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At least 127 records · Page 7

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DOE OSTI2022

Dynamic Material Flow Analysis of Silicon Photovoltaic Modules to Support a Circular Economy Transition

Solar photovoltaics (PV) are the fastest growing renewable energy technologies for clean, cheap, and sustainable electricity generation. To prepare for rapid scale-up, the PV industry needs to project material requirements to build out all aspects of the supply chain appropriately and plan to handle large volumes of module waste. Impacts of deploying different material circularity strategies to reduce waste and conserve primary resources need to be quantified to inform sustainable material management. Here, we introduce the photovoltaic dynamic material flow analysis (PV DMFA) model based on PV electricity generation. The model quantifies material flows and stocks in the cradle-to-cradle life cycles of utility-scale c-Si PV systems in the United States through 2100. We present case studies for solar flat glass and aluminum frame materials under various scenarios to project the impacts of PV performance, reliability, and processing parameters, material circularity strategies, and module design shifts. In the absence of circularity measures, ~100 million MT of flat glass and ~12 million MT of aluminum would be needed for PV installations by 2100 to meet projected growth in domestic utility PV demand to nearly 1000 TWh in 2100. With optimistic but feasible improvements in efficiency, reliability, and circularity, material intensity and waste could be reduced by nearly 50%. Efficient module collection, minimally intrusive recycling, and careful scrap handling and cleaning could improve material circularity in the PV value chain. This model serves as a sustainability data support tool that may aid in the circular economy transition for PV systems.

circular economy↗

NASA NTRS2012

Discrete Adjoint-Based Design for Unsteady Turbulent Flows On Dynamic Overset Unstructured Grids

A discrete adjoint-based design methodology for unsteady turbulent flows on three-dimensional dynamic overset unstructured grids is formulated, implemented, and verified. The methodology supports both compressible and incompressible flows and is amenable to massively parallel computing environments. The approach provides a general framework for performing highly efficient and discretely consistent sensitivity analysis for problems involving arbitrary combinations of overset unstructured grids which may be static, undergoing rigid or deforming motions, or any combination thereof. General parent-child motions are also accommodated, and the accuracy of the implementation is established using an independent verification based on a complex-variable approach. The methodology is used to demonstrate aerodynamic optimizations of a wind turbine geometry, a biologically-inspired flapping wing, and a complex helicopter configuration subject to trimming constraints. The objective function for each problem is successfully reduced and all specified constraints are satisfied.

Nielsen, Eric J.↗

NASA NTRS1980

Minimum Energy Test Direction Design in the Control of Cryogenic Wind Tunnels

The advent of the cryogenic wind tunnel concept is attributable to the need for high Reynolds number flow in wind tunnels. The cryogenic wind tunnel concept consists of operating the test medium of a conventional tunnel at cryogenic temperatures down to 80 K. Nitrogen gas, cooled by injected liquid nitrogen, proves to be ideal for the cryogenic tunnel test medium because of its near perfect behavior in insentropic flow. Cryogenic operation of a wind tunnel results in reduced fan power consumption and no penalty in flow dynamic pressure. In a cryogenic tunnel, the flow parameters (Reynolds number, Mach number and flow dynamic pressure) can be independently controlled by separately controlling the tunnel flow variables: total temperature, test section mass flow, and the tunnel total pressure. The problem of closed-loop control of the tunnel total temperature, flow Mach number, and total pressure is addressed and reported.

Balakrishna, S.↗

NASA NTRS1992

Interferometry and computational studies of an oscillating airfoil compressible dynamic stall flow field

A unique comparison has been made between real time interferograms and full Navier-Stokes computations of the density field over an oscillating airfoil undergoing dynamic stall for compressible flow conditions. Good agreement was found until a dynamic stall vortex formed in the flow. Subsequent evolution of the flow field was found to be very different in the computations. The reasons for this difference have been explained in terms of the leading edge region flow physics and the refined flow modeling that needs to be used for the post-stall flow field.

