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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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All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

MODELLING FIBER ORIENTATION DURING ADDITIVE MANUFACTURING COMPRESSION MOLDING PROCESSES

The production of high-performance thermoplastic composites reinforced with short carbon fibers can be achieved by a novel “additive manufacturing-compression molding” technique. An advantage of such combination is two-fold: controlled fiber orientation in additive manufacturing and less void content by compression molding. In this study, a computational fluid dynamics model has been developed to predict the behavior of printed layers during fiber-reinforced thermoplastic extrusion and subsequent compression molding. The fiber orientation was modelled with a simple quadratic closure model. The interaction between the fibers is included using a rotary diffusion coefficient which becomes significant in concentrated regimes. Finally, the second order orientation tensor is coupled with the momentum equation as an anisotropic part of the stress term. The effect of processing parameters on the behavior of printed layers was investigated to determine the favorable printing scenarios. The developed numerical model enables design of high-performance composites with tunable mechanical properties.

Seta, Berin↗
DOE OSTI2024

Stochastic reconstruction of fracture network pattern using spatial point processes

Fracture spatial patterns can strongly affect fluid flow in the subsurface. Proximity and distribution of fractures control reservoir flow behavior over various length scales. In many studies, however, simplified geometrical patterns are generated for fractures which may lead to unrealistic subsurface models. Here we introduce a new method for characterization and modeling of fracture spatial patterns based on outcrop observations. We use Ripley's K-function to characterize the arrangement of fracture barycenters and intersection points over various length scales. In addition, we use semivariograms to quantify spatial correlation in fracture intensity maps. Using this information, we develop a stochastic algorithm that generates two-dimensional fracture network realizations with spatial properties similar to those of a real fracture network measured in the field. Numerical simulation models indicate that the generated fracture realizations exhibit similar flow behaviors as that of the original fracture network. Furthermore, such modeling tools expand and improve our capability in building representative fracture models and in quantification of uncertainty in naturally and hydraulically fractured reservoirs.

58 GEOSCIENCES↗
DOE OSTI2025

AdditiveFOAM: A Continuum Multiphysics Code for Additive Manufacturing

AdditiveFOAM is a computational framework that simulates transport phenomena in Additive Manufacturing (AM) processes. It is built on OpenFOAM (Weller et al., 1998), the leading free, open-source software package for computational fluid dynamics (CFD). OpenFOAM offers an extensible platform for solving complex multiphysics problems using state-of-the-art finite volume methods. AdditiveFOAM leverages these capabilities to develop specialized tools aimed at addressing challenges in AM processing. Metal additive manufacturing, also known as metal 3D printing, is an advanced manufacturing technique that creates physical parts from a three-dimensional (3D) digital model by melting metal powder or wire feedstock. A significant area of research in metal AM focuses on process planning to mitigate anomalous features during printing that are deleterious to part performance (e.g., porosity and cracking), as well as controlling localized microstructure and material properties. Given the high costs and substantial time requirements associated with experimental methods for qualifying new materials and processes, there is a compelling incentive for researchers to utilize advanced computational simulations. In this context, AdditiveFOAM offers a simulation framework to better understand undesirable features in printing, thereby enhancing process planning and reducing the reliance on labor-intensive experimental campaigns.

Coleman, John [Oak Ridge National Laboratory (ORNL↗
DOE OSTI2022

Evolution of microscopic heterogeneity and dynamics in choline chloride-based deep eutectic solvents

Deep eutectic solvents (DESs) are an emerging class of non-aqueous solvents that are potentially scalable, easy to prepare and functionalize for many applications ranging from biomass processing to energy storage technologies. Predictive understanding of the fundamental correlations between local structure and macroscopic properties is needed to exploit the large design space and tunability of DESs for specific applications. Here, we employ a range of computational and experimental techniques that span length-scales from molecular to macroscopic and timescales from picoseconds to seconds to study the evolution of structure and dynamics in model DESs, namely Glyceline and Ethaline, starting from the parent compounds. We show that systematic addition of choline chloride leads to microscopic heterogeneities that alter the primary structural relaxation in glycerol and ethylene glycol and result in new dynamic modes that are strongly correlated to the macroscopic properties of the DES formed.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Transition state stabilization depends on solvent identity, pore size, and hydrophilicity for epoxidations in zeolites

