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DOE OSTI2019

Development of Critical Experiments to Provide Validation Data for Multiphysics Coupling Methods (Final Report)

Computational simulation has become one of the most important tools in the modern toolbox for nuclear reactor design. Reactor simulations, like the reactors themselves, involve multiple physical processes including neutronics, fluid flow and heat transfer (thermal-hydraulics), thermo-mechanics, fuel behavior, chemistry, and balance of plant. Each process can affect the behavior of the others, and advanced computational tools have been developed that couple separate physics models together to simulate the feedback effects. The objective of this work is to generate experimental data to support the validation of multi-physics reactor codes. It specifically targets the SHARP toolset from the NEAMS Reactor Product Line, but it is intended to be useful in any set of coded that couples thermal-hydraulics with neutronics simulations. The project takes advantage of the inherent flexibility of the RPI Reactor Critical Facility (RCF), a low power open-pool research reactor. The standard configuration of the RCF is used to explore the effects of moderator temperature on neutronic behavior and reactivity. Because the low power of the reactor generates no appreciable temperature change in the moderator, the moderator temperature is artificially changed with two 18 kW electric immersion heaters. The temperature feedback effects can be observed by recording the change in the reactor power as the reactor goes from a supercritical state, to critical, to a subcritical state. To expand the temperature range and temperature rate of change that can be investigated, an experimental apparatus consisting of a heated water loop was designed and installed in the RCF. In this setup, water from a heated reservoir tank is pumped through a pipe placed through the center of the reactor core. The water in the reservoir can be heated to around 70 °C and pumped through the system. The pump has a variable flow rate and electronic control, so a number of scenarios can be developed. A slug of water can be pushed through the system to generate a reasonably fast change in reactivity. The pump speed can be increased or decreased over the course of a measurement, or even oscillated at different periods, to observe the response of the reactor. To complement the experimental data generated by the RCF, a set of computational models have been developed. They are intended to illustrate the usefulness of the experimental data generated in validating coupled multi-physics simulations. A model previously constructed in MCNP has been used in conjunction with safety analysis at the RCF for many years and was modified to support the design of the heated water loop experiment. This model was translated into Serpent 2, a similar Monte Carlo code, which provided the added advantage of being able to produce collapsed cross-section data files for use in the deterministic neutron transport codes that are part of the SHARP toolset. A complete reconstruction of the RCF model, both with and without the heated fluid loop experiment, were necessary for use with the SHARP codes, PROTEUS (neutronics) and Nek5000 (thermal hydraulics), as these require an unstructured mesh format to operate. The computational requirements for fully coupled three dimensional simulations are significant, and challenges to full implementation and comparison with RCF experiments remain. A wide variety of experiments have been conducted for eventual benchmarking and validation of multi-physics reactor codes. A complete database of detailed time- and temperature-dependent measurements have been generated and stored. Several examples of the experimental results are presented here, with refinement and analysis of experiments ongoing. While these experiments still only address a finite range of operating conditions, in particular being limited to water in the sub-boiling regime, they represent a unique (to date) look at the feedback between temperature and neutronic behavior suited for validation of the coupling routines in multi-physics codes. It is hoped that these will be the foundation of future benchmarks that will provide confidence in the tools that will be used to develop the next generation of nuclear reactor systems.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

NASA NTRS1985

A computer analysis program for interfacing thermal and structural codes

A software package has been developed to transfer three-dimensional transient thermal information accurately, efficiently, and automatically from a heat transfer analysis code to a structural analysis code. The code is called three-dimensional TRansfer ANalysis Code to Interface Thermal and Structural codes, or 3D TRANCITS. TRANCITS has the capability to couple finite difference and finite element heat transfer analysis codes to linear and nonlinear finite element structural analysis codes. TRANCITS currently supports the output of SINDA and MARC heat transfer codes directly. It will also format the thermal data output directly so that it is compatible with the input requirements of the NASTRAN and MARC structural analysis codes. Other thermal and structural codes can be interfaced using the transfer module with the neutral heat transfer input file and the neutral temperature output file. The transfer module can handle different elemental mesh densities for the heat transfer analysis and the structural analysis.

