulation of 19 experiment cases which were conducted at low pressures, and the model shows good predictive performance with the remaining 88 experiment cases. However, some discrepancies in void fraction and temperature predictions are found which may require improved constitutive modeling under these low-pressure, low-flow condition. The quantified uncertainty in void fraction predictions in three forced convection benchmarks due to uncertainties in boundary conditions and geometries are relatively small, except for a few cases in the annulus experiment. The output uncertainty of the natural circulation model is quantified by considering the measurement error in boundary conditions, and it is shown that the output uncertainty ranges are relatively small for the range of conditions considered. Through this work, a clear pathway is provided for validation of RELAP7 once the code is available.

42 ENGINEERING↗
DOE OSTI2020

Inertial dynamics of an interface with interfacial mass flux: Stability and flow fields’ structure, inertial stabilization mechanism, degeneracy of Landau’s solution, effect of energy fluctuations, and chemistry-induced instabilities

This work focuses on the long-standing problem of inertial dynamics of an interface with interfacial mass flux and reports new mechanisms for the interface stabilization and destabilization. The interface is a phase boundary separating fluids of different densities and having interfacial mass flux. To analyze the interface dynamics from a far field, we develop and apply the general matrix method to rigorously solve the boundary value problem involving the governing equations in the fluid bulk and the boundary conditions at the interface and at the outside boundaries of the domain. We find the fundamental solutions for the linearized system of equations and analyze the interplay of interface stability with flow fields’ structure by directly linking rigorous mathematical attributes to physical observables. We find that the interface is stable when the dynamics conserves the fluxes of mass, momentum, and energy; the stabilization is due to an inertial mechanism causing small oscillations of the interface velocity. In the classic Landau’s dynamics, the postulate of perfect constancy of the interface velocity leads to the development of Landau–Darrieus instability. This destabilization is also linked to the imbalance of the perturbed energy at the interface. The classic Landau’s solution is found to have degeneracy; lifting of the degeneracy may lead to singularity and self-similar dynamics. Our results compare well with traditional theories of combustion and propose new experiments to study the dynamics of the interface and the flow fields in combustible systems. We further conduct reactive molecular dynamics simulations to elucidate the complexity of chemical processes, to study the destabilizing effect of energy fluctuations on the interface stability, and to illustrate the chemistry-induced instabilities. In summary, we identify the extreme sensitivity of the interface dynamics to the interfacial boundary conditions, including the formal properties of fundamental solutions and the qualitative and quantitative properties of the flow fields. This provides new opportunities for studies, diagnostics, and control of multiphase flows in a broad range of processes in nature and technology.

42 ENGINEERING↗
DOE OSTI2023

Experimental and Computational Investigation of Shaped Film Cooling Holes Designed to Minimize Inlet Separation

Abstract Film cooling is used to protect turbine components from the extreme temperatures by ejecting coolant through arrays of holes to create an air buffer from the hot combustion gases. Limitations in traditional machining meant film cooling holes universally have sharp inlets, which create separation regions at the hole entrance. The present study uses experimental and computational data to show that these inlet separation are a major cause of performance variation in crossflow fed film cooling holes. Three-hole designs were experimentally tested by independently varying the coolant velocity ratio (VR) and the coolant channel velocity ratio (VRc) to isolate the effects of crossflow on hole performance. Leveraging additive manufacturing (AM) technologies, the addition of a 0.25D radius fillet to the inlet of a 7-7-7 shaped hole is shown to significantly improve diffuser usage and significantly reduce variation in performance with VRc. A second AM design used a very large radius of curvature inlet to reduce biasing caused by the inlet crossflow. Experiments showed that this “swept” hole design did minimize biasing of the coolant flow to one side of the shaped hole, and it significantly reduced variations due to varying VRc. RANS simulations at six VR and three VRc conditions were made for each geometry to better understand how the new geometries changed the velocity field within the hole. The sharp and rounded inlets were seen to have very similar tangential velocity fields and jet biasing. Both AM inlets created more uniform, slower velocity fields entering the diffuser. The results of this article indicate that large improvements in film cooling performance can be found by leveraging AM technology.

