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All sources NASA NTRS DOE OSTI

DOE OSTI2016

Arrays of flow channels with heat transfer embedded in conducting walls

Here we illustrate the free search for the optimal geometry of flow channel cross-sections that meet two objectives simultaneously: reduced resistances to heat transfer and fluid flow. The element cross section and the wall material are fixed, while the shape of the fluid flow opening, or the wetted perimeter is free to vary. Two element cross sections are considered, square and equilateral triangular. We find that the two objectives are best met when the solid wall thickness is uniform, i.e., when the wetted perimeters are square and triangular, respectively. In addition, we consider arrays of square elements and triangular elements, on the basis of equal mass flow rate per unit of array cross sectional area. The conclusion is that the array of triangular elements meets the two objectives better than the array of square elements.

36 MATERIALS SCIENCE↗

DOE OSTI2017

Radiochemical Methodology Applied To Determination of gamma-Emitting Radionuclides In Waste Samples From IEA-R1 Reactor - 17265

The Brazilian reactor IEA-R1 has been in operation since 1957. It is an open pool-type nuclear research reactor, operating at 2 to 5 MW that uses water as coolant, moderator and biological shield. Polypropylene filter cartridges are part of the water treatment system of the reactor and become radioactive as they remove suspended solid material from the cooling water during the operation of the reactor. Annually, the replacement of the filters from the reactor's water treatment system generates about 36 units. The development of a method for the characterization of the radionuclides present in the filters is required for routine operation in the Radioactive Waste Management Facility (RWMF) in order to determine the radioisotopic inventory of the waste packages. Wastes from nuclear reactors contain transuranic elements, activation and fission products, only few of them emitting gamma radiation measurable by simple gamma scanning methods. The method of the Scaling Factors (SF) uses empirically determined proportions between the concentrations of Difficult to Measure (DTM) radionuclides and that of easily measurable gamma emitters called Key Nuclide (KN), to calculate DTM concentrations. The objective of this study is to describe a method of the dissolution of the filter cartridges for determination of gamma emitting radionuclides. To determine the activity of a sample by means of of gamma spectrometry, it is necessary previous knowledge of the efficiency curve for a given geometry, which can be obtained by calibrating the efficiency and energy of the detector. The need to dissolve the filter cartridges has arisen given the difficulty in obtaining a standard source with the same filter geometry. Therefore, for this work, the calibration curve was constructed using a mixed gamma-ray standard with known activities, same geometry, density, physical state and chemical composition of the source to be analyzed. A sample with background count (BG) was prepared and analyzed under the same conditions as the samples and the result was subtracted from the results obtained for each filter sample. After many tests, it was possible to establish a method for the dissolution of filter cartridges for the determination of gamma-emitting radionuclides. A mixed gamma-ray standard was produced in liquid form, containing the following radionuclides: {sup 241}Am, {sup 137}Cs and {sup 60}Co, which have photo-peaks at the following energies: 59.54, 661.66 and 1332.49 keV, respectively. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2026

AnisONet: A deep neural operator-based anisotropic permeability upscaler from pore to Darcy scale

Directional permeability variations, which govern directional fluid flow in porous media with anisotropy, are important to accurately predict flow behavior, reactive transport, and fluid–solid interactions for various processes such as enhanced geothermal systems, energy storage devices, and biological systems. However, the intricate architecture of porous media makes it difficult to predict directional permeabilities. In this work, we present a novel machine learning (ML) framework, AnisONet, built upon an integration of a convolutional neural network, Swin transformer, and the deep operator network architecture, designed to predict anisotropic permeability and upscale predictions to larger spatial domains. First, AnisONet was evaluated with three classes of two-dimensional (2D) porous media, including synthetic circular and elliptical grains and natural sandstone grains from micro-computed tomography images. A lattice Boltzmann model (LBM) was used to calculate directional permeabilities at every 10° angle, producing 19 data points per image of porous media. AnisONet is then trained to predict permeability as a function of rotation angle. AnisONet showed strong predictive capability of directional permeability. Second, we tested our model for five upscaling cases with a large image size in the finite-element method (FEM) for 2D Darcy flow with various permeability tensor construction methods. Overall, upscaled permeability tensors in FEM simulations produce a reasonably good match with LBM results, highlighting the importance of selecting appropriate tensor formation strategies for accurate permeability upscaling. AnisONet, as a directional permeability estimator, could be further developed for more complex geometries, with the potential to develop a foundational ML model for various applications in porous media.

