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All sources NASA NTRS DOE OSTI

DOE OSTI2019

Integrated Liquid Metal Flowing First Wall and Open-Surface Divertor for Fusion Nuclear Science Facility: Concept, Design, and Analysis

The Fusion Energy System Studies (FESS) Fusion Nuclear Science Facility (FNSF) project team in the United States is examining the use of liquid metals (LMs) for plasma-facing components (PFCs). Our approach has been to utilize an already established fusion design, FESS-FNSF, which is a tokamak-based machine with 518 MW fusion power, a 4.8-m major radius, a 1.2-m minor radius, and a machine average neutron wall loading of ~1 MW/m 2 . For this design, we propose a PFC concept that integrates a flowing LM first wall (FW) and an open-surface divertor. The flowing LM first removes the surface heat flux from the FW and then proceeds to the lower section of the vacuum chamber to form a large area LM surface for absorbing high peak surface heat flux in the divertor region. In pursuing the application of large open LM surfaces in the FNSF, two new computer codes have been developed and then applied to the analysis of free-surface magnetohydrodynamic flows and heat transfer, including fast thin flowing liquid layers over the solid FW (liquid wall), a tublike divertor, and a fast flow divertor. The analysis is aimed at optimization of the liquid wall design by matching certain proposed design criteria and also at evaluation of the maximum heat fluxes, using liquid lithium (Li) as a working fluid. It was demonstrated that the flowing Li FW (at ~2 cm and ~10 m/s) can tolerate a surface heat flux of ~1 MW/m 2 , while the open-surface Li divertor can remove a maximum high peak heat flux of 10 MW/m 2 . Furthermore, the paper also focuses on the underlying science. One such example is the evaluation and characterization of heat transfer mechanisms and heat transfer intensification in the tublike Li divertor.

36 MATERIALS SCIENCE↗

DOE OSTI2023

Combining synchrotron X-ray diffraction, mechanistic modeling and machine learning for in situ subsurface temperature quantification during laser melting

Laser melting, such as that encountered during additive manufacturing, produces extreme gradients of temperature in both space and time, which in turn influence microstructural development in the material. Qualification and model validation of the process itself and the resulting material necessitate the ability to characterize these temperature fields. However, well established means to directly probe the material temperature below the surface of an alloy while it is being processed are limited. To address this gap in characterization capabilities, a novel means is presented to extract subsurface temperature-distribution metrics, with uncertainty, from in situ synchrotron X-ray diffraction measurements to provide quantitative temperature evolution data during laser melting. Temperature-distribution metrics are determined using Gaussian process regression supervised machine-learning surrogate models trained with a combination of mechanistic modeling (heat transfer and fluid flow) and X-ray diffraction simulation. The trained surrogate model uncertainties are found to range from 5 to 15% depending on the metric and current temperature. The surrogate models are then applied to experimental data to extract temperature metrics from an Inconel 625 nickel superalloy wall specimen during laser melting. The maximum temperatures of the solid phase in the diffraction volume through melting and cooling are found to reach the solidus temperature as expected, with the mean and minimum temperatures found to be several hundred degrees less. The extracted temperature metrics near melting are determined to be more accurate because of the lower relative levels of mechanical elastic strains. However, uncertainties for temperature metrics during cooling are increased due to the effects of thermomechanical stress.

36 MATERIALS SCIENCE↗

DOE OSTI2021

Ducted Assembly Steady-State Heat Transfer Software (DASSH)

The Ducted Assembly Steady-State Heat transfer software (DASSH) is being developed at Argonne National Laboratory to perform a steady-state thermal fluids calculation to determine the coolant flow and temperature distribution for a hexagonal reactor core configuration with ducted assemblies. DASSH is intended to be used in the early stages of the reactor design process when assembly components can be undefined or are undergoing considerable design changes. DASSH provides a rapid assessment of the temperature and flow distribution to allow quick characterization of the system and identification of problem areas. This document is a guide for DASSH users. It summarizes the core capabilities of DASSH and highlights differences between DASSH and SE2-ANL. Instructions for obtaining and installing DASSH are provided along with some guidelines and recommendations for newer Python users. It covers the structure of the input file, provides directions for running DASSH, describes the various output files produced by the code, and provides instructions for visualizing data. Examples demonstrating various DASSH options are included. DASSH is under active development, so it is anticipated that this guide will grow and evolve as the code is updated.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2023

