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DOE OSTI2022

Automated and efficient local adaptive regression for principal component-based reduced-order modeling of turbulent reacting flows

Principal Component Analysis can be used to reduce the cost of Computational Fluid Dynamics simulations of turbulent reacting flows by reducing the dimensionality of the transported variables through projection of the thermochemical state onto a lower-dimensional manifold. However, because of the nonlinearity of the principal component source terms, nonlinear regression techniques must be utilized for the source terms in terms of the principal components. Unfortunately, widely available and utilized nonlinear regression techniques can have prohibitive computational requirements and/or accuracy that is highly dependent on user experience in ad hoc tuning of model architecture and hyperparameters. Here, in this work, a new nonlinear regression approach is proposed that is both computationally efficient and automated so does not require any user input. The approach is evaluated through a priori prediction of principal component source terms using data from a Direct Numerical Simulation of a turbulent nonpremixed n-heptane/air jet flame. In particular, the proposed framework consists of local regressions whose complexity is adapted according to the local nonlinearity of the data: local linear regression when accurate enough and local Artificial Neural Networks when nonlinear regression is required. The number of local clusters for local regression is determined automatically using the Davies-Bouldin index. In addition, Bayesian optimization is utilized for model training (i.e., to select the best architectures and hyperparameters of the nonlinear regressions in an unsupervised fashion), eliminating ad hoc hand-tuning and/or expensive grid searches. Overall, compared to a single, global neural network, the new local adaptive regression approach is shown to have comparable accuracy but 69% less training time due to the utilization of local linear regression and faster training of local neural networks.

42 ENGINEERING↗

NASA NTRS2016

Experimental Investigation of Subsonic Turbulent Boundary Layer Flow Over a Wall-Mounted Axisymmetric Hill

An important goal for modern fluid mechanics experiments is to provide datasets which present a challenge for Computational Fluid Dynamics simulations to reproduce. Such "CFD validation experiments" should be well-characterized and well-documented, and should investigate flows which are difficult for CFD to calculate. It is also often convenient for the experiment to be challenging for CFD in some aspects while simple in others. This report is part of the continuing documentation of a series of experiments conducted to characterize the flow around an axisymmetric, modified-cosine-shaped, wall-mounted hill named "FAITH" (Fundamental Aero Investigates The Hill). Computation of this flow is easy in some ways - subsonic flow over a simple shape - while being complex in others - separated flow and boundary layer interactions. The primary set of experiments were performed on a 15.2 cm high, 45.7 cm base diameter machined aluminum model that was tested at mean speeds of 50 m/s (Reynolds Number based on height = 500,000). The ratio of model height to boundary later height was approximately 3. The flow was characterized using surface oil flow visualization, Cobra probe to determine point-wise steady and unsteady 3D velocities, Particle Image Velocimetry (PIV) to determine 3D velocities and turbulence statistics along specified planes, Pressure Sensitive Paint (PSP) to determine mean surface pressures, and Fringe Imaging Skin Friction (FISF) to determine surface skin friction magnitude and direction. A set of pathfinder experiments were also performed in a water channel on a smaller scale (5.1 cm high, 15.2 cm base diameter) sintered nylon model. The water channel test was conducted at a mean test section speed of 3 cm/s (Reynolds Number of 1500), but at the same ratio of model height to boundary layer thickness. Dye injection from both the model and an upstream rake was used to visualize the flow. This report summarizes the experimental set-up, techniques used, and data acquired. It also describes some details of the dataset that is being constructed for use by other researchers, especially the CFD community.

fluid machanics cfd validation wind tunnel↗

NASA NTRSDate not supplied

Component-Based Development of CFD Software FUN3D

FUN3D, a suite of Computational Fluid Dynamics simulation and design tools developed at the NASA Langley Research Center, has undergone continuous development since the late1980s. It contains a large portion of legacy code. Extending it with new capabilities becomes increasingly difficult. To improve the extensibility and reusability, FUN3D is moving toward component-based development. New features, such as Stabilized Finite Elements, Yoga, and Sparse Linear Algebra Toolkit, are integrated into the system as components. Some existing features such as the Node-Centered Finite Volume Solver, are also being refactored to components. The integration of these components poses new requirements on the development workflow. In this paper, we describe the Continuous Integration of FUN3D to support component-based development, and discuss the tools used, the practices followed, and lessons learned during the transition from the traditional approach.