Chandrasekhara, M. S.↗

NASA NTRS2004

Recent Enhancements to USM3D Unstructured Flow Solver for Unsteady Flows

The NASA USM3D unstructured flow solver is undergoing extensions to address dynamic flow problems in support of NASA and NAVAIR efforts to study the applicability of Computational Fluid Dynamics tools for the prediction of aircraft stability and control characteristics. The initial extensions reported herein include two second-order time stepping schemes, Detached-Eddy Simulation, and grid motion. This paper reports the initial code verification and validation assessment of the dynamic flow capabilities of USM3D. The cases considered are the classic inviscid shock-tube problem, low Reynolds number wake shedding from a NACA 0012 airfoil, high Reynolds number DES-based wake shedding from a 4-to-1 length-to-diameter cylinder, and forced pitch oscillation of a NACA 0012 airfoil with inviscid and turbulent flow.

Pandya, Mohagna J.↗

DOE OSTI2026

Polymer coatings on zirconia microspheres via rotating flow fluid dynamics

Conventional tristructural isotropic (TRISO) coatings for nuclear fuels require multi-step and expensive formation processes; any breakage of the coatings may lead to fission species release. Polymer derived ceramic (PDC) coatings can be a suitable alternative to address these issues. In this study, allylhydridopolycarbosilane (SMP-10) coatings were created on yttria stabilized zirconia (YSZ) microspheres using a Rotating Flow Fluid Dynamics (RFFD) coating method. The effects of curing temperature, rotation speed, and coating cycle/time on the coating were analyzed. Surface functionalization of YSZ microspheres with NaOH resulted in good adhesion between the polymer precursor and the YSZ kernel particles. Spectroscopy analysis revealed complete curing of SMP-10 coated YSZ at 160 °C. Rotation speed and coating time significantly affect the coating characteristics. After 3 cycles at lower rotation speed (50 rpm) for 10 min each, the coating obtained was uniform and homogeneous. In comparison, the coating showed almost 10 times less eccentricity at a high rotation speed of 300 rpm. Compared with the coatings prepared at 300 rpm condition, the coatings have higher sphericity and lower eccentricity at 50 rpm. Overall, this study provides a novel and effective route for fabricating and curing SMP-10 precursor coatings on YSZ microspheres.

Ravi, Nivetha [University of Alabama, Birmingham]↗

DOE OSTI2025

Operando synchrotron X-ray analysis of melt pool dynamics in an Al-Sn immiscible alloy

The melt flow in an Al-50vol.% Sn immiscible alloy, produced by single-track laser melting of Al and Sn elemental powders, was studied in real time. High-speed synchrotron X-ray imaging was used to track Al and Sn liquids’ movements, and also to examine elemental distributions in the laser tracks, complimented by electron microscopy after solidification. Key aspects, including melt pool geometry, keyhole instability, and flow dynamics (flow pattern and velocity), were examined using digital image analysis. Relatively deeper melt pools formed at 400 W and 300 mm/s exhibited greater stability, with smooth surfaces, consistent outward flow, and minor vortices near the keyhole. In contrast, shallower pools produced at higher scanning speeds (>500 mm/s) demonstrated greater instability with increased surface waviness, and stronger velocity fluctuations, leading to numerous micro-vortices and increased Al-Sn heterogeneity. Velocity scale estimations, supported by experimental observations, examined the roles of vapour pressure, Marangoni effect, buoyancy, inertial, and surface tension forces in the flow. The results revealed that vapour pressure and mechanical waves dominated at high scanning speeds (shallow pools), while Marangoni forces were equally significant in deep pools at lower speeds (300 mm/s). Buoyancy was found to have minimal impact in both cases. Furthermore, the interaction between inertial and surface tension forces played a critical role in determining the degree of waviness of the pools’ surfaces. These findings offer valuable insights into melt pool dynamics during laser processing of immiscible alloys and other metallic systems using elemental powders, and provide guidance for developing high-fidelity computational fluid dynamics models.

immiscible alloys↗

DOE OSTI2022

Riverbed Temperature and 4D ERT Monitoring Reveals Heterogenous Horizontal and Vertical Groundwater-Surface Water Exchange Flows Under Dynamic Stage Conditions