Ti-silicates activate H 2 O 2 to form Ti-hydroperoxo and Ti-peroxo intermediates that can react with alkenes to form epoxide products. Comparisons of kinetics for 1-octene epoxidation with H 2 O 2 on Ti-BEA and Ti-MFI catalysts with different hydrophilicities in methanol (CH 3 OH) or acetonitrile (CH 3 CN) solvents show the significance of the solvent for stabilizing catalytically-relevant species and the complex interdependencies between solvent, catalyst topology, and hydrophilicity. Epoxidation turnover rates are higher in CH 3 CN than CH 3 OH for Ti-BEA, but the opposite trend is observed for Ti-MFI. Ti-silicates with greater silanol densities, however, give greater epoxidation turnover rates than their hydrophobic counterparts in both solvents. Kinetic, spectroscopic, and thermodynamic analyses show that differences in turnover rates mainly arise from changes in the stabilization of reactive surface species by solvent mediated interactions, because the mechanism of the reaction and stability of the fluid-phase reactants remain similar in CH 3 CN and CH 3 OH. Specifically, apparent activation free energy values ($ΔG^{‡}_{App}$) indicate that surface intermediates responsible for alkene epoxidation are stabilized to a greater extent in CH 3 CN on Ti-BEA and in CH 3 OH on Ti-MFI. Hydrophilic Ti-silicates present lower ($ΔG^{‡}_{App}$) values regardless of solvent identity, which suggests that these differences correspond to the number of hydrogen-bonding solvent molecules found near reactive species bound to Ti active sites. Finally, taken together, these findings demonstrate the role of solvent molecules in allowing reactive intermediates to recognize the properties of active sites beyond the length-scale of covalent bonds, which carry implications for epoxidation but also other reactions within solvent-filled pores of microporous materials.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2025

Towards Full ‘Galilei General Relativity’: Gravitational Kinematics in Bargmann Spacetimes

Because of the strict separation of mass and energy in Galilei physics, a Galilei-invariant tensor formalism is most at home in a 5-dimensional extended spacetime associated with the Bargmann-Galilei (traditionally ‘Bargmann’) group, a central extension of the Galilei group that explicitly exhibits the transformation properties of kinetic energy. While not necessary for a tensor formalism fully embodying Poincaré physics, a similar central extension of the Poincaré group to the Bargmann-Poincaré group may illuminate a path towards a strong-field ‘Galilei general relativity’. Here the Bargmann metric is generalized to curved spacetime by extending the usual 1+3 (traditionally ‘3+1’) formalism of general relativity on 4-dimensional spacetime to a 1+3+1 formalism, whose spacetime kinematics is shown to be consistent with that of the usual 1+3 formalism. On Bargmann spacetime, tensor laws governing the motion of an elementary classical material particle and the dynamics of a simple fluid reference the foliation of spacetime in a manner that partially reverts the Einstein perspective (accelerated fiducial observers, and geodesic material particles and fluid elements) to a Newton-like perspective (geodesic fiducial observers, and accelerated material particles and fluid elements subject to a gravitational force).