Model-based quantification of margins and uncertainties in metal additive manufacturing for process design and qualification

Laser powder bed fusion (LPBF) Additive Manufacturing (AM) has the potential to enable the production of components with novel designs and material properties unachievable otherwise. However, process repeatability is a challenge, making qualification ill-defined and greatly reducing the utility of what could be an important manufacturing technology. In this work, a combination of modeling, uncertainty quantification (UQ), and experimentation are used in an effort to predict and bound the range of possible outcomes of the LPBF process. Quantities of interest predicted are melt pool dimensions, microstructure features, and mechanical distortions. A combination of high fidelity thermal-fluid models, microstructure growth models, and reduced fidelity, rapid thermal and mechanical models are used. Uncertainty propagation techniques are used to predict probability distributions of quantities of interest from estimates of process uncertainties. Repeated experiments are done to quantify observed probability distributions and compared to predicted distributions to determine if predictions are precise and accurate. Novel modeling methods are microstrucutre characterization techniques are also discussed. It is found that high fidelity models do a generally good job bounding experimentally observed melt pool morphologies for both bead-on-plate and powder bed cases. Microstructure models are able to bound a number of experimentally observed microstructure statistics, but with low precision due to challenges with calibrating the microstructure growth model parameters. A developed modified inherent strain distortion model does not accurately predict observed distortions. A lumped laser distortion model shows promise in being both accurately and precisely bounding observed outcomes from the deflection comb build, but requires further evaluation on more builds and geometries.

36 MATERIALS SCIENCE↗

NASA NTRS1973

Photogeologic mapping of Meridiani Sinus region from Mariner 6 and 7 imagery

Photogeologic mapping of Mariner photographs characterizes major stratigraphic units of the Martian equatorial region. The low resolution photomosaic ship across Meridiani Sinus Deucalionus Regio is divided into regional map units based on albedo and crater density. High resolution frames reveal map units defined by varying surface texture, crater densities, and degree of crater sharpness. Mariner photographs provide clear evidence of eolian action and channelization by fluid flow.

Dehon, R. A.↗

NASA NTRS1997

Noise and Dynamical Pattern Selection in Solidification

The overall goal of this project was to understand in more detail how a pattern-forming system can adjust its spacing. "Pattern-forming systems," in this context, are nonequilibrium contina whose state is determined by experimentally adjustable control parameter. Below some critical value of the control system then has available to it a range of linearly stable, spatially periodic steady states, each characterized by a spacing which can lie anywhere within some band of values. These systems like directional solidification, where the solidification front is planar when the ratio of growth velocity to thermal gradient is below its critical value, but takes on a cellular shape above critical. They also include systems without interfaces, such as Benard convection, where it is the fluid velocity field which changes from zero to something spatially periodic as the control parameter is increased through its critical value. The basic question to be addressed was that of how the system chooses one of its myriad possible spacings when the control parameter is above critical, and in particular the role of noise in the selection process. Previous work on explosive crystallization had suggested that one spacing in the range should be preferred, in the sense that weak noise should eventually drive the system to that spacing. That work had also suggested a heuristic argument for identifying the preferred spacing. The project had three main objectives: to understand in more detail how a pattern-forming system can adjust its spacing; to investigate how noise drives a system to its preferred spacing; and to extend the heuristic argument for a preferred spacing in explosive crystallization to other pattern-forming systems.