Thompson, R. L.↗

NASA NTRS1985

A computer analysis program for interfacing thermal and structural codes

Thompson, R. L.↗

NASA NTRS1991

Spatial adaption procedures on unstructured meshes for accurate unsteady aerodynamic flow computation

Spatial adaption procedures for the accurate and efficient solution of steady and unsteady inviscid flow problems are described. The adaption procedures were developed and implemented within a two-dimensional unstructured-grid upwind-type Euler code. These procedures involve mesh enrichment and mesh coarsening to either add points in a high gradient region or the flow or remove points where they are not needed, respectively, to produce solutions of high spatial accuracy at minimal computational costs. A detailed description is given of the enrichment and coarsening procedures and comparisons with alternative results and experimental data are presented to provide an assessment of the accuracy and efficiency of the capability. Steady and unsteady transonic results, obtained using spatial adaption for the NACA 0012 airfoil, are shown to be of high spatial accuracy, primarily in that the shock waves are very sharply captured. The results were obtained with a computational savings of a factor of approximately fifty-three for a steady case and as much as twenty-five for the unsteady cases.

Rausch, Russ D.↗

NASA NTRS2004

Experimentation Toward the Analysis of Gear Noise Sources Controlled by Sliding Friction and Surface Roughness

In helicopters and other rotorcraft, the gearbox is a major source of noise and vibration (N&V). The two N&V excitation mechanisms are the relative displacements between mating gears (transmission errors) and the friction associated with sliding between gear teeth. Historically, transmission errors have been minimized via improved manufacturing accuracies and tooth modifications. Yet, at high torque loads, noise levels are still relatively high though transmission errors might be somewhat minimal. This suggests that sliding friction is indeed a dominant noise source for high power density rotorcraft gearboxes. In reality, friction source mechanism is associated with surface roughness, lubrication regime properties, time-varying friction forces/torques and gear-mesh interface dynamics. Currently, the nature of these mechanisms is not well understood, while there is a definite need for analytical tools that incorporate sliding resistance and surface roughness, and predict their effects on the vibro- acoustic behavior of gears. Toward this end, an experiment was conducted to collect sound and vibration data on the NASA Glenn Gear-Noise Rig. Three iterations of the experiment were accomplished: Iteration 1 tested a baseline set of gears to establish a benchmark. Iteration 2 used a gear-set with low surface asperities to reduce the sliding friction excitation. Iteration 3 incorporated low viscosity oil with the baseline set of gears to examine the effect of lubrication. The results from this experiment will contribute to a two year project in collaboration with the Ohio State University to develop the necessary mathematical and computer models for analyzing geared systems and explain key physical phenomena seen in experiments. Given the importance of sliding friction in the gear dynamic and vibro-acoustic behavior of rotorcraft gearboxes, there is considerable potential for research & developmental activities. Better models and understanding will lead to quiet and reliable gear designs, as well as the selection of optimal manufacturing processes.

Asnani, Vivake M.↗

DOE OSTI2016

Simple rANDom wALk simulation

SANDAL is a particle-mesh simulation mini-app. The simple simulated physics propagates a set of particles in a constant, 2D wind field with Gaussian turbulence. SANDAL demonstrates the feasibility of formulating a computational physics problem using an alternative, modern design. Specifically, it is implemented using relational tables and queries, rather than array-based data model. It also is implemented with functional language design and cloud deployment, Scala and Apache Spark, rather than Fortran and MPI+X.