Cardall, Christian [ORNL] (ORCID:000000020086105X)↗
DOE OSTI2025

Scanning Electrochemical Microscopy for Kinetic Investigations in Viscous Deep Eutectic Solvents: Identifying Practical Approach Curves and Deviations from Electron Transfer Models

Determining heterogeneous electrochemical electron transfer (ET) kinetics in electrolytes with a wide range of physical properties is of great interest for achieving high-performance redox flow batteries. Among such electrolytes, concentrated hydrogen-bonded electrolytes (CoHBEs), including deep eutectic solvents (DESs), have recently garnered significant attention. Unfortunately, traditional Tafel analysis using macroelectrodes often encounters issues with mass transfer limitations in CoHBEs with high viscosities, thereby restricting kinetic analysis to a narrow potential window. Here, in this work, we introduce a methodology for evaluating ET kinetics in viscous DES using the scanning electrochemical microscopy (SECM). We first determined practical solutions to SECM tip positioning in ethaline DES, which yield pseudopositive feedback responses. Lattice Boltzmann method (LBM) simulations helped us rationalize the impact of the fluid and concentration fields, as well as tip geometry, tip approach velocity v, and the solvent viscosity ηs, on the shape of the approach curves. In addition to successfully recreating approach curves over a variety of conditions, we found that approaching a conductor ensured a practical point where the normalized tip response (Ni T = 2) converged at L = 0.7 within ∼10% error regardless of tip velocity. With positioning capabilities at hand, we investigated the kinetics of Fe 3+ /Fe 2+ redox couple in aqueous and the ethaline media. The experimental kinetic results were interpreted using the Butler–Volmer (BV) and Marcus–Hush–Chidsey (MHC) models. For ethaline, a nonideal kinetic behavior was observed, potentially attributed to solvent dynamics within DESs or to the interplay of chloride anions in the charge transfer process.

electrodes↗
DOE OSTI2023

NRAP-Open-IAM Multisegmented Wellbore Reduced-Order Model: Improvement and Quality Assurance

The multisegmented wellbore model (MSW) semi-analytically estimates the amount of CO 2 and brine leakage from a leaking legacy well by segmenting it into intervals to simulate site-specific stratigraphic and hydrogeologic properties. The model is a component of the National Risk Assessment Partnership Open-Source Integrated Assessment Model (NRAP-Open-IAM), which was developed to perform risk assessment for geologic CO 2 storage. The new wellbore leakage model, which uses deep learning networks for a caprock segment, was developed to enhance the analytical MSW. The model was trained and validated using a synthetic data set of Subsurface Transport Over Multiple Phases (STOMP) multiphase flow simulations from various geological, well attribute, and operational conditions to ensure its quality. The results demonstrate that the model is more accurate than the existing model in predicting the transport of two-phase fluids (brine and injected CO 2 ) through the well. This report provides a detailed explanation of the model development and quality assurance.

58 GEOSCIENCES↗
DOE OSTI2023

Three-dimensional charge density wave in the dual heavy fermion system UPt 2 Si 2

Heavy fermion liquids offer via their Kondo lattice diverse possibilities for exotic ground states. Using variable-temperature atomic pair distribution function analysis, we study the local atomic structure of the "dual" heavy fermion liquid UPt 2 Si 2 , which exhibits antiferromagnetism consistent with localized 5f-electron states and transport properties characteristic to itinerant 5f-"spd" hybridized electron systems. We show that UPt 2 Si 2 exhibits periodic lattice distortions (PLDs) involving both uranium and platinum atoms that are characteristic to three-dimensional charge density waves. Here, the temperature evolution of the PLDs tracks that of the transport and magnetic properties, suggesting the presence of little-known 5f-electron-lattice interactions. We argue that PLDs in heavy fermion liquids in general, and in particular in UPt 2 Si 2 , appear as new degrees of freedom that entangle competing electronic states and, as such, must be accounted for when their rich physics is considered.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Fast solvers for tokamak fluid models with PETSc