Kurtze, Douglas A.↗

NASA NTRSDate not supplied

Investigation of Liquid Fuel Refill Dynamics in a Rotating Detonation Combustor using Megahertz Planar Laser-Induced Fluorescence

Direct imaging of liquid fuel injection is performed within an optically accessible rotating detonation combustor (RDC) using planar laser-induced fluorescence (PLIF) to spatio-temporally resolve the highly dynamic spray characteristics at rates up to 1 MHz. The RDC is operated on air and hydrogen to sustain a stable, cyclically propagating detonation wave with cycle periods of up to ∼250 μs. One of the hydrogen fuel injection sites is replaced with a liquid jet to introduce a diesel spray as a fuel surrogate to enable tracer-free fluorescence excitation using the 355 nm third-harmonic output of a burst-mode Nd:YAG laser. The time-resolved PLIF measurements reveal the evolution of the highly unsteady spray, including the dwell period after the arrival of the detonation wave, the jet recovery, breakup and entrainment into the supersonic crossflow of air, propagation into the detonation chamber, and interaction with the detonation wave. Following passage of the detonation wave, the spray characteristics reveal significant changes in the momentum flux ratio between the liquid and air streams, altering the jet trajectory and temporarily halting fuel delivery to the detonation channel. This temporary cessation of fuel spray injection into the combustor is quantified, along with the fill rate as a function of time. As the injection system recovers, the fuel spray eventually returns to a quasi-steady position prior to the arrival of the detonation wave, allowing qualitative comparisons with theoretical jet trajectories for a range of air mass-flux conditions. These data, enabled by ultra-high-speed PLIF imaging, represent some of the first detailed measurements for characterizing and quantifying the interactions of liquid jets and detonations in an operating RDC.

Propulsion↗

DOE OSTI2018

Simulating the Effect of Fracture Connectivity on Repository Performance with GDSA Framework - 18589

This work examines the possible migration of radionuclides from a deep geologic nuclear waste repository sited in fractured crystalline host rock. The key safety concern is the potential effect on waste isolation of the inter-connectivity of the fracture network, which is primarily established by the temporal evolution of the temperature and stress fields at the time of original rock intrusion and cooling. Two end members are considered in these simulations, one with a high degree of connectivity to the biosphere, such that advective transport through the fracture and fault network controls radionuclide migration, and the other with a low degree of connectivity, such that slow diffusive transport through the crystalline rock matrix is the controlling process for radionuclide migration to the biosphere. Both end members have several areally extensive, high-transmissivity deformation zones, whose distance to the repository is an important factor for waste isolation capability. Uncertainties in fracture properties (transmissivity, orientation, radius) and fracture distribution also give rise to uncertainty in waste isolation capability (i.e., the overall connectivity of the repository with the surface biosphere). These types of natural system uncertainties are generally present in any geologic site-characterization program and thus represent an important factor in assessing repository performance in hard rock environments. The waste considered in these simulations are spent fuel rod assemblies from the U.S. commercial nuclear reactor fleet. Thermal output of the waste must be considered in the simulations and can influence the rate and timing of waste package failure, waste form degradation, and fluid flux due to thermal expansion around the repository horizon. To achieve a high-fidelity representation of radionuclide transport in fractures and rock matrix, combined with thermal energy transport and fluid flow in fractures and matrix, the mathematical model is solved numerically in a parallel high-performance computing (HPC) environment on a finite volume unstructured grid consisting of approximately 5 million cells, using Geologic Disposal Safety Assessment (GDSA) Framework (https://pa.sandia.gov), an open-source performance assessment tool for deep underground disposal of nuclear waste. GDSA Framework uses PFLOTRAN to solve the balance equations on a three-dimensional grid with heterogeneous properties, using multiple processors in a parallel configuration based on domain decomposition. The fracture networks in these simulations are originally generated as discrete fracture networks (DFNs), which are sets of two-dimensional planes distributed in a three-dimensional domain. The method used in GDSA Framework maps the stochastically generated DFN to an equivalent continuous porous medium (ECPM) domain that allows for the simulation of coupled heat flow, fluid flow, and radionuclide transport, including heat conduction through the matrix of the fractured rock, which is a process not easily modeled in a DFN representation. Computational efficiency is also greatly enhanced using the ECPM method, allowing for a realistic representation and analysis of uncertainties in a multi-realization performance assessment of a deep geologic repository. The effect of fracture connectivity on the waste isolation safety function, as brought to light by these GDSA Framework simulations, points to the importance of including a realistic representation of uncertainties in fracture properties and distribution (effectively, uncertainty in spatial heterogeneity) in repository safety assessment simulations. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2016