Groundwater surface water exchange plays a critical role in physical, biological, and geochemical function of coastal and riverine systems. Observing exchange flow behavior in heterogeneous systems is a primary challenge, particularly when flows are governed by dynamic river stage or tidal variations. In this paper we demonstrate a novel application of time-lapse 3D electrical resistivity tomography and temperature monitoring where an array of thermistors installed beneath a riverbed double as resistivity electrodes. We use the array to monitor stage driven exchange flows over a 6-day period in a dynamic, stage-driven high order stream. We present a method for addressing the otherwise confounding effects of the moving river-surface boundary on the raw resistivity data, thereby enabling successful tomographic imaging. Temperature time-series at each thermistor location and time-lapse 3D images of changes in bulk electrical conductivity together provide a detailed description of exchange dynamics over a 10-meter by 45-meter section of the riverbed, to a depth of approximately 5 m. Results reveal highly variable flux behavior throughout the monitoring domain including both horizontal and vertical exchange flows.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2021

Multi-fidelity kinetic theory-based approach for the prediction of particle attrition: Application to jet cup attrition system

The timescale difference between the “fast” flow dynamics of fluidized bed reactors and the relatively “slow” rate of particle degradation makes the direct computational prediction of attrition challenging. An approach to this challenge is a multi-fidelity strategy where a high fidelity model for the flow dynamics is coupled with a lower fidelity model for the long-time resolution of the bulk attrition of the reactor inventory. We implement this approach using high-fidelity kinetic theory simulations to calculate the flow dynamics which are post-processed to calculate the frequency and intensity of the particle-particle and particle-wall collisions (e.g. collision energy spectra). This is combined with the particle breakage properties to construct the coefficients for a low-fidelity model [e.g. Monazam et al., 2018, Powder Technology 340, p. 528-536]. Simulations are performed of a jet cup attrition system containing Canadian hematite (Monazam et al. 2018). Furthermore, these are first analyzed using the collision energy spectra. Quantitative predictions of the mass loss are made using a low-fidelity model derived from the collision-spectra and a calibrated material breakage coefficient. The results are found to compare favorably with the experimental measurements.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗

DOE OSTI2024

Geophysical and Environmental Monitoring Data, and Subsurface Flow Modelling Results for Chicken Bone Meadow, Mt. Snodgrass, Crested Butte, CO

This dataset includes geoelectrical monitoring data acquired between October 2021 and November 2022, soil moisture and temperature data, groundwater data obtained from borehole SNIB covering the period from June 2021 to September 2022, and hydrological modelling results. The data were acquired to investigate how variations in bedrock type and topography, and vegetation cover control subsurface flow dynamics. To provide insights into the subsurface flow dynamics and their controls, a monitoring transect was installed at the Chicken Bone Meadow, Mt. Snodgrass, Crested Butte, CO, measuring the spatio-temporal variations of soil moisture, soil and snow temperature, subsurface electrical resistivity variations, and groundwater dynamics. Field data are organized in a folder structure, with Electrical Resistivity Tomography (ERT) data being provided as one file per measurement, and data of the soil moisture and temperature sensors being provided as text files covering the entire monitoring period. The ‘Locations.csv’ file contains the location of all sensors, given in NAD83 – UTM Zone 13N. ERT monitoring data has been processed to filter data based on reciprocal errors (data with errors > 30% were removed), a linear error model was fitted to each survey, and to ensure a constant set of measurements for time-lapse inversion, filtered data were interpolated and assigned a 100% measurement error. Soil moisture and temperature data were acquired at 15 min intervals, and averaged to provide 1h data. Weather data and borehole data (groundwater depth, conductivity and temperature) were acquired at 30 min intervals, and are provided as daily measurements; all measurements are averaged, except of precipitation values, which are given as daily accumulation. The hydrological model was set up along the ERT monitoring transect, and net infiltration was used as surface boundary condition and derived from the weather data. Four different results are provided, (1) results for a parameterization using hydraulic permeability and porosity as derived from the ERT data through petrophysical relationships, and (2) three simplified model results, using 1 to 3 geological layers above the bedrock. Modelling was performed using PFLOTRAN, and for each model the PFLOTRAN input files are provided. The result files include weekly hydrological modelling results (e.g., saturation, velocities, pressures), as well as the model parameterization. The dataset additionally includes a file-level metadata (flmd.csv) file that lists each file contained in the dataset with associated metadata; and a data dictionary (dd.csv) file that contains column/row headers used throughout the files along with a definition, units, and data type.