Multigrid (MG) is widely recognized as a highly effective solver for the model problem, the Laplacian, but textbook MG fails on most problems of interest. MG methods have been applied to complex, real-world applications with careful consideration of the physical model and discretization. In this work we develop the first step in applying MG methods to science and engineering relevant magnetohydrodynamics (MHD) tokamak models in the M3D-C1 (https://m3dc1.pppl.gov) fusion energy science code. The semi-implicit time integrator in M3D-C1 is composed of many linear solves. The implicit advance of the momentum equation is the most challenging and is the focus of this work. The current production solver in M3D-C1 is a block Jacobi (BJ) preconditioner within a Krylov solver, where blocks group degrees of freedom on planes of constant toroidal coordinate. BJ convergence degrades as the number of planes increases due to the spectral properties of the matrix preconditioned with BJ. The partially magnetic field-aligned, regular toroidal grid structure in M3D-C1 is amenable to semi-coarsening geometric MG in the toroidal direction. This paper develops such a solver and demonstrates competitive performance on a runaway electron model of a SPARC (https://cfs.energy/technology/sparc) disruption, and superior robustness on a stellarator model on which the BJ solver fails to converge.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2020

Recreating Giants Impacts in the Laboratory: Shock Compression of MgSiO 3 Bridgmanite to 14 Mbar

Understanding giant impacts requires accurate description of how extreme pressures and temperatures affect the physical properties of the constituent materials. Here, we report shock experiments on two polymorphs of MgSiO 3 : enstatite and bridgmanite (perovskite) crystals.We obtain pressure-density shock equation of state to 14 Mbar and more than 9 g/cm 3 , a 40% increase in density from previous data on MgSiO 3 . Density-functional-theory molecular dynamics (DFT-MD) simulations provide predictions for the shock Hugoniot curves for bridgmanite and enstatite and suggest that the Grüneisen parameter decreases with increasing density. The good agreement between the simulations and the experimental data, including for the shock temperature along the enstatite Hugoniot reveals that DFT-MD simulations reproduce well the behavior of dense fluid MgSiO 3 .We also reveal a high optical reflectance indicative of a metal-like electrical conductivity which supports the hypothesis that magma oceans may contribute to planetary magnetic field generation.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2026

Progress and innovations in the TCV tokamak research programme

Research on the Tokamak à Configuration Variable addresses a wide range of key questions relevant to ITER and future fusion power plants. Over the past two years, highly productive experimental campaigns have led to major advances across several areas: the ITER baseline scenario; pedestal properties in low-collisionality, peeling-limited conditions; and the development of high- β N , non-inductive regimes. Alternative high-confinement scenarios have likewise received significant attention, with remarkable progress in quasi-continuous exhaust operation, X-point radiator plasmas, and negative triangularity configurations. Substantial achievements were also made in the mitigation or benign termination of runaway electron beams, in elucidating fast-ion loss mechanisms, and in improving exhaust behaviour in both conventional and alternative divertor geometries. These experimental results have been strongly supported by advances in modelling and their direct application to the experiment, ranging from gyrokinetic simulations of core and pedestal turbulence to fluid-based studies of scrape-off layer and divertor physics in diverse geometries. Plasma control has taken on an increasingly important role, with model-based and data-driven approaches now closely intertwined with physics studies. This article provides a overview of these recent activities, together with a brief outlook on forthcoming upgrades and next steps.

EPFL↗
DOE OSTI2023

Multi-injection investigation of a high-volatility diesel in advanced compression ignition combustion for NO x control

Traditional selective catalytic reduction aftertreatment technologies used to reduce [Formula: see text] are very limited at exhaust temperatures below [Formula: see text]. Therefore, under these low engine load conditions, having effective in-cylinder control of [Formula: see text] emissions is important. Previous work by the authors explored the effect of fuel physical properties on the ability to control [Formula: see text] in-cylinder. That work was limited to one direct injection near top dead center. Modern diesel high-pressure fuel systems have the capability of five or more injections in one engine cycle. A higher-volatility diesel fuel and high amounts of exhaust gas recirculation to delay ignition could provide an opportunity for reduction in engine-out [Formula: see text] through an increased level of fuel premixing. By appropriately timing multiple short injections, a more optimal distribution of fuel in-cylinder may be achieved, which could reduce [Formula: see text] while maintaining an efficient combustion phasing. A computational fluid dynamics model previously validated against experimental data was used to explore several injection strategies with increased levels of fuel premixing to assess the potential trade-offs between [Formula: see text] and CO/unburned hydrocarbon (UHC) emissions and thus reduce reliance on the aftertreatment system for [Formula: see text] control. The results show that the devised injection strategies resulted in an increased level of fuel premixing. However, none of the attempted injection strategies resulted in significant [Formula: see text] reductions, and all strategies showed a significant increase in CO and UHC emissions.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2022

