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NASA NTRS2004

Image-Based Computational Fluid Dynamics in Blood Vessel Models: Toward Developing a Prognostic Tool to Assess Cardiovascular Function Changes in Prolonged Space Flights

One of NASA's objectives is to be able to perform a complete, pre-flight, evaluation of cardiovascular changes in astronauts scheduled for prolonged space missions. Computational fluid dynamics (CFD) has shown promise as a method for estimating cardiovascular function during reduced gravity conditions. For this purpose, MRI can provide geometrical information, to reconstruct vessel geometries, and measure all spatial velocity components, providing location specific boundary conditions. The objective of this study was to investigate the reliability of MRI-based model reconstruction and measured boundary conditions for CFD simulations. An aortic arch model and a carotid bifurcation model were scanned in a 1.5T Siemens MRI scanner. Axial MRI acquisitions provided images for geometry reconstruction (slice thickness 3 and 5 mm; pixel size 1x1 and 0.5x0.5 square millimeters). Velocity acquisitions provided measured inlet boundary conditions and localized three-directional steady-flow velocity data (0.7-3.0 L/min). The vessel walls were isolated using NIH provided software (ImageJ) and lofted to form the geometric surface. Constructed and idealized geometries were imported into a commercial CFD code for meshing and simulation. Contour and vector plots of the velocity showed identical features between the MRI velocity data, the MRI-based CFD data, and the idealized-geometry CFD data, with less than 10% differences in the local velocity values. CFD results on models reconstructed from different MRI resolution settings showed insignificant differences (less than 5%). This study illustrated, quantitatively, that reliable CFD simulations can be performed with MRI reconstructed models and gives evidence that a future, subject-specific, computational evaluation of the cardiovascular system alteration during space travel is feasible.

Chatzimavroudis, George P.↗

DOE OSTI2025

Porous Flow Modeling of Axial Gas Redistribution in Fragmented LWR Fuel Rods using MOOSE

Understanding how gas axially redistributes within fragmented fuel pellets is crucial for predicting the behavior of Light Water Reactor (LWR) fuel rods, particularly during transient and accidental scenarios. The time scale of this phenomenon plays a fundamental role in determining the progression and hazard of a Loss Of Coolant Accident (LOCA), especially when high burn-up fuel in a severe state of fragmentation is involved. Here, this study presents a Computational Fluid Dynamics (CFD) model developed within the Multiphysics Object-Oriented Simulation Environment (MOOSE) to predict the time-scale of plenum depressurization in Light-Water Reactor (LWR) fuel rods driven by axial gas transport through fragmented pellets. The model examines the effects of incorporating non-linearities in the friction term by comparing the results with experimental data. The experiment employed surrogate fuel rods containing pellets subjected to mechanical and/or thermal loadings to simulate various severity of cracking, and aimed at studying the influence of fuel conditions on axial gas redistribution. The results of this analysis indicate that under certain flow regime conditions - determined by the value of an equivalent Reynolds number - accounting for the non-linear friction term in Navier-Stokes equations guarantees better predictions for the time-scale of plenum depressurization. Also, the model enabled the simulation of the pressure decay by assigning distinct permeability values to each pellet instead of a single uniform value. Multiple simulations were run across all possible pellet position combinations, having each pellet assigned with values of permeability extracted from the experimental data. This allows to quantify the impact of the considering various non-uniform distributions of permeability on the dynamics of axial gas redistribution. The present work findings enhance the understanding of axial gas transport, and provide valuable insights for the integration of a model for predicting the axial gas redistribution during a LOCA scenario into the BISON fuel performance code.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