computational fluid dynamics software↗

NASA NTRS2013

Exhaust Nozzle Plume and Shock Wave Interaction

Fundamental research for sonic boom reduction is needed to quantify the interaction of shock waves generated from the aircraft wing or tail surfaces with the exhaust plume. Both the nozzle exhaust plume shape and the tail shock shape may be affected by an interaction that may alter the vehicle sonic boom signature. The plume and shock interaction was studied using Computational Fluid Dynamics simulation on two types of convergent-divergent nozzles and a simple wedge shock generator. The nozzle plume effects on the lower wedge compression region are evaluated for two- and three-dimensional nozzle plumes. Results show that the compression from the wedge deflects the nozzle plume and shocks form on the deflected lower plume boundary. The sonic boom pressure signature of the wedge is modified by the presence of the plume, and the computational predictions show significant (8 to 15 percent) changes in shock amplitude.

Castner, Raymond S.↗

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 OSTI2023

Comparison of free vortex wake and blade element momentum results against large-eddy simulation results for highly flexible turbines under challenging inflow conditions

Abstract. Throughout wind energy development, there has been a push to increase wind turbine size due to the substantial economic benefits. However, increasing turbine size presents several challenges, both physically and computationally. Modeling large, highly flexible wind turbines requires highly accurate models to capture the complicated aeroelastic response due to large deflections and nonstraight blade geometries. Additionally, the development of floating offshore wind turbines requires modeling techniques that can predict large rotor and tower motion. Free vortex wake methods model such complex physics while remaining computationally tractable to perform key simulations necessary during the turbine design process. Recently, a free vortex wake model – cOnvecting LAgrangian Filaments (OLAF) – was added to the National Renewable Energy Laboratory's engineering tool OpenFAST to allow for the aerodynamic modeling of highly flexible turbines along with the aero-hydro-servo-elastic response capabilities of OpenFAST. In this work, free vortex wake and low-fidelity blade element momentum (BEM) results are compared to high-fidelity actuator-line computational fluid dynamics simulation results via the Simulator fOr Wind Farm Applications (SOWFA) method for a highly flexible downwind turbine for varying yaw misalignment, shear exponent, and turbulence intensity conditions. Through these comparisons, it was found that for all considered quantities of interest, SOWFA, OLAF, and BEM results compare well for steady inflow conditions with no yaw misalignment. For OLAF results, this strong agreement with the SOWFA results was consistent for all yaw misalignment values. The BEM results, however, deviated significantly more from the SOWFA results with increasing absolute yaw misalignment. Differences between OLAF and BEM results were dominated by the yaw misalignment angle, with varying shear exponent and turbulence intensity leading to more subtle differences. Overall, OLAF results were more consistent than BEM results when compared to SOWFA results under challenging inflow conditions.

17 WIND ENERGY↗

NASA NTRS2019

Minimizing Sonic Boom Through Simulation-Based Design: The X-59 Airplane

One of NASA’s six Strategic Thrusts for aeronautics is “Innovation in Commercial Supersonic Aircraft,” with a vision of fast air travel widely available to the traveling public. Future supersonic aircraft will be efficient, affordable, and environmentally responsible, generating an acceptable level of en-route noise (sonic booms). The first major step is the ongoing construction of the new X-59 Quiet SuperSonic Technology X-plane to demonstrate technologies that reduce sonic booms to gentle thumps. By using highresolution Cart3D computational fluid dynamics simulations, the shape of the aircraft can be designed to control the non-linear interactions of shock waves to reduce the sonic boom noise on the ground to within outdoor ambient levels, thereby enabling supersonic overland flight.

Nemec, Marian↗

DOE OSTI2026

Simulation of Channel Flow with Square Ribs for Blanket First-Wall Cooling: Geometry-Specific Tuning of k-ω Model Using Adjoint Method

Cooling of the plasma-facing first wall is challenging in the design of blanket components because of the high heat flux (on the order of 𝑀𝑊/𝑚2) from the plasma, especially when a low thermal mass medium like helium is chosen as the coolant. Therefore, heat transfer enhancement in which the convective heat transfer rate is augmented by the addition of turbulence-promoting structures becomes a key initiative for providing sufficient cooling capability with helium. Previously, computational fluid dynamics simulations had been performed on pipe flows with different transverse and longitudinal ribbed geometries at Oak Ridge National Laboratory to compare the enhancement performance among different ribbed geometries. Rib shape morphing had been conducted to obtain an optimized rib profile. In the work presented here, the adjoint method is adopted in the ANSYS Fluent solver for turbulence model augmentation, and the Generalized k-ω (GEKO) turbulence model is employed because of its ability of tuning the turbulence model. The Nusselt number and pressure drop obtained from the channel flow with bottom ribbed wall experiments are used as the targets. Sensitivity analysis provides information as guidance to improve the turbulence model accuracy. The augmented GEKO model is tuned for the studied ribbed channel geometry and flow conditions, providing improved predictive accuracy within this context. Extension to other configurations offers potential but may require additional tuning and validation.