Engineering↗
DOE OSTI2020

Reentrant pinning, dynamic row reduction, and skyrmion accumulation for driven skyrmions in inhomogeneous pinning arrays

In this work, we examine the dynamics of skyrmions in systems with a region of strong pinning coexisting with a pin-free region, where the equilibrium state has a uniform skyrmion density. Under an applied drive, skyrmions accumulate in the pin-free region along the edge of the pinned region due to the skyrmion Hall effect. As the drive increases, a series of dynamical structural transitions occur in the flowing skyrmion lattice similar to those observed in the compression dynamics of crystals. These transitions correspond to reductions in the number of flowing rows of skyrmions due to the collective motion of the skyrmions into the pinned region, and they are accompanied by a series of steps in the velocity force curves leading to a negative differential conductivity. When the number of pinning sites is sufficiently large, a drive-induced pinning effect can occur in which the skyrmion Hall effect forces all of the skyrmions to enter the strongly pinned region. This reentrant pinning effect becomes more pronounced for increasing intrinsic skyrmion Hall angle and larger pinning sites.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Counterflow Virtual Impactor (CVI) Inlet Aboard Aircraft (INLETCVI-AIR) Instrument Handbook

The counterflow virtual impactor (CVI) inlet separates out and samples cloud elements via inertial impaction. Warm, dry, particle-free carrier gas of known composition is pumped to the tip of the inlet in the direction opposite of the flow of air. The flow lines of the incoming free stream air are split. Larger droplets and ice crystals suspended in the sample air have enough inertia to penetrate the counterflow and enter the sample flow, while smaller, unactivated particles follow the streamlines of the air flowing around the inlet’s tip (Noone et al. 1988). The instrument is capable of sampling cloud elements as a function of cut size by changing the velocity of counterflow at the probe tip. The CVI cut size is usually defined as a diameter of a smallest particle for which penetration rate is 50%. For the U.S. Department of Energy (DOE) Atmospheric Radiation Measurement (ARM) user facilityGulfstream-159 aircraft’s CVI inlet, that value is usually around 13 microns. The dry heated air, normally used as the carrier gas, also serves to evaporate water from the hydrometeor, leaving the residuals to be sampled by in-cabin aerosol instrumentation. The number concentration of the droplet residue in the CVI sample line is usually increased with respect to corresponding cloud element number concentration. The CVI performance as a concentrator is usually described via CVI enhancement factor, which is a conversion factor between ambient volumetric concentration (not adjusted to standard temperature and pressure) and volumetric concentration in the CVI sample line.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2023

New Insights from Legacy Seismic Data regarding Basalt Elevations and Variability on the Hanford Site

Migration of groundwater contaminants in the Gable Gap area of the Hanford Site in southeastern Washington State is strongly influenced by the distribution and permeability of basalts that lie beneath an unconfined aquifer. Locally, folding and faulting of the Columbia River Basalt associated with the Yakima fold and thrust belt followed by erosion due to the Lake Missoula floods resulted in a complex basalt surface that represents either an impermeable lower boundary to the unconfined aquifer system or localized regions of increased permeability that potentially promote communication between the unconfined aquifer system and deeper, confined aquifer systems. Paleo-channels carved into the basalt by floodwaters are thought to provide preferential flow paths for groundwater contaminants. In 2011, a seismic landstreamer campaign was carried out to image the basalt surface and produced pre-stack depth migrated p-wave reflection images. The reflection images identified two large troughs that may represent paleo-channels and several areas of possible faulting. Here, the streamer data are re-analyzed using refraction travel-time and Rayleigh wave dispersion analyses to obtain images of compressional and shear wave velocities within the suprabasalt sediment sections and the upper basalt surface. The combined interpretation of reflection and seismic velocity images shows complexity in the basalt velocity and elevation, which varies by 50 m or more within the study area. These results, along with other ongoing geophysical investigations, will be used to inform the site geologic model and potentially guide placement of future boreholes needed to quantify vertical flow between the confined and unconfined aquifers.

58 GEOSCIENCES↗
DOE OSTI2021

Catalytic Reduction of Residual Oxygen for the Purification of Carbon Dioxide Streams from Pressurized Oxy-Combustors

