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DOE OSTI2025

Fitness For Service Assessment of a Corroded Heat Exchanger

Within the Fermi National Accelerator complex, there exist various water systems that support accelerator operations. One of these systems is extremely vital to the operation of the machine; that is the cooling system. The cooling system consists of nine relatively large heat exchangers that take untreated pond water and use it to cool the process fluid that further cools machine components. Over the 30 years these heat exchangers have been in operation, they have undergone significant material loss on the channels. This material loss, due to various forms of corrosion such as galvanic and microbiologically influenced corrosion (MIC) and possibly others, has deteriorated more than 80% of the nominal wall thickness of some of the exchangers and placed them in a questionable state. ASME FFS-1 (API 579) has been applied to address the condition of the heat exchangers due to their noncompliance with the governing code, BPVC Sec. VIII Div. 1. The assessments encompassed ASME FFS-1 parts 4: General Metal Loss and 9: Crack Like Flaw using level 1, 2, and 3 analysis techniques based on inspection data obtained by API 510 inspections. Level 1 and 2 assessments were deemed unfit for the corroded regions due to their location relative to a major structural discontinuity (channel to tube-sheet joint), so a level 3 analysis was conducted according to ASME Sec. VIII Div. 2 (design by analysis) rules for pressure vessels. Supplemental information included pond water tests to determine an accurate future corrosion allowance due to lacking inspection history. A leak before break (LBB) route was chosen to evaluate the possibility of leaking prior to the onset of failure. The analysis of one heat exchanger shows that the possibility the channel will develop a pinhole leak over 2.5 more years of operation should not be overlooked, but burst was unlikely from operation. The use of fracture mechanics show, that if a through-wall crack were to develop, it would not propagate further than the channel geometry and cause a leak not greater than 35 GPM. Using ASME Section XI Code Case N-705-1, allowing us to operate with a leak until the next outage given certain operating conditions and developing a leak mitigation procedure, this heat exchanger is deemed fit-for-service.

Humenik, Alex [Fermilab]↗

DOE OSTI2024

Iodine speciation in basaltic melts at depth

The speciation of iodine in basalts has been investigated by combining in situ X-ray diffraction at high pressures and temperatures up to 4.9 GPa and 1600 °C, and Raman spectroscopy on recovered high pressure glasses at ambient conditions. Both methods point to iodine being oxidized in basalts, whether molten or quenched as glasses. Observed interatomic distances and Raman vibrational modes are consistent with iodine being dissolved as complex iodate groups alike polyiodates or periodates, not as IO$^-_3$ groups. Iodine speciation in basalts therefore seems to reflect a trend amongst halogens, with lighter chlorine bonding to network modifying cations, and bromine changing affinity from network modifying cations to oxygen anions under pressure. In the absence of a fluid aqueous phase, iodine could thus reach the Earth’s surface in basaltic magmas as an oxide, not as a reduced species.

58 GEOSCIENCES↗

NASA NTRS1973

Numerical studies of unsteady two dimensional subsonic flows using the ICE method

A numerical program was developed to compute transient compressible and incompressible laminar flows in two dimensions with multicomponent mixing and chemical reaction. The algorithm used the Los Alamos Scientific Laboratory ICE (Implicit Continuous-Fluid Eulerian) method as its base. The program can compute both high and low speed compressible flows. The numerical program incorporating the stabilization techniques was quite successful in treating both old and new problems. Detailed calculations of coaxial flow very close to the entry plane were possible. The program treated complex flows such as the formation and downstream growth of a recirculation cell. An implicit solution of the species equation predicted mixing and reaction rates which compared favorably with the literature.

Wieber, P. R.↗

NASA NTRS2001

A Magnetoresistive Heat Switch for the Continuous ADR

In compensated elemental metals at low temperature, a several Tesla field can suppress electronic heat conduction so thoroughly that heat is effectively carried by phonons alone. In approximately one mm diameter single crystal samples with impurity concentrations low enough that electron conduction is limited by surface scattering, the ratio of zerofield to high-field thermal conductivity can exceed ten thousand. We have used this phenomenon to build a compact, solid-state heat switch with no moving parts and no enclosed fluids. The time scale for switching states is limited by time scale for charging the magnet that supplies the controlling field. Our design and fabrication techniques overcome the difficulties associated with manufacturing and assembling parts from single crystal tungsten. A clear disadvantage of the magnetoresistive switch is the mass and complexity of the magnet system for the controlling field. We have discovered a technique of minimizing this mass and complexity, applicable to the continuous adiabatic demagnetization refrigerator.