Xu, Tracy [ORNL] (ORCID:0009000193700887)↗

DOE OSTI2023

Cold-cap structure in a slurry-fed electric melter

We report as glass batch is charged into an electric melter, a cold cap forms on the glass melt surface. Heat transfer to the cold cap from the molten glass below and the melter atmosphere above determines the melting rate. A mathematical model of the cold cap and the experimental kinetic data of the feed-to-glass conversion that were collected for several simulated low-activity and high-level waste melter feeds allowed us to develop relationships between the internal structure of the cold cap, its properties, its thickness, and the internal heat transfer. This contribution shows the distribution of major crystalline phases and the cumulative evolution of gases within the cold cap. It also examines the temperature, conversion degree, and heating rate the melter feed is experiencing during the passage through the cold cap and their effects on the cold-cap bottom temperature and morphology, which are important for the computational fluid dynamics simulations of melters.

36 MATERIALS SCIENCE↗

NASA NTRSDate not supplied

In Pursuit of CFD-based Wind Tunnel Calibrations

Computational fluid dynamic simulations of models tested in wind tunnels require a high level of fidelity and accuracy, particularly for the purposes of CFD validation efforts. Considerable effort is required to ensure a sufficient characterization of both the physical geometry of the wind tunnel, the thermodynamics of the tunnel, and flow conditions in the test section. The condition setting process among subsonic wind tunnels, closed or open throat, is generally the same, though they can differ in specific details of the thermodynamics. The derivation, application, and error estimation of condition setting and calibration is discussed. Computational flow solutions of the high-speed leg of the NASA Langley Research Center 14- by 22-Foot Subsonic Tunnel are used to evaluate the calibration process and discuss calibration curve sensitivities. Duplicating the characteristics of a particular wind tunnel is difficult at best. A calibration curve derived from the computational method is the most consistent method to use for tunnel condition setting.

wind tunnel↗

DOE OSTI2022

Spark-Assisted HCCI Residential CHP

A transformative small spark ignition (SI) internal combustion (IC) engine fueled with natural gas was developed for combined heat and power (CHP) applications using a combination of cycle simulations, computational fluid dynamics (CFD) modeling, and engine experiments. The resulting 1 kW CHP engine was demonstrated to achieve 36.1% brake thermal efficiency (BTE) while meeting aggressive exhaust emissions targets using a low-cost three-way catalyst. Starting from a “clean-sheet” design, modeling tools were used to select the optimal engine parameters and operating characteristics. The disruptive technologies developed for the CHP system have a target lifetime of at least 10 years. The engine cost at volume of 10,000 units was estimated to be $\$$1,050. A combination of experimental and simulation results were used to identify a path to the program target of 38.6% BTE. Base engine design parameters (i.e., displacement, speed, bore, stroke, valve timings, and compression ratio) were optimized to reduce friction, heat transfer, and exhaust losses. The base clean sheet prototype engine achieved 32% BTE. Optimization of the lube oil and coolant temperatures added 1.8% BTE. The addition of exhaust gas recirculation added 1.1% BTE. Novel thermal barrier coatings (TBCs) developed over the course of the project added 1.2% BTE. Further improvements in engine friction reduction (1.3% BTE) and improved combustion (1.2% BTE) are estimated to meet the program target 38.6% BTE, while also meeting the stringent criteria pollutant emissions targets.