Pressurized oxy-combustion (OC) is regarded as an energy-efficient alternative to atmospheric OC. To utilize the captured carbon dioxide (CO2) from pressurized OC for enhanced oil recovery or carbon storage in geological formations, the CO2 product stream must meet the required purity specifications. One major impurity in OC flue gases is residual O2 (e.g., 3 vol%). In this study, a catalytic approach has been investigated to remove the residual O2 through a reduction reaction with injected methane (CH4) in a reverse-flow fixed-bed (RFFB) reactor. The performance was tested for a supported copper (Cu)-based catalyst synthesized by incipient wetness impregnation and a cobalt-manganese (CoMn) oxide catalyst synthesized by a coprecipitation method. A commercial Cu-based catalyst was also studied as the reference. Experimental results revealed that under the reverse-flow operation, the temperature profiles in the reactor were symmetrical on both sides of the catalyst zone and were more homogenous than those under the conventional one-direction-flow operation. Among the tested catalysts, the CoMn catalyst was the most reactive for promoting the reduction of O2 with CH4, able to attain >95% O2 removal at 475 °C and a gas hourly space velocity (GHSV) of 18,000 h-1 with a feed gas containing 3 vol% O2. Under all experiments, the concentrations of carbon monoxide (CO) were lower than 30 ppmv in the effluent gas streams. The reaction between O2 and CH4 could be depicted by using the Mars–van Krevelen redox mechanism based on a two-step reduction–oxidation reaction pathway.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Uncertainty quantification of bank vegetation impacts on the flood flow field in the American River, California, using large‐eddy simulations

Bank vegetation plays a key role in both hydrodynamics and morphodynamics of natural rivers; however, these effects are often unaccounted for in the computational flow dynamics of natural waterways. Recent studies using the large‐eddy simulation (LES), however, have attempted to gain insights into the impacts of bank vegetation on the mean flow field of the natural rivers using a vegetation model, which applies a sink term to the momentum equations of motion. This approach accounts for the effects of the vegetation and provides a practical approach to account for the complex patches of bank vegetation in large‐scale rivers. To implement the vegetation model, a drag coefficient reflecting the overall resistance of vegetal structures to the flow is needed, but due to the lack of calibrated data and range of size, density and type of vegetation, this parameter can be a significant source of uncertainty in the model results. Here, in this study, we use uncertainty quantification (UQ) to investigate the hydrodynamics and bed shear results when a bank vegetation is incorporated in an LES model. To this end, we used the polynomial chaos expansion and Monte Carlo sampling techniques to determine the uncertainties associated with the drag coefficient in the vegetation model and from uncertainties in the bed roughness and inflow discharge. The UQ analysis provided spatially varying confidence levels for the spanwise and vertical distribution of velocity magnitude and for the bed shear stress distributions. In addition, Sobol indices were computed to indicate the relative influence that each parameter had on the overall uncertainty. In general, it was found that uncertainty in flow discharge was the dominant source of uncertainty; however, the drag coefficient in the vegetation model and the bed roughness parameter also made significant contribution to the uncertainty near the banks and bed, respectively.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2020

Significance of the Direct Excitation Mechanism for High-Frequency Response of Premixed Flames to Flow Oscillations

Premixed flames are sensitive to flow disturbances, which can arise from acoustic or vortical fluctuations. For transverse instabilities, it is known that a dominant mechanism for flame response is “injector coupling,” whereby pressure oscillations associated with transverse waves excite axial flow disturbances. These axial flow disturbances then excite heat release oscillations. The objective of this paper is to consider another mechanism—the direct sensitivity of the unsteady heat release to transverse acoustic waves—and to compare its significance relative to the induced axial disturbances, in a linear framework. The rate at which the flame adds energy to the disturbance field is quantified using the Rayleigh criterion and evaluated over a range of control parameters, such as flame length and swirl number. The results show that radial modes induce heat release fluctuations that always add energy to the acoustic field, whereas heat release fluctuations induced by mixed radial-azimuthal modes can add or remove energy. These amplification rates are then compared to the flame response from induced axial fluctuations. For combustor-centered flames, these results show that the direct excitation mechanism has negligible amplification rates relative to the induced axial mechanism for radial modes. For transverse modes, the fact that the nozzle is located at a pressure node indicates that negligible induced axial velocity disturbances are excited; as such, the direct mechanism dominates. As a result, for flames that are not centered on pressure nodes, the direct mechanism for mixed modes dominates for certain nozzle locations and flame angles.