42 ENGINEERING↗

DOE OSTI2016

Utilizing a Novel Acoustic Backscatter Array to Characterize Waste Consolidation and Settling in a Horizontal Flow Clarifier - 16051

As part of a collaboration between the University of Leeds, Sellafield Ltd and MMI Engineering Ltd, bespoke acoustic instrumentation and numerical simulation methods have been established to optimize nuclear legacy waste transfers. Specifically, a new ultrasonic measurement system has been developed, allowing suspended particle concentration and consolidation to be measured remotely. This technology has been combined with computational fluid dynamics (CFD) modelling of settling particulate systems, permitting full characterization, simulation and prediction of sludge separation processes. Presented here are experimental and numerical results on the transport and settling behavior of non-active nuclear-analogue suspensions in two flow geometries: gravitational settling of glass dispersions in a 250-liter column; and transport and sedimentation of flocculated calcite in a close-to-full-scale clarifier (9 m{sup 3} total volume and 4.8 m{sup 2} length). In addition, details of the design, construction and calibration of a custom-built Ultrasonic Array Research Platform (UARP) are described. Settling column results suggested that particle concentration changes could be simulated with good accuracy by a CFD model (developed using the open source OpenFOAM framework) when compared to measured samples. Large-scale clarifier trials were used to assess the effectiveness of the UARP controller with an attached in situ acoustic backscatter array (ABA). The ABA consisted of 8 transducers angled down at 20 deg. to the vertical, pulsing at 2-2.5 MHz in cycles (covering 1.8 m total depth). In comparison to a range of sampled concentrations across the length of the clarifier, results confirmed that the UARP-ABA system was highly successful at characterizing these complex flows over several hours of operation, allowing visualization of depth-wise bulk density changes and bed build-up over time. Collectively, this work highlights the capability of these tools to monitor and optimize a number of current waste transfer operations at Sellafield, with further potential applications for solid-liquid separations across waste, water treatment and minerals engineering industries. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

NASA NTRS2003

Flow Visualization of Low Prandtl Number Fluids using Electrochemical Measurements

It is well established that residual flows exist in contained liquid metal processes. In 1-g processing, buoyancy forces often drive these flows and their magnitudes can be substantial. It is also known that residual flows can exist during microgravity processing, and although greatly reduced in magnitude, they can influence the properties of the processed materials. Unfortunately, there are very few techniques to visualize flows in opaque, high temperature liquid metals, and those available are not easily adapted to flight investigation. In this study, a novel technique is developed that uses liquid tin as the model fluid and solid-state electrochemical cells constructed from Yttria-Stabilized Zirconia (YSZ) to establish and measure dissolved oxygen boundary conditions. The melt serves as a common electrode for each of the electrochemical cells in this design, while independent reference electrodes are maintained at the outside surfaces of the electrolyte. By constructing isolated electrochemical cells at various locations along the container walls, oxygen is introduced or extracted by imposing a known electrical potential or passing a given current between the melt and the reference electrode. This programmed titration then establishes a known oxygen concentration boundary condition at the selected electrolyte-melt interface. Using the other cells, the concentration of oxygen at the electrolyte-melt interface is also monitored by measuring the open-circuit potentials developed between the melt and reference electrodes. Thus the electrochemical cells serve to both establish boundary conditions for the passive tracer and sense its path. Rayleigh-Benard convection was used to validate the electrochemical approach to flow visualization. Thus, a numerical characterization of the second critical Rayleigh numbers in liquid tin was conducted for a variety of Cartesian aspect ratios. The extremely low Prandtl number of tin represents the lowest value studied numerically. Additionally, flow field oscillations are visualized and the effect of tilt on convecting systems is quantified. Experimental studies of the effect of convection in liquid tin are presented. Three geometries are studied: (1) double electrochemical cell with vertical concentration gradients; (2) double cell with horizontal concentration gradients; and (3) multiple cells with vertical temperature gradients. The first critical Rayleigh number transition is detected with geometry (1) and it is concluded that current measurements are not as affected by convection as EMF measurements. The system is compared with numerical simulations in geometry (2), and oscillating convection is detected with geometry (3).