54 ENVIRONMENTAL SCIENCES↗

NASA NTRS1991

Reattachment studies of an oscillating airfoil dynamic stall flow field

The reattaching flow over an oscillating airfoil executing large amplitude sinusoidal motion around a mean angle of attack of 10 degrees has been studied using the techniques of stroboscopic schlieren, two component laser Doppler velocimetry and point diffraction interferometry, for a free stream Mach number of 0.3 and a reduced frequency of 0.05. The results show that the dynamically stalled flow reattaches in a process that begins when the airfoil is very close to the static stall angle on its downward stroke and progresses over the airfoil through a large range of angles of attack as the airfoil decreases to about 6 degrees. The airfoil suction peak shows a dramatic rise as the static stall angle is approached and the velocity profiles develop such that the flow near the surface is accelerated. The process completes through the disappearance of a separation bubble that forms over the airfoil.

Ahmed, S.↗

NASA NTRS1990

An experimental study of the nonlinear dynamic phenomenon known as wing rock

An experimental investigation into the physical phenomena associated with limit cycle wing rock on slender delta wings has been conducted. The model used was a slender flat plate delta wing with 80-deg leading edge sweep. The investigation concentrated on three main areas: motion characteristics obtained from time history plots, static and dynamic flow visualization of vortex position, and static and dynamic flow visualization of vortex breakdown. The flow visualization studies are correlated with model motion to determine the relationship between vortex position and vortex breakdown with the dynamic rolling moments. Dynamic roll moment coefficient curves reveal rate-dependent hysteresis, which drives the motion. Vortex position correlated with time and model motion show a time lag in the normal position of the upward moving wing vortex. This time lag may be the mechanism responsible for the hysteresis. Vortex breakdown is shown to have a damping effect on the motion.

Arena, A. S., Jr.↗

DOE OSTI2023

Review of rotating wing dynamic stall: Experiments and flow control

Dynamic stall has been a technical challenge and a fluid dynamical subject of interest for more than fifty years; but in the last decade significant advances have been made in the understanding, prediction, modeling, and control of dynamic stall on rotors. This paper provides a summary of the state of the art of dynamic stall experiments and future directions in the understanding of dynamic stall on rotors. Experimental data sets are discussed, as well the direction of future research for control of dynamic stall. Coordinated testing between airfoils and rotating blades, as well as close integration between computational and experimental studies were found to be productive approaches. Advanced analysis methods, including statistical methods, modal representations, and artificial intelligence methods have led to significant advances in the understanding of dynamic stall. Investigations of dynamic stall control devices have allowed many useful targeted investigations of the transition to separated flow, but have not yet resulted in a commercially implemented device.

42 ENGINEERING↗

DOE OSTI2025

Dynamic Heat Flow and Current Distribution Analysis in the Bottom Anode of an Electric Arc Furnace Using Fiber-Optic Sensors

A reliable method for monitoring bottom anode wear during DC Electric Arc Furnace (DC-EAF) operation is of critical importance for safe and efficient steel production. Underestimation of bottom wear poses a serious safety risk that must be avoided, while overestimation of bottom wear also poses challenges, as premature anode replacement is expensive and affects EAF productivity. Previously, we demonstrated that fiber-optic sensors can be successfully deployed to create a spatially distributed temperature map to monitor the health of the anode. The present work explores the heat flow and current density distribution in bottom anode pins to predict bottom wear, steel penetration events, and monitor refractory erosion. Small dynamic variations in pin temperature induced by joule heating during arcing also provide a means to observe local current flows in each pin. When mapped, these measurements provide a real-time view of the non-uniform and dynamic current flow in the bottom anode during EAF operation that can affect bottom wear.

Bottom Anode↗

DOE OSTI2021

Pore-Scale Dynamics of Liquid CO2–Water Displacement in 2D Axisymmetric Porous Micromodels Under Strong Drainage and Weak Imbibition Conditions: High-Speed μPIV Measurements