NASA NTRS2022

Design of Hypervelocity Flow Generator (HFG) and Its Diagnostics

Ground facilities for hypersonic research are a key element for successful development of aerodynamically proven hypervelocity vehicles. Design concepts and diagnostics of a hypervelocity flow generator (HFG) were made as a test platform for hypersonic/hypervelocity spacecraft models at the NASA Langley Research Center. The HFG is a hypersonic flow field generator using optically heated gas which is blown into an 80 cu m vacuum chamber. The vacuum chamber is kept at a stable vacuum pressure with a combination of three large vacuum pumps, while the HFG is in the test mode. The HFG provides a relatively small test section with approximately a 20 cm window. This facility was designed to generate 2.45 km/sec of flow speed, and potentially generate a continuous flow with the nozzle and vacuum system. The window in test section provides a direct view of the shock wave around a model in order to measure temperature, pressure, and density profile within the shock layer. One of the key test goals under this project is to understand why the emission spectra from the standing shockwave plasma predicted by Lora-Loran codes are significantly different from the measured emission spectra from the Flight Investigation Reentry Environment (FIRE II) Flight. The correct estimate of the thermal loading on the leading edge of hypersonic vehicles greatly affects the aerodynamic design, the material selection for the vehicle, and the cooling requirement and can be obtained by the precise modeling of emission spectra from shockwave plasma. However, the estimation of thermal loading is not an easy task due to complex non-equilibrium radiative process within high temperature shock layers that still falls into a category of cold plasma. Direct flight experiments are the most desirable, but not a cost-effective approach. Analysis by computational fluid dynamics (CFD) offers many test flexibilities. However, the CFD codes must be fully tested and validated with experimental data before the codes are effectively used for practical design. Large discrepancies between experiments and codes appear in hypersonic/hypervelocity flow regimes at high altitudes of 60 km ~ 90 km. This HFG facility offers some important parameters for CFD code validation, such as collision cross-sections, relaxation times, reaction rate coefficients and transportation coefficients. The HFG test facility is based on the ejection flow of high temperature gas heated over to 3500 K through a nozzle. The tungsten gas chamber of the HFG is heated up to a desired temperature by a 60 kW optical power beam source. This system consists of an optical power source, a thermal chamber, an expansion nozzle, a test section, and an 80 cu m vacuum tank. 60 kW optical input power is obtained from the 150 kW Vortek arc lamp system (by Vortek Industries, Vancouver, Canada). This optical beam is focused to heat the gas chamber within which a flow media is heated. The maximum achievable temperature of the flow medium reached approximately 3500 K or even higher but is limited by the melting point of the chamber material used. The exhaust velocity through the nozzle was determined by the stagnation temperature and the molecular weight of the working medium at the test section. To provide design parameters, a NASA Chemical Equilibrium with Application (CEA) computer program is used for the simulation of aerothermal data. This CEA program can calculate chemical equilibrium and properties of complex mixtures using shock tube parameters. For nitrogen gas at 2666 K stagnation temperature, the maximum achievable velocity at the test section is approximately 2.45 km/sec which is within the range of the thermal velocity of 8000 K shock layer. Based on the calculation through the CEA program, the design parameters of a HFG were determined and implemented for the test section that includes an expansion nozzle. The installed test section of the experimental facility can sustain a condition of a re-entry vehicle from the Space at an altitude of 60-90 km. After installation of the HFG, the system was fully tested and its operational parameters were measured. An 80 cu m vacuum chamber of HFG was set at 1 torr level to keep a stable downstream condition. The pumping time to reach the minimum vacuum pressure (~ 1 torr) at the test chamber from atmospheric pressure was approximately an hour using Kinney (MBV-14000/MB -1600/KT-300) and Stokes (Model 1772 and 412) pumps. Such a setup condition allowed a continued stable operation of the HFG experiment with flowrates through 1-, 3-, or 5-mm diameters of nozzle throat. The flow characteristics of the HFG for various operating conditions were performed using a focused Schlieren method. At 0.8 torr chamber pressure, a barrel shock was observed at the test section. With a sphere obstacle of 12 mm diameter in the flow, a bow shock (~ 2-mm thickness) was observed by a focused Schlieren visualization method.

Hypervelocity flow↗

NASA NTRS2021

Anti-Phase Vortex Reduction Control for Rotor Noise Suppression

An investigation is conducted in 2019 under the NASA Ames Center Innovation Funds (CIF) project entitled “Anti-Phase Vortex Reduction Control for Rotor Noise Suppression“ to experimentally validate an anti-phase rotor noise suppression concept. The first objective of the investigation is to conduct computational fluid dynamics (CFD) simulations to investigate the noise characteristics of several anti-phase rotor designs. The second objective is to conduct a series of acoustic tests of anti-phase rotors in an anechoic chamber at Pennsylvania State University (PSU) to evaluate the merit of the anti-phase rotor concept. The CFD investigation seeks to optimize the anti-phase alternating trailing edge patterns for rotor noise suppression. The design objective is to maximize the noise reduction while maintaining the aerodynamic thrust. The investigation is performed using a three-dimensional (3D) Unsteady Reynolds-Averaged Navier-Stokes (URANS) commercial solver STAR-CCM+ together with the Ffowcs-Williams and Hawkings (FW-H) formula to obtain the aerodynamic thrust and far-field noise level. An acoustic study is conducted for 13 anti-phase design candidates based on a proprietary rotor design. The CAD geometry of the rotor is furnished by PSU. These design candidates include different alternating trailing edge (TE) waveforms, TE segment lengths, TE deflection amplitudes, and transition characteristics. The best design candidate among those explored is an anti-phase rotor that has a four-period TE waveform which results in a reduction in far-field noise level of 2.1 dB in the hover condition and a reduction of 1.1 dB in the forward flight condition at 9.7 m/s. A further acoustic study is conducted for a different rotor manufactured by APC. Five APC rotor design candidates are simulated. The best anti-phase design candidate for the APC rotor results in a reduction in far-field noise level of 4.0 dB in the hover condition. An in-phase design candidate is also studied. This in-phase design provides a noise reduction of 2.5 dB. A series of acoustic experiments in the PSU anechoic chamber have been conducted in July 2019 and October 2019. Both anti-phase and in-phase rotors fabricated for the left-hand and right-hand rotations are tested. In the hover condition, all the rotors do not provide sufficient evidence of improved acoustic performance. However, the experimental data in the hover condition are deemed to be inconclusive due to the flow recirculation in the anechoic chamber caused by the rotor downwash. In the forward flight condition at 9.7 m/s, the anti-phase right-hand rotor produces a noise reduction by as much as 6.5 dB in the frequency range of 2000-4000 Hz, while the in-phase right-hand rotor produces a noise reduction by as much as 5 dB in the same frequency range. Both the anti-phase and in-phase left hand rotors offer no evidence of noise reduction. The difference in the acoustic performance of the left-hand and right-hand rotors could be explained by the location of the microphone array which is placed to the left side of the rotors. This microphone array location could create a bias in the sound pressure level in favor of the right-hand rotor. Using the average noise reduction values, the anti-phase 4H rotor could offer a noise reduction by as much as 3.25 dB while the in-phase 4I rotor could produce up to a 2.5 dB noise reduction. Both the computational and experimental results have provided sufficient evidence to support the noise suppression capability of the proposed anti-phase rotor concepts.