Crunkleton, D.↗

NASA NTRS2004

Vibration Characteristics Determined for Stainless Steel Sandwich Panels With a Metal Foam Core for Lightweight Fan Blade Design

The goal of this project at the NASA Glenn Research Center is to provide fan materials that are safer, weigh less, and cost less than the currently used titanium alloy or polymer matrix composite fans. The proposed material system is a sandwich fan construction made up of thin solid face sheets and a lightweight metal foam core. The stiffness of the sandwich structure is increased by separating the two face sheets by the foam layer. The resulting structure has a high stiffness and lighter weight in comparison to the solid facesheet material alone. The face sheets carry the applied in-plane and bending loads (ref. 1). The metal foam core must resist the transverse shear and transverse normal loads, as well as keep the facings supported and working as a single unit. Metal foams have ranges of mechanical properties, such as light weight, impact resistance, and vibration suppression (ref. 2), which makes them more suitable for use in lightweight fan structures. Metal foams have been available for decades (refs. 3 and 4), but the difficulties in the original processes and high costs have prevented their widespread use. However, advances in production techniques and cost reduction have created a new interest in this class of materials (ref. 5). The material chosen for the face sheet and the metal foam for this study was the aerospace-grade stainless steel 17-4PH. This steel was chosen because of its attractive mechanical properties and the ease with which it can be made through the powder metallurgy process (ref. 6). The advantages of a metal foam core, in comparison to a typical honeycomb core, are material isotropy and the ease of forming complex geometries, such as fan blades. A section of a 17-4PH sandwich structure is shown in the following photograph. Part of process of designing any blade is to determine the natural frequencies of the particular blade shape. A designer needs to predict the resonance frequencies of a new blade design to properly identify a useful operating range. Operating a blade at or near the resonance frequencies leads to high-cycle fatigue, which ultimately limits the blade's durability and life. So the aim of this study is to determine the variation of the resonance frequencies for an idealized sandwich blade as a function of its face-sheet thickness, core thickness, and foam density. The finite element method is used to determine the natural frequencies for an idealized rectangular sandwich blade. The proven Lanczos method (ref. 7) is used in the study to extract the natural frequency.

Ghosn, Louis J.↗

DOE OSTI2015

SU-E-T-312: Dosimetric Consideration for the Agility MLC When Planning Rotational SRT/SBRT Treatments

Purpose: To analyze the radiation transmission of the Agility MLC and make recommendation based on the MLC dosimetric characteristics for SRT, SBRT and VMAT planning Method and Materials: Agility MLC is the newest model from Elekta and has no back up diaphragm behind leaves for this generation. Leaves are single focused with rounded end; composed of leafs each 0.5cm wide, 9cm thick, constructed from tungsten alloy and provide low transmission <0.5%. Total radiation transmission from leaves and diaphragm is <0.13%. A 360degree arc was generated using iCom tools; leaves were programmed closed while keeping the diaphragm fully open to maximize the MLC transmission effect. Gafchromic EBT films were sandwiched between 4cm of solid water and situated at midplane to take dose measurement. 5000MU was delivered using 6MV VersaHD, various collimator angles, and a 5cm central axis offset was tested also. Films were scanned with Epson 10000XL scanner and analyzed using DoseLab Pro. Results: Due to the rounded leaf end and nature of rotation therapy, dose accumulation through the leaf gap is significant. By offsetting the leaf gap from central axis, this accumulation can be greatly reduced. There are dark bands showing accumulation of interleaf transmission which is improved by increasing collimator angle from 0 to 45dgree. However for 45 degree, in most cases, there are larger volumes sweeping under MLC alone, which needs considered planning. Conclusions: While inter-leaf leakage is minimized by using collimator angles greater than 0 degrees, the location of the leaf gap must also be managed. The leaf gap position becomes critically important when the treatment area is off axis such is the case when more than one PTV is being treated. With VMAT for SRT, SBRT becoming a more popular planning technique, special attention needs to be paid when initially setting up the field geometry.