Resolving pore-scale transient flow dynamics is crucial to understanding the physics underlying multiphase flow in porous media and informing large-scale predictive models. Surface properties of the porous matrix play an important role in controlling such physics, yet interfacial mechanisms remain poorly understood, in part due to a lack of direct observations. This study reports on an experimental investigation of the pore-scale flow dynamics of liquid CO 2 and water in two-dimensional (2D) circular porous micromodels with different surface characteristics employing high-speed microscopic particle image velocimetry (μPIV). The design of the micromodel minimized side boundary effects due to the limited size of the domain. The high-speed μPIV technique resolved the spatial and temporal dynamics of multiphase flow of CO 2 and water under reservoir-relevant conditions, for both drainage and imbibition scenarios. When CO 2 displaced water in a hydrophilic micromodel (i.e., drainage), unstable capillary fingering occurred and the pore flow was dominated by successive pore-scale burst events (i.e., Haines jumps). When the same experiment was repeated in a nearly neutral wetting micromodel (i.e., weak imbibition), flow instability and fluctuations were virtually eliminated, leading to a more compact displacement pattern. Energy balance analysis indicates that the conversion efficiency between surface energy and external work is less than 30%, and that kinetic energy is a disproportionately smaller contributor to the energy budget. This is true even during a Haines jump event, which induces velocities typically two orders of magnitude higher than the bulk velocity. These novel measurements further enabled direct observations of the meniscus displacement, revealing a significant alteration of the pore filling mechanisms during drainage and imbibition. While the former typically featured burst events, which often occur only at one of the several throats connecting a pore, the latter is typically dominated by a cooperative filling mechanism involving simultaneous invasion of a pore from multiple throats. This cooperative filling mechanism leads to merging of two interfaces and releases surface energy, causing instantaneous high-speed events that are similar, yet fundamentally different from, burst events. Finally, pore-scale velocity fields were statistically analyzed to provide a quantitative measure of the role of capillary effects in these pore flows.

Li, Yaofa↗

DOE OSTI2025

Insight into pseudo-film-boiling in supercritical water under simplified interfacial conditions

The focus of this paper is the physics of supercritical water film boiling through the simulation of natural convection of supercritical water in a rectangular cavity. It has been widely believed that above a fluid's critical point, only one phase exists. However, recent research has indicated the existence of distinct gas-like and liquid-like regions separated by the Widom line, which is the locus of the maxima of the specific heat. Along the Widom line, density decreases sixfold, viscosity drops by a factor of two, while specific heat spikes by an order of magnitude. These variations, specifically in density and viscosity, produce a thick pseudo-interface and flow dynamics behavior akin to film-boiling, denoted here as pseudo-two-phase flow dynamics. When the cavity is heated from the bottom, a pseudo-film of gas-like fluid is formed at the heated wall, and the flow complexity evolves, characterized by the formation of multiple vortices. Results demonstrate the ability of modern conjugate heat transfer computational fluid dynamics to capture the pseudo two-phase regime, with the formation of a pseudo-film at the heated wall. Further, the boiling curve is studied, showing an increase in heat flux with an increase in the temperature differential between the wall and the pseudo-critical temperature. Furthermore, results also show a previously uncharacterized instability, where the convection cells in the cavity oscillate and can flip directions under certain conditions.

Computational fluid dynamics↗

NASA NTRS2016

Dynamic Gas Flow Effects on the ESD of Aerospace Vehicle Surfaces

The purpose of this work is to develop a dynamic version of Paschen's Law that takes into account the flow of ambient gas past aerospace vehicle surfaces. However, the classic Paschen's Law does not take into account the flow of gas of an aerospace vehicle, whose surfaces may be triboelectrically charged by dust or ice crystal impingement, traversing the atmosphere. The basic hypothesis of this work is that the number of electron-ion pairs created per unit distance by the electric field between the electrodes is mitigated by the electron-ion pairs removed per unit distance by the flow of gas. The revised Paschen equation must be a function of the mean velocity, v(sub xm), of the ambient gas and reduces to the classical version of Paschen's law when the gas mean velocity, v(sub xm) = 0. New formulations of Paschen's Law, taking into account Mach number and dynamic pressure, derived by the authors, will be discussed. These equations will be evaluated by wind tunnel experimentation later this year. Based on the results of this work, it is hoped that the safety of aerospace vehicles will be enhanced with a redefinition of electrostatic launch commit criteria. It is also possible that new products, such as new anti-static coatings, may be formulated from this data.

Paschens Law↗

NASA NTRS2016

Dynamic Gas Flow Effects on the ESD of Aerospace Vehicle Surfaces

Electrostatic Discharge↗