Rotor noise↗

NASA NTRSDate not supplied

Automated Unstructured Grid Adaptation on a Strut Fuel Injector at Hypervelocity Flow Conditions

Computational fluid dynamics (CFD) analysis is presented with the use of an automated unstructured grid adaptation tool on a strut fuel injector at hypervelocity flow conditions. The analysis was carried out with the VULCAN-CFD solver using Reynolds-averaged simulations (RAS). The hypervelocity flow conditions match the high Mach number flow of the experiments conducted as part of the Enhanced Injection and Mixing Project (EIMP) at the NASA Langley Research Center (LaRC). The current work uses an automated grid adaptation tool recently implemented in VULCAN-CFD, and explores this tool’s ability to solve highspeed mixing problems. Simulation results obtained using the unstructured adaptive grid approach are compared to those on a user-generated structured grid. These results are evaluated by analyzing how efficiently comparable fidelity results are obtained from both adapted and structured simulations. In addition, two adaptation strategies were used to explore the impact on the final solution. In the current work, the unstructured grid adaptation tool automatically generates unstructured grids and performs adaptation of the grid based on a Hessian error estimate of a specified flowfield parameter. Multiple adaptations were executed using each run strategy with the one-dimensional values of the mixing efficiency used to determine grid convergence and for comparison with the structured grid simulation results. It was found that the unstructured adaptive grid simulations were able to produce results that matched closely with those on structured grids using far fewer grid cells, and thus, requiring far less computational time to reach the solution. It was also discovered that the adaptation run strategy influenced the total number of grid cells and the efficiency with which a final grid-adapted solution was reached. Furthermore, motivated by the grid convergence index (GCI) used for structured grid simulations, a grid convergence estimate (GCE) was developed and demonstrated for the grid adaptation. Overall, the investigation demonstrated that the automated unstructured grid adaptation tool implemented in VULCAN-CFD is capable of accurately and efficiently solving complex high-speed mixing problems with only a fraction of the grid cells required to obtain comparable results on a user-generated structured grid.

hypersonics↗

NASA NTRSDate not supplied

Automated Unstructured Grid Adaptation on a Strut Fuel Injector at Hypervelocity Flow Conditions

hypersonics↗

NASA NTRSDate not supplied

Automated Unstructured Grid Adaptation on a Strut Fuel Injector at Hypervelocity Flow Conditions

Computational fluid dynamics (CFD) analysis is presented with the use of an automated unstructured grid adaptation tool on a strut fuel injector at hypervelocity flow conditions. The analysis was carried out with the VULCAN-CFD solver using Reynolds-averaged simulations (RAS). The hypervelocity flow conditions match the high Mach number flow of the experiments conducted as part of the Enhanced Injection and Mixing Project (EIMP) at the NASA Langley Research Center (LaRC). The current work utilizes an automated grid adaptation tool recently implemented into VULCAN-CFD, and explores this tool’s ability to solve high-speed mixing problems. Simulation results obtained using the unstructured adaptive grid approach are compared to those on a user generated structured grid. These results are evaluated by analyzing how efficiently comparable fidelity results are obtained from both adapted and structured simulations. In addition, two adaptation strategies were used to explore the impact on the final solution. In the current work, the unstructured grid adaptation tool automatically generates unstructured grids and performs adaptation of the grid based on a Hessian error estimate of a specified flow field parameter. Multiple adaptations were executed using each run strategy with the one-dimensional values of the mixing efficiency used to determine grid convergence and for comparison with the structured grid simulation results. It was found that the unstructured adaptive grid simulations were able to produce results that matched closely with those on structured grids using far fewer grid cells, and thus, requiring far less computational time to reach the solution. It was also discovered that the adaptation run strategy influenced the total number of grid cells and the efficiency with which a final grid-adapted solution was reached. Overall, the investigation demonstrated that the automated unstructured grid adaptation tool implemented in VULCAN-CFD is capable of accurately and efficiently solving complex highspeed mixing problems using only a fraction of the grid cells required to obtain comparable results using a user-generated structured grid.