Development and characterization of an ice-selecting pumped counterflow virtual impactor (IS-PCVI) to study ice crystal residuals

Separation of particles that play a role in cloud activation and ice nucleation from interstitial aerosols has become necessary to further understand aerosol-cloud interactions. The pumped counterflow virtual impactor (PCVI), which uses a vacuum pump to accelerate the particles and increase their momentum, provides an accessible option for dynamic and inertial separation of cloud elements. However, the use of a traditional PCVI to extract large cloud hydrometeors is difficult mainly due to its small cut-size diameters (< 5 µm). Here, for the first time we describe a development of an ice-selecting PCVI (IS-PCVI) to separate ice in controlled mixed-phase cloud system based on the particle inertia with the cut-off diameter ≥ 10 µm. We also present its laboratory application demonstrating the use of the impactor under a wide range of temperature and humidity conditions. The computational fluid dynamics simulations were initially carried out to guide the design of the IS-PCVI. After fabrication, a series of validation laboratory experiments were performed coupled with the Aerosol Interaction and Dynamics in the Atmosphere (AIDA) expansion cloud simulation chamber. In the AIDA chamber, test aerosol particles were exposed to the ice supersaturation conditions (i.e., RH ice > 100 %), where a mixture of droplets and ice crystals was formed during the expansion experiment. In parallel, the flow conditions of the IS-PCVI were actively controlled, such that it separated ice crystals from a mixture of ice crystals and cloud droplets, which were of diameter ≥ 10 µm. These large ice crystals were passed through the heated evaporation section to remove the water content. Afterwards, the residuals were characterized with a suite of online and offline instruments downstream of the IS-PCVI. These results were used to assess the optimized operating parameters of the device in terms of (1) the critical cut-size diameter, (2) the transmission efficiency and (3) the counterflow-to-input flow ratio. Particle losses were characterized by comparing the residual number concentration to the rejected interstitial particle number concentration. Overall results suggest that the IS-PCVI enables inertial separation of particles with a volume-equivalent particle size in the range of ~ 10–30 µm in diameter with small inadvertent intrusion (~  5 %) of unwanted particles.

54 ENVIRONMENTAL SCIENCES↗

NASA NTRS1990

Characterization of blood drawn rapidly for use in blood volume expansion studies: An animal model for simulated weightlessness

It was demonstrated that up to 8ml of blood can be drawn from donar rats without significantly increasing volume and stress sensitive hormones, and thus can be used for volume expansion studies. Infusion of whole blood allows more physiological changes that can be seen with volume expansion by saline or other ionic solutions. The infusion of whole blood to induce hypervolemia may provide an improved model to study the fluid balance and control mechanisms operative in weightlessness. Blood samples were drawn as quickly as possible from femoral artery catheters chronically implanted in Sprague Dawley rats and analyzed for hematocrit, plasma sodium, potassium, osmolality, corticosterone, epinepherine, norepinephrine, and vasopressin. The levels were found to be comparable to those of normal rats.