Lo, Li-Ta↗

DOE OSTI2015

DRACS thermal performance evaluation for FHR

Direct Reactor Auxiliary Cooling System (DRACS) is a passive decay heat removal system proposed for the Fluoride-salt-cooled High-temperature Reactor (FHR) that combines coated particle fuel and a graphite moderator with a liquid fluoride salt as the coolant. The DRACS features three coupled natural circulation/convection loops, relying completely on buoyancy as the driving force. These loops are coupled through two heat exchangers, namely, the DRACS Heat Exchanger and the Natural Draft Heat Exchanger. In addition, a fluidic diode is employed to minimize the parasitic flow into the DRACS primary loop and correspondingly the heat loss to the DRACS during normal operation of the reactor, and to keep the DRACS ready for activation, if needed, during accidents. To help with the design and thermal performance evaluation of the DRACS, a computer code using MATLAB has been developed. This code is based on a one-dimensional formulation and its principle is to solve the energy balance and integral momentum equations. By discretizing the DRACS system in the axial direction, a bulk mean temperature is assumed for each mesh cell. The temperatures of all the cells, as well as the mass flow rates in the DRACS loops, are predicted by solving the governing equations that are obtained by integrating the energy conservation equation over each cell and integrating the momentum conservation equation over each of the DRACS loops. In addition, an intermediate heat transfer loop equipped with a pump has also been modeled in the code. This enables the study of flow reversal phenomenon in the DRACS primary loop, associated with the pump trip process. Experimental data from a High-Temperature DRACS Test Facility (HTDF) are not available yet to benchmark the code. A preliminary code validation is performed by using natural circulation experimental data available in the literature, which are as closely relevant as possible. The code is subsequently applied to the HTDF that is under construction at the Ohio State University.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2018

Cadmium and atherosclerosis: A review of toxicological mechanisms and a meta-analysis of epidemiologic studies

Cadmium has been proposed to be the one of the factors of atherosclerosis development, although the existing data are still controversial. The primary objective of the present study is the review and the meta-analysis of studies demonstrating the association between Cd exposure and atherosclerosis as well as review of the potential mechanisms of such association. We performed a systematic search in the PubMed-Medline database using the MeSH terms cadmium, cardiovascular disease, atherosclerosis, coronary artery disease, myocardial infarction, stroke, mortality and humans up through December 20, 2017. Elevated urinary Cd levels were associated with increased mortality for cardiovascular disease (HR = 1.34, 95% CI: 1.07–1.67) as well as elevated blood Cd levels (HR = 1.78, 95% CI: 1.24–2.56). Analysis restricted to never smokers showed similar, though more imprecise, results. Consistently, we also observed an association between Cd exposure markers (blood and urine) and coronary heart disease, stroke, and peripheral artery disease. Moreover, Cd exposure was associated with atherogenic changes in lipid profile. High Cd exposure was associated with higher TC levels (OR = 1.48, 95% CI: 1.10–2.01), higher LDL-C levels (OR = 1.31, 95% CI 0.99–1.73) and lower HDL-C levels (OR = 1.96, 95% CI: 1.09–3.55). The mechanisms of atherogenic effect of cadmium may involve oxidative stress, inflammation, endothelial dysfunction, enhanced lipid synthesis, up-regulation of adhesion molecules, prostanoid dysbalance, as well as altered glycosaminoglycan synthesis.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2026

Convective Biases in the US DOE Global Storm‐Resolving Model: Insights From Regionally Refined Simulations During the CACTI Campaign

Accurately simulating convective processes in complex terrain remains a critical challenge for global storm-resolving models (GSRMs). This study systematically evaluates moist convective biases in the Regionally Refined Mesh configuration of the U.S. Department of Energy Simple Cloud-Resolving E3SM Atmosphere Model (RRM-SCREAM) using comprehensive observations and large-eddy simulations from the Cloud, Aerosol, and Complex Terrain Interactions (CACTI) campaign in the mountainous area of central Argentina. Comparisons of simulations with high-resolution observations and reanalysis data indicate that RRM-SCREAM effectively captures large-scale meteorological patterns, including regional atmospheric gradients and diurnal variability. However, RRM-SCREAM disproportionately produces smaller precipitation clusters referred to as “popcorn convection,” and exaggerated rainfall intensities compared to observations and reference models. Detailed examination of a representative orographic shallow-to-deep convective transition case shows that RRM-SCREAM delays initial shallow convection growth due to lower-tropospheric dryness and sustained convective inhibition, but once triggered, deep convection becomes overly vigorous with excessively strong vertical velocities and elevated cloud ice content, linked to a thermodynamic structure characterized by suppressed low-level moistening and excessive upper-level moisture retention. Our results highlight specific deficiencies in the model representation of convective vertical velocity, cloud microphysical processes, and convective precipitation organization within RRM-SCREAM. Addressing these biases is essential for improving the predictions of convective clouds and precipitation in the global high-resolution atmospheric models.