grid adaptation↗

NASA NTRS2000

Measurement Requirements for Improved Modeling of Arcjet Facility Flows

Current efforts to develop new reusable launch vehicles and to pursue low-cost robotic planetary missions have led to a renewed interest in understanding arc-jet flows. Part of this renewed interest is concerned with improving the understanding of arc-jet test results and the potential use of available computational-fluid- dynamic (CFD) codes to aid in this effort. These CFD codes have been extensively developed and tested for application to nonequilibrium, hypersonic flow modeling. It is envisioned, perhaps naively, that the application of these CFD codes to the simulation of arc-jet flows would serve two purposes: first. the codes would help to characterize the nonequilibrium nature of the arc-jet flows; and second. arc-jet experiments could potentially be used to validate the flow models. These two objectives are, to some extent, mutually exclusive. However, the purpose of the present discussion is to address what role CFD codes can play in the current arc-jet flow characterization effort, and whether or not the simulation of arc-jet facility tests can be used to eva1uate some of the modeling that is used to formu1ate these codes. This presentation is organized into several sections. In the introductory section, the development of large-scale, constricted-arc test facilities within NASA is reviewed, and the current state of flow diagnostics using conventional instrumentation is summarized. The motivation for using CFD to simulate arc-jet flows is addressed in the next section, and the basic requirements for CFD models that would be used for these simulations are briefly discussed. This section is followed by a more detailed description of experimental measurements that are needed to initiate credible simulations and to evaluate their fidelity in the different flow regions of an arc-jet facility. Observations from a recent combined computational and experiment.al investigation of shock-layer flows in a large-scale arc-jet facility are then used to illustrate the current state of development of diagnostic instrumentation, CFD simulations, and general knowledge in the field of arc-jet characterization. Finally, the main points are summarized and recommendations for future efforts are given.

Fletcher, Douglas G.↗

NASA NTRS2016

Computational Study of Flow Interactions in Coaxial Rotors

Although the first idea of coaxial rotors appeared more than 150 years ago, most helicopters have used single main-rotor/tail-rotor combination. Since reactive moments of coaxial rotors are canceled by contra-rotation, no tail rotor is required to counter the torque generated by the main rotor. Unlike the single main rotor design that distributes power to both main and tail rotors, all of the power for coaxial rotors is used for vertical thrust. Thus, no power is wasted for anti-torque or directional control. The saved power helps coaxial rotors reach a higher hover ceiling than single rotor helicopters. Another advantage of coaxial rotors is that the overall rotor diameter can be reduced for a given vehicle gross weight because each rotor provides a maximum contribution to vertical thrust to overcome vehicle weight. However, increased mechanical complexity of the hub has been one of the challenges for manufacturing coaxial rotorcraft. Only the Kamov Design Bureau of Russia had been notably successful in production of coaxial helicopters until Sikorsky built X2, an experimental compound helicopter. Recent developments in unmanned aircraft systems and high-speed rotorcraft have renewed interest in the coaxial configuration. Multi-rotors are frequently used for small electric unmanned rotorcraft partly due to mechanical simplicity. The use of multiple motors provides redundancy as well as cost-efficiency. The multi-rotor concept has rarely been used until recently because of its inherent stability and control problems. However, advances in inexpensive electronic flight control systems have opened the floodgates for small drones using multirotors. Coaxial rotors have started to appear in some multi-rotor configurations. Small coaxial rotors have often been designed using a hundred year old approach that is "sketch, build, fly, and iterate." In that approach, there is no systematic way to explore trade-offs or determine logical next steps. It is neither possible to account for multiple real-world constraints up front in design nor possible to know what performance is possible with a given design. Since unmanned vehicles are sized and optimized for the particular mission, a modern low-fidelity conceptual design and sizing tool that has been used for the design of large helicopters can be used for design of small coaxial rotorcraft. However, unlike most helicopters with single main rotor, the interactions between the upper and lower rotors emerge as an important factor to consider in design because an increase in performance of a multi-rotor system is not proportional to the number of rotors. Interference losses and differences in thrusts between the upper and lower rotors were investigated by theoretical methods as well as a computational fluid dynamics (CFD) method using the Reynolds-Averaged Navier-Stokes (RANS) equations. In this work, hybrid turbulence models are used to investigate the physics of interactions between coaxial rotors and a fuselage that are not well understood. Present study covers not only small-scale drones but also large-scale coaxial rotors for heavy-lifting missions. Considering the recently proposed FAA drone rules that require the flight only in visual line-of-sight, a large multirotor might be used as an airborne carrier for launch and recovery of unmanned aircraft systems with a human operator onboard. For applications to civil operations, their aerodynamic performance and noise levels need to be assessed. Noise is one of the largest limiting factors to rotorcraft operations in urban area. Since the high-frequency noise of multi-rotors may increase the annoyance, noise may turn out to be a key issue that must be addressed for market acceptability. One of the objectives of the present work is to study the effects of inter-rotor spacing and collectives on the performance, efficiency, and acoustics of coaxial rotor systems.