60 APPLIED LIFE SCIENCES↗

DOE OSTI2017

HPC Institutional Computing Project: W15_lesreactiveflow KIVA-hpFE Development: A Robust and Accurate Engine Modeling Software

KIVA-hpFE is a high performance computer software for solving the physics of multi-species and multiphase turbulent reactive flow in complex geometries having immersed moving parts. The code is written in Fortran 90/95 and can be used on any computer platform with any popular complier. The code is in two versions, a serial version and a parallel version utilizing MPICH2 type Message Passing Interface (MPI or Intel MPI) for solving distributed domains. The parallel version is at least 30x faster than the serial version and much faster than our previous generation of parallel engine modeling software, by many factors. The 5th generation algorithm construction is a Galerkin type Finite Element Method (FEM) solving conservative momentum, species, and energy transport equations along with two-equation turbulent model k-ω Reynolds Averaged Navier-Stokes (RANS) model and a Vreman type dynamic Large Eddy Simulation (LES) method. The LES method is capable modeling transitional flow from laminar to fully turbulent; therefore, this LES method does not require special hybrid or blending to walls. The FEM projection method also uses a Petrov-Galerkin (P-G) stabilization along with pressure stabilization. We employ hierarchical basis sets, constructed on the fly with enrichment in areas associated with relatively larger error as determined by error estimation methods. In addition, when not using the hp-adaptive module, the code employs Lagrangian basis or shape functions. The shape functions are constructed for hexahedral, prismatic and tetrahedral elements. The software is designed to solve many types of reactive flow problems, from burners to internal combustion engines and turbines. In addition, the formulation allows for direct integration of solid bodies (conjugate heat transfer), as in heat transfer through housings, parts, cylinders. It can also easily be extended to stress modeling of solids, used in fluid structure interactions problems, solidification, porous media modeling and magneto hydrodynamics.

97 MATHEMATICS AND COMPUTING↗

NASA NTRS1993

Flow visualization study in high aspect ratio cooling channels for rocket engines

The structural integrity of high pressure liquid propellant rocket engine thrust chambers is typically maintained through regenerative cooling. The coolant flows through passages formed either by constructing the chamber liner from tubes or by milling channels in a solid liner. Recently, Carlile and Quentmeyer showed life extending advantages (by lowering hot gas wall temperatures) of milling channels with larger height to width aspect ratios (AR is greater than 4) than the traditional, approximately square cross section, passages. Further, the total coolant pressure drop in the thrust chamber could also be reduced, resulting in lower turbomachinery power requirements. High aspect ratio cooling channels could offer many benefits to designers developing new high performance engines, such as the European Vulcain engine (which uses an aspect ratio up to 9). With platelet manufacturing technology, channel aspect ratios up to 15 could be formed offering potentially greater benefits. Some issues still exist with the high aspect ratio coolant channels. In a coolant passage of circular or square cross section, strong secondary vortices develop as the fluid passes through the curved throat region. These vortices mix the fluid and bring lower temperature coolant to the hot wall. Typically, the circulation enhances the heat transfer at the hot gas wall by about 40 percent over a straight channel. The effect that increasing channel aspect ratio has on the curvature heat transfer enhancement has not been sufficiently studied. If the increase in aspect ratio degrades the secondary flow, the fluid mixing will be reduced. Analysis has shown that reduced coolant mixing will result in significantly higher wall temperatures, due to thermal stratification in the coolant, thus decreasing the benefits of the high aspect ratio geometry. A better understanding of the fundamental flow phenomena in high aspect ratio channels with curvature is needed to fully evaluate the benefits of this geometry. The fluid dynamic and conjugate heat transfer problem of high aspect ratio rocket engine coolant channels are being investigated numerically, but these efforts have been hampered by a lack of validating data. Wall temperature data is available for the conjugate problem for channels without curvature and aspect ratio = 5.0, and unheated fluid dynamic data are available for square and circular cross section channels with curvature at Reynold's numbers up to 40,000. But the effects of aspect ratio on secondary flow development have not been experimentally studied. To provide some insight into the effects of channel aspect ratio on secondary flow and to qualitatively provide anchoring for the numerical codes, a flow visualization experiment was initiated at the NASA Lewis Research Center.