Canavan, E. R.↗

NASA NTRS2011

Enhancements to TetrUSS for NASA Constellation Program

The NASA Constellation program is utilizing Computational Fluid Dynamics (CFD) predictions for generating aerodynamic databases and design loads for the Ares I, Ares I-X, and Ares V launch vehicles and for aerodynamic databases for the Orion crew exploration vehicle and its launch abort system configuration. This effort presents several challenges to applied aerodynamicists due to complex geometries and flow physics, as well as from the juxtaposition of short schedule program requirements with high fidelity CFD simulations. NASA TetrUSS codes (GridTool/VGRID/USM3D) have been making extensive contributions in this effort. This paper will provide an overview of several enhancements made to the various elements of TetrUSS suite of codes. Representative TetrUSS solutions for selected Constellation program elements will be shown. Best practices guidelines and scripting developed for generating TetrUSS solutions in a production environment will also be described.

Pandya, Mohagna J.↗

NASA NTRS2012

Sonic Boom Mitigation Through Aircraft Design and Adjoint Methodology

This paper presents a novel approach to design of the supersonic aircraft outer mold line (OML) by optimizing the A-weighted loudness of sonic boom signature predicted on the ground. The optimization process uses the sensitivity information obtained by coupling the discrete adjoint formulations for the augmented Burgers Equation and Computational Fluid Dynamics (CFD) equations. This coupled formulation links the loudness of the ground boom signature to the aircraft geometry thus allowing efficient shape optimization for the purpose of minimizing the impact of loudness. The accuracy of the adjoint-based sensitivities is verified against sensitivities obtained using an independent complex-variable approach. The adjoint based optimization methodology is applied to a configuration previously optimized using alternative state of the art optimization methods and produces additional loudness reduction. The results of the optimizations are reported and discussed.

Rallabhandi, Siriam K.↗

NASA NTRS2007

An Application of Overset Grids to Payload/Fairing Three-Dimensional Internal Flow CFD Analysis

The application of overset grids to the computational fluid dynamics analysis of three-dimensional internal flow in the payload/fairing of an expendable launch vehicle is described. In conjunction with the overset grid system, the flowfield in the payload/fairing configuration is obtained with the aid of OVERFLOW Navier-Stokes code. The solution exhibits a highly three dimensional complex flowfield with swirl, separation, and vortices. Some of the computed flow features are compared with the measured Laser-Doppler Velocimetry (LDV) data on a 1/5th scale model of the payload/fairing configuration. The counter-rotating vortex structures and the location of the saddle point predicted by the CFD analysis are in general agreement with the LDV data. Comparisons of the computed (CFD) velocity profiles on horizontal and vertical lines in the LDV measurement plane in the faring nose region show reasonable agreement with the LDV data.

Kandula, Max↗

DOE OSTI2025

Deconvoluting thermomechanical effects in X-ray diffraction data using machine learning

X-ray diffraction is ideal for probing the sub-surface state during complex or rapid thermomechanical loading of crystalline materials. However, challenges arise as the size of diffraction volumes increases due to spatial broadening and because of the inability to deconvolute the effects of different lattice deformation mechanisms. Here, we present a novel approach that uses combinations of physics-based modeling and machine learning to deconvolve thermal and mechanical elastic strains for diffraction data analysis. The method builds on a previous effort to extract thermal strain distribution information from diffraction data. The new approach is applied to extract the evolution of the thermomechanical state during laser melting of an Inconel 625 wall specimen which produces significant residual stress upon cooling. A combination of heat transfer and fluid flow, elasto-plasticity and X-ray diffraction simulations is used to generate training data for machine-learning (Gaussian process regression, GPR) models that map diffracted intensity distributions to underlying thermomechanical strain fields. First-principles density functional theory is used to determine accurate temperature-dependent thermal expansion and elastic stiffness used for elasto-plasticity modeling. The trained GPR models are found to be capable of deconvoluting the effects of thermal and mechanical strains, in addition to providing information about underlying strain distributions, even from complex diffraction patterns with irregularly shaped peaks.