Study↗

DOE OSTI2022

Computational Methods to Characterize Panel Loading Conditions for Accelerated Testing

Panel cracking and degradation due to wind loading are known to have a detrimental effect on power output. Recreating these damaging conditions in a controlled experimental setting requires an understanding of the loads being generated at the panel surface as a function of both wind speed, wind direction, and panel orientation. To better understand these relationships, a computational fluid dynamics (CFD) simulation package was constructed using an open-source Python library for solving partial differential equations with the finite element method. This CFD package allows the simulated wind speed and panel orientation of a multi-panel array to be easily changed and provides the capability to measure the traction forces at discrete points along the sun-facing and ground-facing surface of an interior panel residing in the wake of one or more upstream panels. A parameter exploration was performed in which the panel angle was varied in even increments from -70 deg to 70 deg and the wind speed was varied from 2 to 30 m/s. During post processing, the measured traction along the panel surface was averaged spatially and interpreted as a time-varying signal, where further processing of this signal yielded the root mean square amplitude and a characteristic frequency associated with the loading. This study found that higher wind speeds are generally associated with increased amplitude of loading and that the panel orientation angle can significantly exacerbate or mitigate this loading. These outcomes are presented along with current work on higher-fidelity verification simulations and recommendations for performing accelerated experimental testing.

loading↗

NASA NTRS2004

Automated Extraction of Flow Features

Computational Fluid Dynamics (CFD) simulations are routinely performed as part of the design process of most fluid handling devices. In order to efficiently and effectively use the results of a CFD simulation, visualization tools are often used. These tools are used in all stages of the CFD simulation including pre-processing, interim-processing, and post-processing, to interpret the results. Each of these stages requires visualization tools that allow one to examine the geometry of the device, as well as the partial or final results of the simulation. An engineer will typically generate a series of contour and vector plots to better understand the physics of how the fluid is interacting with the physical device. Of particular interest are detecting features such as shocks, recirculation zones, and vortices (which will highlight areas of stress and loss). As the demand for CFD analyses continues to increase the need for automated feature extraction capabilities has become vital. In the past, feature extraction and identification were interesting concepts, but not required in understanding the physics of a steady flow field. This is because the results of the more traditional tools like; iso-surface, cuts and streamlines, were more interactive and easily abstracted so they could be represented to the investigator. These tools worked and properly conveyed the collected information at the expense of a great deal of interaction. For unsteady flow-fields, the investigator does not have the luxury of spending time scanning only one "snapshot" of the simulation. Automated assistance is required in pointing out areas of potential interest contained within the flow. This must not require a heavy compute burden (the visualization should not significantly slow down the solution procedure for (co-processing environments). Methods must be developed to abstract the feature of interest and display it in a manner that physically makes sense.

Dorney, Suzanne↗

NASA NTRS2005

Automated Extraction of Flow Features

Computational Fluid Dynamics (CFD) simulations are routinely performed as part of the design process of most fluid handling devices. In order to efficiently and effectively use the results of a CFD simulation, visualization tools are often used. These tools are used in all stages of the CFD simulation including pre-processing, interim-processing, and post-processing, to interpret the results. Each of these stages requires visualization tools that allow one to examine the geometry of the device, as well as the partial or final results of the simulation. An engineer will typically generate a series of contour and vector plots to better understand the physics of how the fluid is interacting with the physical device. Of particular interest are detecting features such as shocks, re-circulation zones, and vortices (which will highlight areas of stress and loss). As the demand for CFD analyses continues to increase the need for automated feature extraction capabilities has become vital. In the past, feature extraction and identification were interesting concepts, but not required in understanding the physics of a steady flow field. This is because the results of the more traditional tools like; isc-surface, cuts and streamlines, were more interactive and easily abstracted so they could be represented to the investigator. These tools worked and properly conveyed the collected information at the expense of a great deal of interaction. For unsteady flow-fields, the investigator does not have the luxury of spending time scanning only one "snapshot" of the simulation. Automated assistance is required in pointing out areas of potential interest contained within the flow. This must not require a heavy compute burden (the visualization should not significantly slow down the solution procedure for co-processing environments). Methods must be developed to abstract the feature of interest and display it in a manner that physically makes sense.