Meyer, Michael L.↗

DOE OSTI2025

High-resolution 3D-printed plastic scintillators with tertiary dye

Additive manufacturing offers efficient production of plastic scintillators with nontrivial geometries using vat polymerization, allowing fabrication of geometries which would be difficult or even impossible to produce using conventional subtractive manufacturing. This work presents a novel photocurable scintillator formula that includes coumarin 450 as a tertiary dye to enable high-resolution 3D printing via the manipulation of the 405 nm cure light. Bulk photocured and 3D printed (with and without tertiary dye) samples were compared through observational assessment and spectral response. All samples showed pulse shape discrimination between neutron and gamma events. Inclusion of the tertiary dye has minimal impact on emission spectrum and light output, but significant impact on print resolution as shown by comparison of printed high-complexity geometries and feature resolution test objects. With the use of a cure-limiting dye, unsupported features — such as freestanding pillars — were resolvable down to 0.7 mm. Even finer resolution at or below 0.1 mm was achieved in fully supported, integrated structures printed with off-the-shelf 405 nm desktop 3D printer. Scintillators demonstrated a light output up to 50% of EJ-200 with a PSD figure of merit up to 1.35 at 0.9–1.1 MeVee.

36 MATERIALS SCIENCE↗

NASA NTRSDate not supplied

System Modeling of a Lunar Molten Regolith Electrolysis Plant

Introduction: In-Situ Resource Utilization (ISRU) is the process of extracting local resources to produce commodities for propulsion, life support systems, and off-planet construction rather than transporting consumables from Earth. Molten Regolith Electrolysis (MRE) is a novel ISRU method of extracting oxygen gas and metal alloy from lunar regolith. The MRE process involves placing lunar regolith between two electrodes, through which current is passed, to melt the regolith and reduce the metal oxide constituents by direct electrolysis (e.g. FeO, SiO2, MgO, Al2O3) into oxygen gas and metal alloys. The oxygen is liquefied and used as propellant for landers, while the metals (e.g. Ferro-alloys) are further processed and used in structural building materials and parts manufacturing. A system model was developed that accounted for the major processes of an MRE plant (from excavation of raw materials to storage of products) to assess the feasibility of a lunar MRE plant. The System Engineering and Integration (SE&I) ISRU Modeling and Analysis (SIMA) team utilized its previously documented system sizing model, the Mission Analysis and Integration Tool (MAIT) [1] as framework of the system model. MAIT uses MATLAB/Simulink to integrate subsystem models into a complete system model of the MRE plant. Total mass, volume, and power requirements were computed for numerous iterations of a MRE plant. System Model: Figure 1: MRE Plant Block Diagram The regolith excavation model determines the mass and power needed to excavate sufficient regolith. The preheating auger initiates the regolith heating process before regolith enters the MRE re-actor to reduce the energy required to turn the solid into a molten liquid. The MRE reactor is modeled in COMSOL Multiphysics and based on the research by Dominguez, Sibille, and Schreiner [2, 3, 4]. This preliminary reactor model provides an accurate calculation of thermal equilibrium during electrochemical operation of the reactor system to assess the optimal mass and power required to process the inlet flow of regolith. The model also computes the outlet flowrates of oxygen and molten products. For this analysis, the primary components of the metal alloy considered were iron and silicon. The oxygen is then purified using an Yttrium Stabilized Zirconia (YSZ) electrode, followed by liquefaction using a 90K cryocooler to be stored as liquid oxygen in insulated cylindrical tanks. In future iterations of the system model, the molten metal tapped from the MRE reactor will undergo additional processing or refinement. However, downstream handling of metals is currently a technology gap that is missing a high TRL subsystem model. Therefore, for this analysis, the accumulated metal alloy stream terminates after leaving the MRE reactor. Study Goals: This analysis investigates multiple input variables to the system to determine the sensitivity of a (near) complete plant at full-scale. This preliminary investigation ran parametric sweeps on the MRE reactor geometry, electrical current supply, layers of multi-layer insulation (MLI) on the reactor, size of the electrodes in the oxygen purification model, and regolith composition (based on landing site location). Three production targets of oxygen (1,000, 10,000, and 50,000 kg/yr) were investigated for this analysis. The parametric sweeps conducted in this analysis provide valuable insight into the expected impact of the various model inputs on plant size. This information can be used to identify the most critical components of the plant and guide future decisions on allocating funding for research and development, providing subsystem developers with appropriate interfaces with downstream and upstream processes, and assessing the overall feasibility of MRE when compared to other ISRU plants. References: [1] Carlson, A. et al. (2024) ICES, ICES-2024-53. [2] Dominguez, D.A., and Sibille, L. (2011) AIAA, AIAA-2011-700. [3] Schreiner, S.S. (2015) MIT, Dissertation. [4] Schreiner, S.S. et al. (2016) ASR, 57(7), pp.1585-1603.