42 ENGINEERING↗
DOE OSTI2024

On the Flow of a Cement Suspension: The Effects of Nano-Silica and Fly Ash Particles

Additives such as nano-silica and fly ash are widely used in cement and concrete materials to improve the rheology of fresh cement and concrete and the performance of hardened materials and increase the sustainability of the cement and concrete industry by reducing the usage of Portland cement. Therefore, it is important to study the effect of these additives on the rheological behavior of fresh cement. In this paper, we study the pulsating Poiseuille flow of fresh cement in a horizontal pipe by considering two different additives and when they are combined (nano-silica, fly ash, combined nano-silica, and fly ash). To model the fresh cement suspension, we used a modified form of the power-law model to demonstrate the dependency of the cement viscosity on the shear rate and volume fraction of cement and the additive particles. The convection–diffusion equation was used to solve for the volume fraction. After solving the equations in the dimensionless forms, we conducted a parametric study to analyze the effects of nano-silica, fly ash, and combined nano-silica and fly ash additives on the velocity and volume fraction profiles of the cement suspension. According to the parametric study presented here, larger nano-silica content results in lower centerline velocity of the cement suspension and larger non-uniformity of the volume fraction. Compared to nano-silica, fly ash exhibits an opposite effect on the velocity. Larger fly ash content results in higher centerline velocity, while the effect of the fly ash on the volume fraction is not obvious. For cement suspension containing combined nano-silica and fly ash additives, nano-silica plays a dominant role in the flow behavior of the suspension. The findings of the study can help the design and operation of the pulsating flow of fresh cement mortars and concrete in the 3D printing industry.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Hydrodynamic spin-orbit coupling in asynchronous optically driven micro-rotors

Abstract Vortical flows of rotating particles describe interactions ranging from molecular machines to atmospheric dynamics. Yet to date, direct observation of the hydrodynamic coupling between artificial micro-rotors has been restricted by the details of the chosen drive, either through synchronization (using external magnetic fields) or confinement (using optical tweezers). Here we present a new active system that illuminates the interplay of rotation and translation in free rotors. We develop a non-tweezing circularly polarized beam that simultaneously rotates hundreds of silica-coated birefringent colloids. The particles rotate asynchronously in the optical torque field while freely diffusing in the plane. We observe that neighboring particles orbit each other with an angular velocity that depends on their spins. We derive an analytical model in the Stokes limit for pairs of spheres that quantitatively explains the observed dynamics. We then find that the geometrical nature of the low Reynolds fluid flow results in a universal hydrodynamic spin-orbit coupling. Our findings are of significance for the understanding and development of far-from-equilibrium materials.

47 OTHER INSTRUMENTATION↗
DOE OSTI2024

Testing- and Model- Based Optimization of Coal-fired Primary Heater Design for Indirect Supercritical CO 2 Power Cycles (Final Scientific and Technical Report)

The overall objective of this project was to perform the R&D necessary to mitigate the risk associated with the design of a primary heat exchanger for a solid-fired combustion system coupled with an indirect-fired closed-loop Brayton Cycle utilizing supercritical CO 2 . The key technological hurdle was the coupling of a solid-fuel firing system with the primary heater, which poses a singular challenge, which is the management of burner performance and operational conditions in a way to manage heat exchanger tube metal temperatures and temperature ramp rates in the absence of fluid phase change on the inside of the tubes. We designed and built the first ever pseudo power system employing a simple recuperated supercritical CO 2 closed-loop Brayton Cycle coupled to a solid-fuel fired system. Advanced coupled CFD and process modeling were used to design the primary heat exchanger (PHX), which consisted of both radiative and convective sections, to limit tube metal temperatures resulting from the heat release profile of the solid fuel flame near the radiative tubes. The heat exchanger was designed to produce finished CO 2 temperatures of 600 °C a pressure of 20.7 MPa and CO 2 flow of 5.5 kg/s. The constructed PHX was capable of 1.2 MWth heat uptake. During design of the PHX, the modeling showed that most variables influencing flame shape (burner stoichiometric ratio and register velocities and swirl) were not suitable to manage heat flux to the metal surfaces. This is because they substantially increased adiabatic flame temperature through the influence of localized stoichiometric ratio. Excess air and firing rate were the two most powerful variables that could be used to control tube surface temperatures. The coupled system was operated for a total of 407 hours, with the longest continuous run of 248 hours. For 62% of the operational time, the unit was unmanned and in automatic control. The fuels used for the testing included natural gas, two Utah Bituminous coals, woody biomass, and bagasse. During the testing we were able to verify the 1.2 MWth heat uptake and we operated at a finished CO 2 temperature of 607 °C and a pressure of 20.3 MPa simultaneously. The real-time corrosion rate of the Super 304H tube CO 2 surface in the region of the radiative section of the PHX were measured, at an approximate temperature of 550 °C. The two key variables related to corrosion rate are the pressure and flow rate of the CO 2 . A technoeconomic analysis was performed at a scale of 120 MWE. The updated analysis showed that the efficiency of an sCO 2 power producing plant will be related to the pressure drop of the PHX.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2023