Enriched immersed boundary method (EIBM) for interface-coupled multi-physics and applications to convective conjugate heat transfer

It is challenging to develop numerical methods that simultaneously maintain accuracy of resolving boundary conditions and mesh flexibility to handle the interface in interface-coupled multi-physics problems involving large property discontinuity. On the one hand, boundary-fitted methods possess high accuracy in capturing the interfacial phenomenon but involve complicated volumetric mesh generation, mesh-motion, and even re-meshing procedures. On the other hand, immersed boundary methods (IBM) provide mesh flexibility but sometimes suffer from inferior interface representations, leading to poor enforcement of boundary conditions. This paper presents an enriched immersed boundary method (EIBM) to overcome this challenge and demonstrates its efficacy in conjugate heat transfer, a representative example in interface-coupled multi-physics systems that have implications for many industrial processes. Further, the core technique of the method is to enhance IBM’s accuracy of the fluid–solid interface by enriching the degrees of freedom of the cut elements to enforce temperature and flux compatibilities and resolve all the physical unknowns on the background mesh to simplify the volumetric mesh generation. We implement the EIBM under the framework of a variational multiscale formulation for coupled Navier–Stokes and thermodynamics equations. The enriched DoFs enable better enforcement of temperature and flux compatibilities with large conductivity ratios across the fluid–solid interface. At the same time, the immersed nature of the proposed method still attains mesh flexibility. The EIBM’s accuracy is thoroughly evaluated through a set of examples, ranging from benchmark problems with analytical solutions to real-world cooling processes of a moving metallic structure with complex geometry.

42 ENGINEERING↗
DOE OSTI2022

Additive manufacturing and testing of a ceramic heat exchanger for high-temperature and high-pressure applications for concentrating solar power

Heat exchangers with excellent corrosion and oxidation resistances are essential for the next-generation concentrating solar power (CSP) plants using a molten salt heat transfer fluid and a supercritical CO 2 Brayton power cycle that can operate at temperatures > 700 °C for higher efficiencies. Techniques were developed for additively manufacturing ceramic materials for applications involving high temperature, high pressure, and high corrosion resistance as needed for the CSP application. Based on a previous ceramic heat exchanger design with its cross-section geometry of the flow channels optimized for heat transfer and mechanical strength, lab-scale prototype heat exchangers, with integrated headers and incorporated flow channel dimensional compensations, were fabricated by using the binder jetting process. The printed prototype heat exchangers were successfully densified through the processes of liquid polymer infiltration and pyrolysis. In addition, thermophysical properties of the densified silicon carbide parts were measured to provide necessary design information. Experimental heat transfer testing of the lab-scale prototype heat exchanger was conducted, and the experimental data agreed reasonably well with the simulated results. Furthermore, this agreement provides validation of the simulation models for their applicability to the development of a full-scale ceramic heat exchanger.

14 SOLAR ENERGY↗
DOE OSTI2026

Nonlocal Effect of Percolated Particle Networks on Viscoelasticity of Polymer–Filler Nanocomposites: A Mesoscale Simulation Study