42 ENGINEERING↗

NASA NTRS1996

Experimental and Computational Aerothermodynamics of a Mars Entry Vehicle

An aerothermodynamic database has been generated through both experimental testing and computational fluid dynamics simulations for a 70 deg sphere-cone configuration based on the NASA Mars Pathfinder entry vehicle. The aerothermodynamics of several related parametric configurations were also investigated. Experimental heat-transfer data were obtained at hypersonic test conditions in both a perfect gas air wind tunnel and in a hypervelocity, high-enthalpy expansion tube in which both air and carbon dioxide were employed as test gases. In these facilities, measurements were made with thin-film temperature-resistance gages on both the entry vehicle models and on the support stings of the models. Computational results for freestream conditions equivalent to those of the test facilities were generated using an axisymmetric/2D laminar Navier-Stokes solver with both perfect-gas and nonequilibrium thermochemical models. Forebody computational and experimental heating distributions agreed to within the experimental uncertainty for both the perfect-gas and high-enthalpy test conditions. In the wake, quantitative differences between experimental and computational heating distributions for the perfect-gas conditions indicated transition of the free shear layer near the reattachment point on the sting. For the high enthalpy cases, agreement to within, or slightly greater than, the experimental uncertainty was achieved in the wake except within the recirculation region, where further grid resolution appeared to be required. Comparisons between the perfect-gas and high-enthalpy results indicated that the wake remained laminar at the high-enthalpy test conditions, for which the Reynolds number was significantly lower than that of the perfect-gas conditions.

Hollis, Brian R.↗

NASA NTRSDate not supplied

Computational Aerodynamics Study of the Lift+Cruise VTOL Concept Vehicle Components

This paper describes a building-block approach for high-fidelity computational fluid dynamic simulations of NASA’s Lift+Cruise (L+C) Vertical Take-off and Landing (VTOL) concept vehicle. The Reynolds-Averaged Navier-Stokes (RANS) equations are solved on overset structured grids using OVERFLOW. For these analyses, overset meshes are generated using recently developed automated meshing tools. A baseline study is initially performed on the vehicle fuselage with wings and tails. Vehicle components such as pylons and gears are then added individually and together to study incremental component aerodynamic effects. The results from this study are also used to demonstrate the capabilities of the automatic meshing tools for performing rapid computational analyses.

RVLT↗

DOE OSTI2021

Thermal-striping analysis methodology for sodium-cooled reactor design

Computational fluid dynamics simulations have been performed to study the applicability of engineering CFD methods for thermals striping analysis. Thermal striping is the fluctuating temperature profile in a solid caused by fluctuating fluid temperature, and the resulting fluctuating thermal stresses cause high cycle fatigue and eventual material failure. Here this study presents the methodology for thermal striping analysis that including a transient conjugate heat transfer RANS model and benchmark the results against a sodium triple jet experiment. The multiphysics calculations are implemented to analyze the thermal stresses in the solid domain caused by the coupled heat transfer between the fluid and solid domains. Validation data from a liquid sodium triple jet experiment include time-averaged temperature measurements and power spectra of the temperature signal. The numerical results agree well with these experimental measures, demonstrating key features such as the dominant frequency of temperature fluctuations. The applicability of a low-cost wall treatment method is demonstrated, enabling key computational savings. Finally, the performance of two finite element stress analysis software packages is compared, and the validity of the lower-cost method is confirmed. These results demonstrate the applicability of engineering methods for computational thermal striping calculations, enabling thermal striping estimations in large fluid systems such as the core of a Sodium-cooled nuclear reactor.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2024

A three-dimensional model of terrain-induced updrafts for movement ecology studies

Abstract Background Spatially explicit simulation models of animal movements through the atmosphere necessarily require a representation of the spatial and temporal variation of atmospheric conditions. In particular, for movements of soaring birds that rely extensively on vertical updrafts to avoid flapping flight, accurate and reliable estimation of the vertical component of wind is critical. The interaction between wind and complex terrain shapes both the horizontal and vertical wind fields, highlighting the need to model the coupling between local terrain features and atmospheric conditions at scales relevant to animal movement. Methods In this work, we propose a new empirical model for estimating the orographic updraft field. The model is developed using computational fluid dynamics simulations of canonical atmospheric conditions over moderately complex terrain. To isolate buoyancy and thermal effects, and focus on terrain-induced effects, we use only simulations of a neutrally stratified atmosphere to develop the model. The model, which we name Engineering Vertical Velocity Estimator (EVVE), is simple to implement and is a function of the underlying terrain elevation map, the desired height above ground level (AGL), and wind conditions at a reference height (80 m). We validate the model with data from the Alaiz mountain (Spain) field campaign. Results Compared to observations, the proposed improved model estimates the updrafts at 120 m AGL with a mean error of 0.11 m/s ( $$\sigma =0.28$$ σ = 0.28 m/s), compared to 0.85 m/s ( $$\sigma =0.58$$ σ = 0.58 m/s) for its baseline. For typical land-based wind turbine hub heights of 80 m AGL, the proposed model has a mean error of 0.04 m/s ( $$\sigma =0.25$$ σ = 0.25 m/s), compared to baseline 0.54 m/s ( $$\sigma =0.45$$ σ = 0.45 m/s) estimations. We illustrate an application of the model in movement ecology by comparing simulated tracks and presence maps of golden eagles ( Aquila chrysaetos ) moving across two distinct landscapes. The tracks and presence maps are obtained using a simple heuristic-based movement model, with the updraft field given by the proposed model and a wind vector-based estimation approach that is currently in wide use in movement ecology studies of raptors and other soaring birds. Conclusions We highlight that movement model results can be sensitive to the underlying orographic updraft model, especially in studies of fine-scale movements in regions of complex topography. We suggest adopting the proposed model rather than the wind vector estimation method for studies of soaring bird movements.