Chenault, V. Michelle↗

DOE OSTI2017

Transport dynamics of self-consistent, near-marginal drift-wave turbulence. II. Characterization of transport by means of passive scalars

From theoretical and modeling points of view, following Lagrangian trajectories is the most straightforward way to characterize the transport dynamics. In real plasmas, following Lagrangian trajectories is difficult or impossible. Using a blob of passive scalar (a tracer blob) allows a quasi-Lagrangian view of the dynamics. Using a simple two-dimensional electrostatic plasma turbulence model, this work demonstrates that the evolution of the tracers and the passive scalar field is equivalent between these two fluid transport viewpoints. When both the tracers and the passive scalar evolve in tandem and closely resemble stable distributions, namely, Gaussian distributions, the underlying turbulent transport character can be recovered from the temporal scaling of the second moments of both. This local transport approach corroborates the use of passive scalar as a turbulent transport measurement. The correspondence between the local transport character and the underlying transport is quantified for different transport regimes ranging from subdiffusive to superdiffusive. In conclusion, this correspondence is limited to the initial time periods of the spread of both the tracers and the passive scalar in the given transport regimes

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2022

Development of an Integrated Electro-Hydraulic Machine to Electrify Off-highway Vehicles

Electrification of off-highway vehicles is notoriously challenging due to extreme power density requirements. This paper proposes and develops an axial flux machine integrated with a hydraulic pump to realize a single modular, electro-hydraulic machine to electrify off-highway vehicle implements. This integrated machine eliminates redundant bearings, couplings, and shaft seals, re-uses surfaces, and enables direct cooling of the electric machine with the hydraulic fluid, to significantly increase power density. Three popular axial flux machine variants are first compared using an FEA-based design optimization approach. The single rotor, single stator variant is identified to be the most promising for integration with the hydraulic pump. Next, a multi-physics framework of the complete integrated hydraulic pump and axial flux machine is developed to characterize the design space. The results indicate promising potential for this concept to realize efficiency over 85% and power density over 5kW/kg for the complete machine (electric machine, hydraulic pump, and thermal management system), while utilizing conventional materials (thin gauge silicon steel, N45 magnets, and enamelled copper wire). Furthermore, a prototype axial flux machine has been experimentally characterized and integrated with a hydraulic pump to demonstrate the integrated electro-hydraulic machine concept.

33 ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2020

Comparison of Single-Phase Convection in Additive Manufactured Versus Traditional Metal Foams

Abstract Metal foams have been often used for thermal management due to their favorable characteristics including high specific surface area (SSA), high thermal conductivity, and low relative density. However, they are accompanied by shortcomings including the significant contact resistances due to attachment method, as well as the need for characterization of foam parameters such as pore diameter and SSA. Additive manufactured (AM) metal foams would eliminate the substrate/foam thermal resistance, decrease the need for pre-usage characterization, and allow for tailoring structures, while also taking advantage of the characteristics of traditionally manufactured foams. A commercial, aluminum foam (nominally 5 pores per inch (PPI), 86.5% porosity) was analyzed using X-ray microcomputed tomography, and a custom-designed metal foam based on the cell diameter and porosity of the commercial sample was subsequently manufactured. Reduced domain computational fluid dynamics/heat transfer (CFD-HT) models were compared against experimental data. Postvalidation, the flow behavior, effect of varying attachment thermal conductivities, and thermal performance were numerically investigated, demonstrating the usefulness of validated pore-scale models, as well as the potential for improved performance using AM metal foams over traditionally manufactured foams.