Dorney, Suzanne↗

NASA NTRS2019

Full Facility Shock Frame Simulations of the Electric Arc Shock Tube

Radiative heating computations are performed for high speed lunar return experiments conducted in the Electric Arc Shock Tube (EAST) facility at NASA Ames Research Center. The nonequilibrium radiative transport equations are solved via NASA's in-house radiation code NEQAIR using flow field input from US3D flow solver. The post-shock flow properties for the 10 km/s Earth entry conditions are computed using the stagnation line of a blunt-body and a full facility CFD (Computational Fluid Dynamics) simulation of the EAST shock tube. The shocked gas in the blunt-body flow achieves a thermochemical equilibrium away from the shock front whereas EAST flow exhibits a nonequilibrium behavior due to strong viscous dissipation of the shock by boundary layer. The full-tube flow calculations capture the influence of the boundary layer on the shocked gas state and provide a realistic fluid dynamic input for the radiative predictions. The integrated radiance behind the shock is calculated in NEQAIR for wavelength regimes from Vacuum-UltraViolet (VUV) to InfraRed (IR), which are pertinent to the emission characteristics of high enthalpy shock waves in air. These radiance profiles are validated against corresponding EAST shots. The full-tube simulations successfully predict a sharp radiance peak at the shock front which gets smeared in the test data due to the spatial resolution in the measurements. The full facility based radiance behind the shock shows a slightly better match with the test data in the VUV and Red spectral regions, as compared to that from a blunt-body based predictions. The UV radiance is very similar for both geometries and under-predicts the test behavior. The IR test data matches better with the blunt-body based predictions where the full-tube simulations show a significant over-prediction.

Radiation↗

DOE OSTI2024

High-Fidelity and High-Performance Computational Simulations for Rapid Design Optimization of Sulfur Thermal Energy Storage

Industrial process heating (IPH) accounts for approximately 70% of US manufacturing energy use and is primarily produced by fossil fuel combustion. Approximately 1500 TWht (approximately 60%) of IPH demand is in the temperature range of 100-300. Industrial applications in this temperature range include drying, hydrothermal processing, thermal enhanced oil recovery, food and beverage, bioethanol production, etc. Cost-effective thermal energy storage (TES) that increases the utilization of waste and renewable heat (solar, geothermal, etc.) could provide significant energy savings and reliable heat sources, decrease emissions, and increase US manufacturing competitiveness through reductions in fuel consumption. TES development has historically been dominated by technologies suitable for deployment with concentrating solar power (CSP). State-of-the-art thermal storage deployed commercially with power tower CSP plants uses a 60%/40% NaNO3/KNO3 molten salt and operates between temperatures of approximately 280 degrees Celsius and 570 degrees Celsius using a two-tank configuration. However, these nitrate salts are unsuitable for operation outside of this temperature range due to a high freezing point of approximately 220 degrees Celsius, and limits on high-temperature salt stability and corrosion resistance of containment alloys. Other materials being investigated for TES include those based on: (1) sensible energy storage (various molten salt compositions, inert solid particles, rocks or pebble beds, sulfur, water, concrete, graphite, etc.), (2) latent energy storage in materials that undergo solid-liquid phase change at relevant temperatures (organic materials for low-temperature applications, inorganic salts and/or metals for high-temperature applications), or (3) thermochemical energy storage (hydrides, hydroxides, carbonates, metal oxides, etc.). The application temperature and challenges pertaining to storage material and/or containment cost, energy density, long-term thermal and cyclic stability, and charge/discharge heat transfer effectiveness drive material selection for a given IPH or electricity generation application. Sulfur is a cheap commodity at $80/ton compared to $1100 - 1300/ton for conventional salts. When using a metric of storage cost per kWh, sulfur costs around 2-3 $/kWh. Previous sulfur TES development focused on high temperature (>600 degrees) concentrated solar power applications with sulfur encapsulated in pipes and flow of gaseous HTF (air) in the shell side. However, for lower-temperature IPH applications in the range of approximately 100-300 degrees Celsius Element 16 adopted a compact and scalable TES design with molten sulfur in the shell and HTF pipes submerged in the molten sulfur bath. The low-cost molten sulfur TES for dispatchable IPH has deployment potential for broad applications. The spatial and temporal evolution of the HTF and sulfur temperature is critical to the TES system performance, and thus detailed modeling can improve understanding of the performance and facilitate design improvements. Using high performance computing and computational fluid dynamics (CFD) a low-cost molten sulfur thermal energy storage (TES) system for industrial process heating (IPH) applications was developed. The unique challenges in CFD modeling of sulfur TES are the sharp property changes of sulfur relevant to the working temperatures. Above 159, liquid sulfur undergoes polymerization, and the viscosity of sulfur rapidly increases by several orders of magnitude between 159 degrees Celsius and 188 degrees Celsius, followed by a decrease in viscosity beyond 188 degrees Celsius due to thermal bound dissociation. In addition, various concentrations of H2S impurities can also modify sulfur viscosity. This numerical challenge is especially relevant to transient simulation of the sulfur TES charging and discharging processes as the extreme property variations limit the applicability of traditional heat transfer correlations. Transient CFD simulations including the temperature-dependent sulfur properties and geometric complexity of the TES design were used to predict the effect of natural convection during charging and discharging on the heat transfer process, sulfur temperature uniformity, charge/discharge rates, and performance of the storage devices. The CFD model was validated with experimental results for a full charge and discharge cycle. The work will show 3D and 2D simulation comparisons aimed to facilitate rapid design iterations and a machine learning based design optimization approach.