36 MATERIALS SCIENCE↗

DOE OSTI2024

A Workflow for Characterizing Legacy Wells as Potential Leakage Pathways for Integration to NRAP-Open-IAM

Carbon capture and storage is a crucial component of climate change mitigation strategies, involving the capture of carbon dioxide (CO2) from point sources and its injection into permeable subsurface formation. Many suitable CO2 storage sites coincide with legacy wells since the conditions that kept hydrocarbons in-situ for thousands of years are also ideal for storage of carbon dioxide. To protect underground sources of drinking water (USDW) during greenhouse gas injection, the Environmental Protection Agency (EPA) mandates area of review evaluations. These evaluations ensure that drinking water sources would not be contaminated by injected fluids. They include identification of legacy wellbores, integrity assessments, and implementing any necessary corrective action. Previous assessment approaches of legacy wells include high-level scoring of regional data and well construction and abandonment evaluation. This work describes a novel methodology that evaluates well construction and abandonment, ranks them based on complexity, and performs a risk assessment with NRAP-Open-IAM. A workflow of the methodology is presented, highlighting its capabilities and limitations.

Wise, Jarrett↗

DOE OSTI2025

Viscosity Measurements in Extreme Conditions

Radiation-hydrodynamics simulations are critical to the NNSA complex for understanding high energy density physics and for addressing problems in national security science. However, current rad-hydro codes typically do not account for viscosity, which generally leads to large uncertainties in problems involving mixing of materials under shock loading. This report details progress made towards experimental measurements of fluid viscosity at high pressures and temperatures achieved by shock wave compression techniques, as well as complementary material model development and hydrodynamic simulations.

36 MATERIALS SCIENCE↗

NASA NTRS1986

Evolution and status of CFD techniques for scramjet applications

Computational Fluid Dynamics (CFD) methods are presently applied to the design and analysis of scramjet propulsion systems for missiles and aircraft operating at speeds in excess of Mach 5, in forms ranging from simple inviscid codes for parametric studies of inlet geometries to Navier-Stokes codes incorporating chemistry models which address complex scramjet combustion phenomena. Attention is given to the development history of CFD for the hypersonic regime, as well as to scramjet flowfield modeling in inlets, combustors and nozzles, and prospective development trends.

White, M. E.↗

NASA NTRS1991

Frontogenesis driven by horizontally quadratic distributions of density

Attention is given to the quadratic density distribution in a channel, which has been established by Simpson and Linden to be the simplest case of the horizontally nonlinear distribution of fluid density required for the production of frontogenesis. The porous-media and Boussinesq flow models are examined, and their evolution equations are reduced to one-dimensional systems. While both the porous-media and the inviscid/nondiffusive Boussinesq systems exhibit classic frontogenesis behavior, the viscous Boussinesq system exhibits a more complex behavior: boundary-layer effects force frontogenesis away from the lower boundary, and at late times the steepest density gradients are close to mid-channel.

Jacqmin, David↗

NASA NTRS1945

On two-dimensional flows of compressible fluids

This report is devoted to the study of two-dimensional steady motion of a compressible fluid. It is shown that the complete flow pattern around a closed obstacle cannot be obtained by the method of Chaplygin. In order to overcome this difficulty, a formula for the stream-function of a two-dimensional subsonic flow is derived. The formula involves an arbitrary function of a complex variable and yields all possible subsonic flow patterns of certain types. Conditions are given so that the flow pattern in the physical plane will represent a flow around a closed curve. The formula obtained can be employed for the approximate determination of a subsonic flow around an obstacle. The method can be extended to partially supersonic flows.

HODOGRAPHY METHOD↗

NASA NTRS2001

Investigation of Vibrational Control of the Bridgman Crystal Growth Technique

The character of natural buoyant convection in rigidly contained inhomogeneous fluids can be drastically altered by vibrating the container. Vibrations are expected to play a crucial influence on heat and mass transfer onboard the International Space Station (ISS). It is becoming evident that substantial vibrations will exist on the ISS in the wide frequency spectrum. In general, vibrational flows are very complex and governed by many parameters. In many terrestrial crystal growth situations, convective transport of heat and constituent components is dominated by buoyancy driven convection arising from compositional and thermal gradients. Thus, it may be concluded that vibro-convective flow can potentially be used to influence and even control transport in some crystal growth situations.