Su, Tianning [Lawrence Livermore National Laborato↗

DOE OSTI2015

A continuous surface reconstruction method on point cloud captured from a 3D surface photogrammetry system

Purpose: To accurately and efficiently reconstruct a continuous surface from noisy point clouds captured by a surface photogrammetry system (VisionRT). Methods: The authors have developed a level-set based surface reconstruction method on point clouds captured by a surface photogrammetry system (VisionRT). The proposed method reconstructs an implicit and continuous representation of the underlying patient surface by optimizing a regularized fitting energy, offering extra robustness to noise and missing measurements. By contrast to explicit/discrete meshing-type schemes, their continuous representation is particularly advantageous for subsequent surface registration and motion tracking by eliminating the need for maintaining explicit point correspondences as in discrete models. The authors solve the proposed method with an efficient narrowband evolving scheme. The authors evaluated the proposed method on both phantom and human subject data with two sets of complementary experiments. In the first set of experiment, the authors generated a series of surfaces each with different black patches placed on one chest phantom. The resulting VisionRT measurements from the patched area had different degree of noise and missing levels, since VisionRT has difficulties in detecting dark surfaces. The authors applied the proposed method to point clouds acquired under these different configurations, and quantitatively evaluated reconstructed surfaces by comparing against a high-quality reference surface with respect to root mean squared error (RMSE). In the second set of experiment, the authors applied their method to 100 clinical point clouds acquired from one human subject. In the absence of ground-truth, the authors qualitatively validated reconstructed surfaces by comparing the local geometry, specifically mean curvature distributions, against that of the surface extracted from a high-quality CT obtained from the same patient. Results: On phantom point clouds, their method achieved submillimeter reconstruction RMSE under different configurations, demonstrating quantitatively the faith of the proposed method in preserving local structural properties of the underlying surface in the presence of noise and missing measurements, and its robustness toward variations of such characteristics. On point clouds from the human subject, the proposed method successfully reconstructed all patient surfaces, filling regions where raw point coordinate readings were missing. Within two comparable regions of interest in the chest area, similar mean curvature distributions were acquired from both their reconstructed surface and CT surface, with mean and standard deviation of (μ{sub recon} = − 2.7 × 10{sup −3} mm{sup −1}, σ{sub recon} = 7.0 × 10{sup −3} mm{sup −1}) and (μ{sub CT} = − 2.5 × 10{sup −3} mm{sup −1}, σ{sub CT} = 5.3 × 10{sup −3} mm{sup −1}), respectively. The agreement of local geometry properties between the reconstructed surfaces and the CT surface demonstrated the ability of the proposed method in faithfully representing the underlying patient surface. Conclusions: The authors have integrated and developed an accurate level-set based continuous surface reconstruction method on point clouds acquired by a 3D surface photogrammetry system. The proposed method has generated a continuous representation of the underlying phantom and patient surfaces with good robustness against noise and missing measurements. It serves as an important first step for further development of motion tracking methods during radiotherapy.

60 APPLIED LIFE SCIENCES↗

NASA NTRS1987

Identification and proposed control of helicopter transmission noise at the source

Helicopter cabin interiors require noise treatment which is expensive and adds weight. The gears inside the main power transmission are major sources of cabin noise. Work conducted by the NASA Lewis Research Center in measuring cabin interior noise and in relating the noise spectrum to the gear vibration of the Army OH-58 helicopter is described. Flight test data indicate that the planetary gear train is a major source of cabin noise and that other low frequency sources are present that could dominate the cabin noise. Companion vibration measurements were made in a transmission test stand, revealing that the single largest contributor to the transmission vibration was the spiral bevel gear mesh. The current understanding of the nature and causes of gear and transmission noise is discussed. It is believed that the kinematical errors of the gear mesh have a strong influence on that noise. The completed NASA/Army sponsored research that applies to transmission noise reduction is summarized. The continuing research program is also reviewed.