CFD↗

NASA NTRS1997

Predictive Modeling in Plasma Reactor and Process Design

Research continues toward the improvement and increased understanding of high-density plasma tools. Such reactor systems are lauded for their independent control of ion flux and energy enabling high etch rates with low ion damage and for their improved ion velocity anisotropy resulting from thin collisionless sheaths and low neutral pressures. Still, with the transition to 300 mm processing, achieving etch uniformity and high etch rates concurrently may be a formidable task for such large diameter wafers for which computational modeling can play an important role in successful reactor and process design. The inductively coupled plasma (ICP) reactor is the focus of the present investigation. The present work attempts to understand the fundamental physical phenomena of such systems through computational modeling. Simulations will be presented using both computational fluid dynamics (CFD) techniques and the direct simulation Monte Carlo (DSMC) method for argon and chlorine discharges. ICP reactors generally operate at pressures on the order of 1 to 10 mTorr. At such low pressures, rarefaction can be significant to the degree that the constitutive relations used in typical CFD techniques become invalid and a particle simulation must be employed. This work will assess the extent to which CFD can be applied and evaluate the degree to which accuracy is lost in prediction of the phenomenon of interest; i.e., etch rate. If the CFD approach is found reasonably accurate and bench-marked with DSMC and experimental results, it has the potential to serve as a design tool due to the rapid time relative to DSMC. The continuum CFD simulation solves the governing equations for plasma flow using a finite difference technique with an implicit Gauss-Seidel Line Relaxation method for time marching toward a converged solution. The equation set consists of mass conservation for each species, separate energy equations for the electrons and heavy species, and momentum equations for the gas. The sheath is modeled by imposing the Bohm velocity to the ions near the walls. The DSMC method simulates each constituent of the gas as a separate species which would be analogous in CFD to employing separate species mass, momentum, and energy equations. All particles including electrons are moved and allowed to collide with one another with the stipulation that the electrons remain tied to the ions consistent with the concept of ambipolar diffusion. The velocities of the electrons are allowed to be modified during collisions and are not confined to a Maxwellian distribution. These benefits come at a price in terms of computational time and memory. The DSMC and CFD are made as consistent as possible by using similar chemistry and power deposition models. Although the comparison of CFD and DSMC is interesting, the main goal of this work is the increased understanding of high-density plasma flowfields that can then direct improvements in both techniques. This work is unique in the level of the physical models employed in both the DSMC and CFD for high-density plasma reactor applications. For example, the electrons are simulated in the present DSMC work which has not been done before for low temperature plasma processing problems. In the CFD approach, for the first time, the charged particle transport (discharge physics) has been self-consistently coupled to the gas flow and heat transfer.

Hash, D. B.↗

NASA NTRS2023

Turbulence Model Validation Through Joint Experimental /Computational Studies of Separated Flow Over A Three-Dimensional Tapered Bump: Part I - Experimental Investigation

The results of a three-year experimental campaign aimed at comprehensively documenting the separated flow over a three-dimensional bump are presented with the purpose of generating a benchmark experimental database useful in validating computational fluid dynamics (CFD) flow simulations. The bump model geometry was designed to provide well-defined and repeatable smooth-body flow separation conditions that were suitable for both experiments and simulations. The bump had a Gaussian streamwise profile with a constant height equal to 8.5% of its width over the central 60% of the test section width. The remaining 40% were outboard spanwise portions that gradually taper to zero using an error function profile to minimize side-wall boundary layer effects. The model was immersed in a turbulent boundary layer that was developed on a suspended flat plate in the Notre Dame Mach 0.6 Wind Tunnel. In order to document the effect of the incoming boundary layer thickness on the flow separation, the bump model could be located at two streamwise positions. The mean velocity and turbulence intensity of the wind tunnel freestream flow field and approaching turbulent boundary layer were fully documented. The measurements of the flow separation region included surface visualization, wall shear stress using oil-film interferometry, mean and dynamic surface pressure, and planar and stereoscopic particle image velocimetry. The experiments were conducted over a range of Mach numbers from 0.05 to 0.2 corresponding to a range of Reynolds numbers based on the test section spanwise dimension (0.914m) of 1.0 × 10 6 ≤ Re L = U ∞ L/ν ≤ 4.0 × 10 6 . The bulk of the results are presented for the higher Mach number conditions of 0.1 and 0.2 with Re L = 2.0 × 10 6 and 4.0 × 10 6 , respectively. Extensive uncertainty analysis of the data was performed. The data is archived in the NASA Langley Turbulence Modeling Resource website at https://turbmodels.larc.nasa.gov/Other_exp_Data/speedbump_sep_exp.html. In addition to the experiments, a computational effort was made in parallel by the CFD group at Boeing Research & Technology highlighting the usefulness of the data set, which is outlined in the accompanying CFD report.