Fedoseyev, Alexandre I.↗

NASA NTRS2003

Numerical Models of Human Circulatory System under Altered Gravity: Brain Circulation

A computational fluid dynamics (CFD) approach is presented to model the blood flow through the human circulatory system under altered gravity conditions. Models required for CFD simulation relevant to major hemodynamic issues are introduced such as non-Newtonian flow models governed by red blood cells, a model for arterial wall motion due to fluid-wall interactions, a vascular bed model for outflow boundary conditions, and a model for auto-regulation mechanism. The three-dimensional unsteady incompressible Navier-Stokes equations coupled with these models are solved iteratively using the pseudocompressibility method and dual time stepping. Moving wall boundary conditions from the first-order fluid-wall interaction model are used to study the influence of arterial wall distensibility on flow patterns and wall shear stresses during the heart pulse. A vascular bed modeling utilizing the analogy with electric circuits is coupled with an auto-regulation algorithm for multiple outflow boundaries. For the treatment of complex geometry, a chimera overset grid technique is adopted to obtain connectivity between arterial branches. For code validation, computed results are compared with experimental data for steady and unsteady non-Newtonian flows. Good agreement is obtained for both cases. In sin-type Gravity Benchmark Problems, gravity source terms are added to the Navier-Stokes equations to study the effect of gravitational variation on the human circulatory system. This computational approach is then applied to localized blood flows through a realistic carotid bifurcation and two Circle of Willis models, one using an idealized geometry and the other model using an anatomical data set. A three- dimensional anatomical Circle of Willis configuration is reconstructed from human-specific magnetic resonance images using an image segmentation method. The blood flow through these Circle of Willis models is simulated to provide means for studying gravitational effects on the brain circulation under auto-regulation.

Kim, Chang Sung↗

NASA NTRS2004

Numerical, Analytical, Experimental Study of Fluid Dynamic Forces in Seals: Description of Gas Seal Codes GCYLT and GFACE - Volume 2

The objectives of the program were to develop computational fluid dynamics (CFD) codes and simpler industrial codes for analyzing and designing advanced seals for air-breathing and space propulsion engines. The CFD code SCISEAL is capable of producing full three-dimensional flow field information for a variety of cylindrical configurations. An implicit multidomain capability allow the division of complex flow domains to allow optimum use of computational cells. SCISEAL also has the unique capability to produce cross-coupled stiffness and damping coefficients for rotordynamic computations. The industrial codes consist of a series of separate stand-alone modules designed for expeditious parametric analyses and optimization of a wide variety of cylindrical and face seals. Coupled through a Knowledge-Based System (KBS) that provides a user-friendly Graphical User Interface (GUI), the industrial codes are PC based using an OS/2 operating system. These codes were designed to treat film seals where a clearance exists between the rotating and stationary components. Leakage is inhibited by surface roughness, small but stiff clearance films, and viscous pumping devices. The codes have demonstrated to be a valuable resource for seal development of future air-breathing and space propulsion engines.

Liang, Anita D.↗

NASA NTRS2004

Numerical, Analytical, Experimental Study of Fluid Dynamic Forces in Seals: Executive Summary and Description of Knowledge-Based System - Volume 1

The objectives of the program were to develop computational fluid dynamics (CFD) codes and simpler industrial codes for analyzing and designing advanced seals for air-breathing and space propulsion engines. The CFD code SCISEAL is capable of producing full three-dimensional flow field information for a variety of cylindrical configurations. An implicit multidomain capability allows the division of complex flow domains to allow optimum use of computational cells. SCISEAL also has the unique capability to produce cross-coupled stiffness and damping coefficients for rotordynamic computations. The industrial codes consist of a series of separate stand-alone modules designed for expeditious parametric analyses and optimization of a wide variety of cylindrical and face seals. Coupled through a Knowledge-Based System (KBS) that provides a user-friendly Graphical User Interface (GUI), the industrial codes are PC based using an OS/2 operating system. These codes were designed to treat film seals where a clearance exists between the rotating and stationary components. Leakage is inhibited by surface roughness, small but stiff clearance films, and viscous pumping devices. The codes have demonstrated to be a valuable resource for seal development of future air-breathing and space propulsion engines.

Liang, Anita D.↗

NASA NTRS2004

Numerical, Analytical, Experimental Study of Fluid Dynamic Forces in Seals: Description of Spiral-Groove Codes SPIRALG and SPIRALI - Volume 3

Liang, Anita D.↗