Coy, John J.↗

NASA NTRS1988

Identification and proposed control of helicopter transmission noise at the source

Coy, John J.↗

NASA NTRS1991

Spatial adaption procedures on unstructured meshes for accurate unsteady aerodynamic flow computation

Spatial adaption procedures for the accurate and efficient solution of steady and unsteady inviscid flow problems are described. The adaption procedures were developed and implemented within a two-dimensional unstructured-grid upwind-type Euler code. These procedures involve mesh enrichment and mesh coarsening to either add points in high gradient regions of the flow or remove points where they are not needed, respectively, to produce solutions of high spatial accuracy at minimal computational cost. The paper gives a detailed description of the enrichment and coarsening procedures and presents comparisons with alternative results and experimental data to provide an assessment of the accuracy and efficiency of the capability. Steady and unsteady transonic results, obtained using spatial adaption for the NACA 0012 airfoil, are shown to be of high spatial accuracy, primarily in that the shock waves are very sharply captured. The results were obtained with a computational savings of a factor of approximately fifty-three for a steady case and as much as twenty-five for the unsteady cases.

Rausch, Russ D.↗

NASA NTRS1991

Development of a low pass far infrared filter for Lunar Observer horizon sensor application

A study was conducted to (1) determine the feasibility of design and fabrication of a low pass filter with a relatively sharp cut-on at higher wavelengths (i.e. 30-40 microns), using metallic mesh technique; and (2) investigate whether the combination of this filter and a suitable IR detector, as a part of a Lunar Observer (LO) horizon sensor, is capable of detecting radiation emanating from two blackbody sources kept at temperatures simulating space and the surface temperature of dark or lit sides of the moon. Various designs of multilayer metallic mesh filters with different mesh parameters and substrate thicknesses were simulated. Using mesh parameters corresponding to the optimum four-layer filter design, a filter was fabricated on a 6.35 micron thick mylar substrate. The transmission curve of the fabricated filter is very close to what the simulation predicted. Room temperature signal level tests were performed on the combination of filter-detector assemblies. The data obtained from these tests indicate that the assembly can detect temperature differences as low as few degrees K between two black bodies.

Mobasser, Sohrab↗

NASA NTRS2011

Design and Analysis of a Stiffened Composite Structure Repair Concept

A design and analysis of a repair concept applicable to a stiffened thin-skin composite panel based on the Pultruded Rod Stitched Efficient Unitized Structure is presented. Since the repair concept is a bolted repair using metal components, it can easily be applied in the operational environment. Initial analyses are aimed at validating the finite element modeling approach by comparing with available test data. Once confidence in the analysis approach is established several repair configurations are explored and the most efficient one presented. Repairs involving damage to the top of the stiffener alone are considered in addition to repairs involving a damaged stiffener, flange and underlying skin. High fidelity finite element modeling techniques such as mesh-independent definition of compliant fasteners, elastic-plastic metallic material properties and geometrically nonlinear analysis are utilized in the effort. The results of the analysis are presented and factors influencing the design are assessed and discussed.