Flow separation↗

DOE OSTI2025

Recent Improvements in Pronghorn for Advanced Reactor Modeling

Pronghorn is a thermal-hydraulics computational tool developed using the Idaho National Laboratory's Multiphysics Object-Oriented Simulation Environment (MOOSE). It is designed to support Computational Fluid Dynamics (CFD) modeling, ranging from subchannel and porous media analysis to Reynolds Averaged Navier-Stokes (RANS) turbulence modeling. As an integral part of the MOOSE-based suite of tools, Pronghorn seamlessly couples with other MOOSE-based applications to simulate a variety of physical phenomena. This article highlights recent significant enhancements to Pronghorn's CFD modeling capabilities and demonstrates their application to advanced nuclear reactor designs. The recent improvements in Pronghorn primarily focus on modifications to its turbulence modeling capabilities, near-wall corrections and numerical schemes. In terms of turbulence modeling, the two-equation $k-\epsilon$ and $k-\omega$ SST models have been implemented and validated with both equilibrium and non-equilibrium wall treatments. Additionally, corrections for wall roughness, and curvature, and wall-channeling in pebble beds have been introduced in the near-wall modeling. These developments enable more accurate simulations of advanced nuclear reactors. Two case studies are presented in this work: a pool-type Molten Chloride Reactor and a salt-cooled Pebble-Bed High Temperature Reactor. In both cases, the previous models in Pronghorn are compared with the new implementations, demonstrating the improved accuracy achieved with the updated models.

22 - GENERAL STUDIES OF NUCLEAR REACTORS↗

NASA NTRS2000

Use Computer-Aided Tools to Parallelize Large CFD Applications

Porting applications to high performance parallel computers is always a challenging task. It is time consuming and costly. With rapid progressing in hardware architectures and increasing complexity of real applications in recent years, the problem becomes even more sever. Today, scalability and high performance are mostly involving handwritten parallel programs using message-passing libraries (e.g. MPI). However, this process is very difficult and often error-prone. The recent reemergence of shared memory parallel (SMP) architectures, such as the cache coherent Non-Uniform Memory Access (ccNUMA) architecture used in the SGI Origin 2000, show good prospects for scaling beyond hundreds of processors. Programming on an SMP is simplified by working in a globally accessible address space. The user can supply compiler directives, such as OpenMP, to parallelize the code. As an industry standard for portable implementation of parallel programs for SMPs, OpenMP is a set of compiler directives and callable runtime library routines that extend Fortran, C and C++ to express shared memory parallelism. It promises an incremental path for parallel conversion of existing software, as well as scalability and performance for a complete rewrite or an entirely new development. Perhaps the main disadvantage of programming with directives is that inserted directives may not necessarily enhance performance. In the worst cases, it can create erroneous results. While vendors have provided tools to perform error-checking and profiling, automation in directive insertion is very limited and often failed on large programs, primarily due to the lack of a thorough enough data dependence analysis. To overcome the deficiency, we have developed a toolkit, CAPO, to automatically insert OpenMP directives in Fortran programs and apply certain degrees of optimization. CAPO is aimed at taking advantage of detailed inter-procedural dependence analysis provided by CAPTools, developed by the University of Greenwich, to reduce potential errors made by users. Earlier tests on NAS Benchmarks and ARC3D have demonstrated good success of this tool. In this study, we have applied CAPO to parallelize three large applications in the area of computational fluid dynamics (CFD): OVERFLOW, TLNS3D and INS3D. These codes are widely used for solving Navier-Stokes equations with complicated boundary conditions and turbulence model in multiple zones. Each one comprises of from 50K to 1,00k lines of FORTRAN77. As an example, CAPO took 77 hours to complete the data dependence analysis of OVERFLOW on a workstation (SGI, 175MHz, R10K processor). A fair amount of effort was spent on correcting false dependencies due to lack of necessary knowledge during the analysis. Even so, CAPO provides an easy way for user to interact with the parallelization process. The OpenMP version was generated within a day after the analysis was completed. Due to sequential algorithms involved, code sections in TLNS3D and INS3D need to be restructured by hand to produce more efficient parallel codes. An included figure shows preliminary test results of the generated OVERFLOW with several test cases in single zone. The MPI data points for the small test case were taken from a handcoded MPI version. As we can see, CAPO's version has achieved 18 fold speed up on 32 nodes of the SGI O2K. For the small test case, it outperformed the MPI version. These results are very encouraging, but further work is needed. For example, although CAPO attempts to place directives on the outer- most parallel loops in an interprocedural framework, it does not insert directives based on the best manual strategy. In particular, it lacks the support of parallelization at the multi-zone level. Future work will emphasize on the development of methodology to work in a multi-zone level and with a hybrid approach. Development of tools to perform more complicated code transformation is also needed.

Jin, H.↗