With nanoparticles (NPs) as fillers, polymer nanocomposites (PNCs) usually exhibit enhanced mechanical properties. However, a direct connection between the microscopic structural relaxation and macroscopic mechanical properties of PNCs remains to be established. To investigate the micro-to-macro connection, we develop a mesoscale model, in which the NPbridging polymer chains are represented by a dynamic bonded interaction between NPs, and the bulk polymer matrix is implicitly modeled by overdamped Langevin dynamics. Extensive equilibrium simulations are performed to quantify the microscopic dynamics of model PNCs. Systematic analyses of modified Rouse dynamics, dynamic structure factor, and relaxation modulus uncover that the microscopic relaxation dynamics of PNCs are significantly decelerated across different length scales because of nonlocal effects of percolated particle networks a phenomenon that has not been adequately captured in prior simulation studies. We find that NPvolume- fraction and NP-bonding-energy barrier are the two critical variables that affect bulk viscoelasticity the most. The proposed mesoscale model is versatile and provides a powerful framework for studying structure−property relations of different PNCs.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2024

Design Optimization and Measurement Uncertainty of an Electromagnetic Level Sensor for Liquid Metal Reactors

Here, this article describes the design and operation of a prototype mutual inductance level sensor (MILS) and the development and validation of a finite-element analysis (FEA) model describing its behavior. The MILS was designed for use in liquid sodium up to temperatures of 650 °C in the Mechanisms Engineering Test Loop (METL) at Argonne National Laboratory (ANL). Preliminary testing was performed in a room temperature test stand with aluminum acting as an analog for the sodium to better understand sensor performance and provide accurate code validation data. This experimental data, along with material properties found in literature, were used to validate an FEA model in ANSYS Maxwell. The validated ANSYS Maxwell model was used to examine the performance of the MILS in various environments and under various operating conditions. Simulations suggest the following: The MILS will perform adequately in liquid sodium and liquid lead at temperatures up to 650 °C . The temperature dependence of electrical conductivity imposes a temperature dependence on the sensor that requires proper compensation. The MILS signal sensitivity is maximized when mutual inductance between sensor coils is maximized, and sensor geometry should be selected to account for this factor. The operating frequency of the MILS can be optimized and is dependent on process fluid material, operating temperature, and materials/geometry of sensor system. Finally, the use of a stainless-steel isolating thimble does not adversely affect the sensor signal. The primary sources of error for this MILS system are the accuracy of the calibration standard against which the sensor is calibrated, and the temperature dependence of the sensor. This work contains all the necessary details to recreate the FEA model and results. This model can be used to optimize the performance of a MILS in any operating environment to read any electrically conductive working fluid.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2025

Technical Report on Subsurface Monitoring of the Brady Hot Spring Geothermal Site, Nevada, based upon Full Waveform Inversion

Abilities to accurately characterize the subsurface in a geothermal setting is key to assess and support production. An important element of geothermal reservoir monitoring is also the ability to investigate fluid transport within fracture network. This report focuses on improving subsurface imaging and monitoring in geothermal settings using full waveform inversion based on the adjoint method and time-lapse imaging. To assess our method, we rely on a dense seismic dataset collected in 2016 at the Brady Hot Springs geothermal site in Nevada for the DOE-funded project Poroelastic Tomography by Adjoint Inverse Modeling of Data from Seismology, Geodesy, and Hydrology. This dataset captures subsurface changes across four stages of geothermal power plant operations, which involve varying rates of fluid injection and extraction. Two velocity models were previously derived from this dataset using different methods: one based on travel times and another on sweep interferometry. Our first step is to refine these models using adjoint tomography, which has been applied successfully at global and regional-scales but is less common at the reservoir-scale. Two approaches are then explored for time-lapse analysis: directly comparing refined tomographic models from different stages or backpropagating waveform differences relative to a baseline tomographic model. The main take away is that both approaches highlight similar reservoir behaviors, but the latter approach is more computationally effective in capturing small-scale changes in subsurface properties. For this work, we leverage the use of Salvus (www.mondaic.com), an end-to-end seismic imaging solution, relying on the spectral element method to compute forward and adjoint simulations, and developed by Mondaic Ltd. It includes integrated workflow management that handles waveform and metadata, launches simulations, computes waveform misfits and adjoint sources, and iterates for model updates by nonlinear optimization.

15 GEOTHERMAL ENERGY↗