Przekop, Adam↗

NASA NTRS2017

SpaRibs Geometry Parameterization for Wings with Multiple Sections using Single Design

The SpaRibs topology of an aircraft wing has a significant effect on its structural behavior and stability as well as the flutter performance. The development of additive manufacturing techniques like Electron Beam Free Form Fabrication (EBF3) has made it feasible to manufacture aircraft wings with curvilinear spars, ribs (SpaRibs) and stiffeners. In this article a new global-local optimization framework for wing with multiple sections using curvilinear SpaRibs is described. A single design space is used to parameterize the SpaRibs geometry. This method has been implemented using MSC-PATRAN to create a broad range of SpaRibs topologies using limited number of parameters. It ensures C0 and C1 continuities in SpaRibs geometry at the junction of two wing sections with airfoil thickness gradient discontinuity as well as mesh continuity between all structural components. This method is advantageous in complex multi-disciplinary optimization due to its potential to reduce the number of design variables. For the global-local optimization the local panels are generated by an algorithm which is totally based on a set algebra on the connectivity matrix data. The great advantage of this method is that it is completely independent of the coordinates of the nodes of the finite element model. It is also independent of the order in which the elements are distributed in the FEM. The code is verified by optimizing of the CRM Baseline model at trim condition at Mach number equal to 0.85 for five different angle of attack (-2deg, 0deg,2deg,4deg and 6deg). The final weight of the wing is 19,090.61 lb. This value is comparable to that obtained by Qiang et al. 6 (19,269 lb).

wing sections↗

DOE OSTI2018

Evaluating On-Node GPU Interconnects for Deep Learning Workloads

Scaling deep learning workloads across multiple GPUs on a single node has become increasingly important in data analytics. A key question is how well a PCIe-based GPU interconnect can perform relative to a custom high-performance interconnect such as NVIDIA's NVLink. This paper evaluates two such on-node interconnects for eight NVIDIA Pascal P100 GPUs: (a) the NVIDIA DGX-1's NVLink 1.0 `hybrid cube mesh'; and (b) the Cirrascale GX8's two-level PCIe tree using dual SR3615 switch risers. To show the effects of a range of neural network workloads, we define a parameterized version of the popular ResNet. We define a workload intensity metric that characterizes the expected computation/communication ratio; we also locate AlexNet and GoogLeNet within that space. As expected, the DGX-1 typically has superior performance. However, when equalizing GPU SM frequencies, the GX8 is very competitive on all ResNet workloads. With 8 GPUs, the GX8 can outperform the DGX-1 on all-to-all reductions by 10% for medium-sized payloads; and in rare cases, the GX8 slightly outperforms on ResNet.

Tallent, Nathan R.↗

DOE OSTI2025

Meshfree simulation and prediction of recrystallized grain size in friction stir processed 316L stainless steel

Friction stir processing (FSP) is a promising solid-phase microstructural modification technique that can repair and enhance damaged stainless steel surfaces exposed to harsh environments. The quality of the repaired material is closely correlated to the recrystallized grain size in the stir zone (SZ), which is influenced by the thermomechanical conditions dictated by FSP process parameters. Thus, establishing a reliable relationship between these parameters and recrystallized grain size in the SZ is crucial for optimizing repair quality. However, existing experimental approaches often rely on indirect temperatures measured far from the SZ, along with rough strain rate estimations, which are imprecise and time-consuming. Meanwhile, existing mesh-based modeling methods usually face numerical challenges when dealing with the large material deformations inherent in FSP. Here, to address these issues, this study introduces a meshfree process model for FSP based on the smoothed particle hydrodynamics (SPH) method, aimed at predicting process conditions under different parameters. The model is validated using experimental data from 11 combinations of tool traverse and rotation speeds on 316 L stainless steel. Correlations between process parameters, material flow, temperature, strain, strain rate, and recrystallized grain size are revealed through SPH simulations and electron backscatter diffraction (EBSD) imaging. The results show that in situ SZ temperatures range from 1071 to 1322°C, which exceed the tool temperature by over 300°C. Furthermore, SZ temperature, strain rate, and grain size increase monotonically with higher tool temperature and faster traverse speed. A relationship is then established between the model-predicted Zener-Hollomon parameter and the recrystallized grain size based on EBSD data, expressed as ln(d) = -0.364 ln(Z) + 14.673. Finally, this relationship exhibits satisfactory accuracy with errors of less than 26.9% in predicting grain sizes at various SZ locations, which offers valuable insights for optimizing FSP repair processes for 316 L stainless steel.

316L stainless steel↗