ISRU↗

DOE OSTI2016

Fast ignition realization experiment with high-contrast kilo-joule peta-watt LFEX laser and strong external magnetic field

A petawatt laser for fast ignition experiments (LFEX) laser system [N. Miyanaga et al., J. Phys. IV France 133, 81 (2006)], which is currently capable of delivering 2 kJ in a 1.5 ps pulse using 4 laser beams, has been constructed beside the GEKKO-XII laser facility for demonstrating efficient fast heating of a dense plasma up to the ignition temperature under the auspices of the Fast Ignition Realization EXperiment (FIREX) project [H. Azechi et al., Nucl. Fusion 49, 104024 (2009)]. In the FIREX experiment, a cone is attached to a spherical target containing a fuel to prevent a corona plasma from entering the path of the intense heating LFEX laser beams. The LFEX laser beams are focused at the tip of the cone to generate a relativistic electron beam (REB), which heats a dense fuel core generated by compression of a spherical deuterized plastic target induced by the GEKKO-XII laser beams. Recent studies indicate that the current heating efficiency is only 0.4%, and three requirements to achieve higher efficiency of the fast ignition (FI) scheme with the current GEKKO and LFEX systems have been identified: (i) reduction of the high energy tail of the REB; (ii) formation of a fuel core with high areal density using a limited number (twelve) of GEKKO-XII laser beams as well as a limited energy (4 kJ of 0.53-μm light in a 1.3 ns pulse); (iii) guiding and focusing of the REB to the fuel core. Laser–plasma interactions in a long-scale plasma generate electrons that are too energetic to efficiently heat the fuel core. Three actions were taken to meet the first requirement. First, the intensity contrast of the foot pulses to the main pulses of the LFEX was improved to >10{sup 9}. Second, a 5.5-mm-long cone was introduced to reduce pre-heating of the inner cone wall caused by illumination of the unconverted 1.053-μm light of implosion beam (GEKKO-XII). Third, the outside of the cone wall was coated with a 40-μm plastic layer to protect it from the pressure caused by imploding plasma. Following the above improvements, conversion of 13% of the LFEX laser energy to a low energy portion of the REB, whose slope temperature is 0.7 MeV, which is close to the ponderomotive scaling value, was achieved. To meet the second requirement, the compression of a solid spherical ball with a diameter of 200-μm to form a dense core with an areal density of ∼0.07 g/cm{sup 2} was induced by a laser-driven spherically converging shock wave. Converging shock compression is more hydrodynamically stable compared to shell implosion, while a hot spot cannot be generated with a solid ball target. Solid ball compression is preferable also for compressing an external magnetic field to collimate the REB to the fuel core, due to the relatively small magnetic Reynolds number of the shock compressed region. To meet the third requirement, we have generated a strong kilo-tesla magnetic field using a laser-driven capacitor-coil target. The strength and time history of the magnetic field were characterized with proton deflectometry and a B-dot probe. Guidance of the REB using a 0.6-kT field in a planar geometry has been demonstrated at the LULI 2000 laser facility. In a realistic FI scenario, a magnetic mirror is formed between the REB generation point and the fuel core. The effects of the strong magnetic field on not only REB transport but also plasma compression were studied using numerical simulations. According to the transport calculations, the heating efficiency can be improved from 0.4% to 4% by the GEKKO and LFEX laser system by meeting the three requirements described above. This efficiency is scalable to 10% of the heating efficiency by increasing the areal density of the fuel core.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