17 WIND ENERGY↗

NASA NTRS2001

Factors Influencing Lava-Substrate Heat Transfer and Implications for Thermomechanical Erosion

We develop numerical simulations of basaltic lava flowing laminarly over a basalt substrate in order to examine the details of the lava dynamics and thermal boundary layers and to understand the implications for substrate heating. As the initial stage of a larger study of thermomechanical erosion in different planetary environments, we aim to understand why erosion occurs on Earth, why erosion features are not ubiquitous given the high temperatures involved, and whether it is a plausible mechanism for the formation of planetary channels such as lunar sinuous rilles and Venusian canali. Here we confine our attention to terrestrial lavas with well-known properties and eruption parameters. With relatively simple computational fluid dynamic simulations, most closely representing tube-fed hawaiian basalts (for which erosion has been documented), we demonstrate the importance of incorporating several key factors in models of lava flow/ substrate heat transfer, which have commonly been neglected in previous treatments. By addressing the interaction of the flow dynamics and heat transfer in the lava, our work suggests that the development of a temperature gradient in the base of the lava, even for undeveloped flow, has a significant influence on substrate temperature. The sensitivity of the lava-substrate interface temperature to the thermophysical properties of the lava and substrate suggests that a delicate balance is required for partial melting to occur. Thus, it might take weeks of continuous flow to initiate partial melting of the substrate at distances of several kilometers from the vent. These durations exceed the periods of stability typical of lava flowing in tubes; pauses, blockages, surges, and break-outs frequently disrupt the flow. However, natural irregularities in the flow dynamics or substrate topography might help to initiate and maintain substrate melting on shorter timescales by disturbing the intimately coupled dynamic and thermal boundary layers. Although a purely thermal mechanism cannot be ruled out, our findings support the premise that mechanical erosion may play a key role in reports of erosion based on field evidence.

Fagents, S. A.↗

NASA NTRSDate not supplied

Computational Assessment of the Impact of Wave Count on Rotating Detonation Engine Performance

The impact of the number of azimuthally propagating waves on the performance of a Rotating Detonation Engine (RDE) is investigated using a simplified two-dimensional computational fluid dynamic simulation. The basic RDE configuration examined has no exit throat. The inlet is assumed lossless and does not allow backflow. The adiabatic, inviscid, and premixed simulation utilizes a particularly simple finite rate reaction mechanism that allows user control over the relative amounts of deflagration and detonation that occur, the presence and extent of a reaction delay associated with fuel and oxidizer mixing, and the number of waves present in the domain. The simplifications and idealizations decouple the effect of wave count from other potential loss mechanisms. Performance is measured using exhaust flow total pressure gain relative to the inlet total pressure. One, two, and three wave solutions are computed under identical boundary conditions and grid resolution. For simulations with no mixing delay and minimal deflagration, the number of waves present has negligible impact on performance. With a mixing delay, performance decreases with increasing wave number. With increased deflagration, performance increases with increasing wave number. With both effects simulated it is found that the two wave solution performs better than either the one or three wave solutions. The causes of these trends are explored. They imply that for practical, RDE’s, the number of waves that are present can impact performance.

Detonation↗

NASA NTRSDate not supplied

Computational Assessment of the Impact of Wave Count on Rotating Detonation Engine Performance

Detonation↗