Analytical Study and Experimental Verification of Shear-Thinning Ink Flow in Direct Ink Writing Process

Abstract Direct ink writing (DIW) process is a facile additive manufacturing technology to fabricate three-dimensional (3D) objects with various materials. Its versatility has attracted considerable interest in academia and industry in recent years. As such, upsurging endeavors are invested in advancing the ink flow behaviors in order to optimize the process resolution and the printing quality. However, so far, the physical phenomena during the DIW process are not revealed in detail, leaving a research gap between the physical experiments and its underlying theories. Here, we present a comprehensive analytical study of non-Newtonian ink flow behavior during the DIW process. Different syringe-nozzle geometries are modeled for the comparative case studies. By using the computational fluid dynamics (CFD) simulation method, we reveal the shear-thinning property during the ink extrusion process. Besides, we study the viscosity, shear stress, and velocity fields, and analyze the advantages and drawbacks of each syringe-nozzle model. On the basis of these investigations and analyses, we propose an improved syringe-nozzle geometry for stable extrusion and high printing quality. A set of DIW printing experiments and rheological characterizations are carried out to verify the simulation studies. The results developed in this work offer an in-depth understanding of the ink flow behavior in the DIW process, providing valuable guidelines for optimizing the physical DIW configuration toward high-resolution printing and, consequently, improving the performance of DIW-printed objects.

Engineering↗
DOE OSTI2022

Numerical investigation of the influence of shear and thermal stratification on the wind turbine tip‐vortex stability

Summary The interaction between wind turbine wakes and atmospheric turbulence is characterised by complex dynamics. In this study, two major components of the atmospheric boundary layer dynamics have been isolated, namely, the mean velocity profile shear and the thermal stratification, to examine their impact on the near‐wake development by undertaking a series of highly resolved large‐eddy simulations. Subsequently, instantaneous flow fields are extracted from the simulations and used to conduct Fourier analysis and proper orthogonal decomposition (POD) and compute the mean kinetic energy fluxes by different POD modes to better understand the tip‐vortex instability mechanisms. Our findings indicate that shear can significantly affect the breakup of the wind turbine tip‐vortices and the shape and stable length of the wake, whereas thermal stratification seems to only have limited contribution to the spatial development of the near‐wake field. Finally, our analysis shows that the applied perturbation frequency determines the tip‐vortex breakup location as it controls the onset of the mutual inductance instability.

17 WIND ENERGY↗
DOE OSTI2025

Impact of molten salt inflow on the temperature distribution in thermal energy storage tanks at startup for central receiver concentrating solar power plants

Concentrating Solar Power (CSP) systems with molten salt thermal energy storage (TES) tanks are one of the most promising, renewable-based energy conversion technologies for larger-scale power generation. The TES tank is one of the most critical components in CSP plants due to its high-temperature operation (up to 565 °C), daily thermal cycling, and intermittent solar radiation conditions. The plant startup is one of the most challenging operation conditions that could lead to damaging thermal gradients due to low salt inventory levels. In this study an analytical model for the sparger ring was developed and integrated with a detailed computational fluid dynamics model of a commercial-scaled molten salt tank. The integrated model allows an accurate representation of the tank operation to evaluate the effect of molten salt inflow on the mixing process. The tank filling process during plant startup was analyzed considering sparger rings with variations in design features, including inlet orifice configurations, number of orifices, direction of the inlets, and orifice diameter. The results demonstrated that higher temperature gradients are obtained in the tank floor during the plant startup. A sparger ring configuration with a predetermined orifice inlet inclination (30°, 45° and 60°) leads to significant temperature differences in the floor, between 57 °C and 62 °C, but better homogeneity in the temperature of the salt inventory. Lower salt inflow velocities result in a more homogeneous floor temperature, with maximum temperature differences under 38 °C. The sparger ring configuration with 52 orifices of 1-in. diameter and vertical flow showed better homogeneity in the temperature differences as a function of the salt level and lower temperature gradients in the tank floor. Because large temperature gradients in the tank's floor have been identified as one of the main factors contributing to tank failures, assessing various sparger ring design features is fundamental to determining proper inflow conditions that lead to low-temperature gradients and reducing failure susceptibility.

14 SOLAR ENERGY↗