Engineering↗

DOE OSTI2014

Thermodynamic Assessment of the Ternary Alloy System Li-Sn-Zn

The goal of this project is to predict thermodynamics and structure-properties relationships of a series of Li-based alloys for the development of advanced tritium breeding materials that exhibit the beneficial properties of pure lithium while mitigating its chemical reactivity issues for fusion applications. This project makes use of phenomenological thermodynamics based on the CALPHAD (CALculation of PHAse Diagrams), and the use of the Thermo-Calc software (see Appendix A), and experimental calorimetric data and structural characterization for the purpose of validating the data. The initial selection of Sn and Zn as solutes is considered in this first report. Originally Li-Sn alloys have shown promise in meeting tritium breeding ratio (TBR) and energy multiplication requirements. However with the addition of Zn, we expect an improvement in the nuclear, thermal, and chemical requirements of the working fluid. Other substitutes will be considered once neutronic calculations are carried out. Hence the objective of this first task is to carry out a thermodynamic assessment of the Li-Sn-Zn alloy system, as part of the development of a self-consistent and validated thermodynamic database that will include other solute elements for optimizing the properties of blanket materials in fusion-based reactors. This obviously involves the thermodynamic assessment of the three binary subsystems, namely Li-Sn, Li-Zn, and Sn-Zn.

36 MATERIALS SCIENCE↗

DOE OSTI2023

Earth Sciences Applications for Energy and Global Security: A Few Vignettes [Slides]

Understanding the physics of flow and transport in the subsurface environment is crucial to several National Security applications. In the Energy Security realm, some examples include characterizing radioactive waste disposal, exploring natural gas extraction and sequestering CO2. An example in the Global Security arena is to be able to distinguish between anthropogenic and naturally occurring seismic disturbances, the former being of particular concern as underground nuclear testing activity has seen an increase in recent years. A common theme across these applications is the ability to accurately model fluid flow in porous and/or fractured subsurface media. For decades, researchers have grappled with how to include the effects of uncertainties in these models, including but not limited to heterogeneity, unknown initial and boundary conditions and issues with scalability. More recently advances in computing and machine learning methodologies have allowed a broader exploration of the uncertainty space as we strive for real time decision making. I will present an overview of the field and discuss a few examples of how my own research in these topics has evolved over nearly two decades.

58 GEOSCIENCES↗

NASA NTRS1988

BEM for wave equation with boundary in arbitrary motion and applications to compressible potential aerodynamics of airplanes and helicopters

The wave equation for an object in arbitrary motion is investigated analytically using a BEM approach, and practical applications to potential flows of compressible fluids around aircraft wings and helicopter rotors are considered. The treatment accounts for arbitrary combined rotational and translational motion of the reference frame and for the wake motion. The numerical implementation as a computer algorithm is demonstrated on problems with prescribed and free wakes, the former in compressible flows and the latter for incompressible flows; results are presented graphically and briefly characterized.

Morino, Luigi↗

NASA NTRS1992

Experimental studies of characteristic combustion-driven flows for CFD validation

A series of rocket-related studies intended to develop a suitable data base for validation of Computational Fluid Dynamics (CFD) models of characteristic combustion-driven flows was undertaken at the Propulsion Engineering Research Center at Penn State. Included are studies of coaxial and impinging jet injectors as well as chamber wall heat transfer effects. The objective of these studies is to provide fundamental understanding and benchmark quality data for phenomena important to rocket combustion under well-characterized conditions. Diagnostic techniques utilized in these studies emphasize determinations of velocity, temperature, spray and droplet characteristics, and combustion zone distribution. Since laser diagnostic approaches are favored, the development of an optically accessible rocket chamber has been a high priority in the initial phase of the project. During the design phase for this chamber, the advice and input of the CFD modeling community were actively sought through presentations and written surveys. Based on this procedure, a suitable uni-element rocket chamber was fabricated and is presently under preliminary testing. Results of these tests, as well as the survey findings leading to the chamber design, were presented.

Santoro, R. J.↗

NASA NTRS1993

Examination of nonequilibrium effects in an ionized nitrogen flow

A thermo-chemical nonequilibrium ionized nitrogen flow in a shock tube is examined. A one-dimensional computational fluid dynamics code has been developed to study the flowfield incorporating a novel treatment of the electron energy equation. In the present approach, the electron pressure is included in the electron energy flux. In contrast, previous work has removed this term from the flux to facilitate the flux splitting. The code uses a five-species gas model for ionized nitrogen characterized by translational-rotational, vibrational, and electron-electronic temperatures. The results give good agreement with experimental data except for an inadequacy in the electronic source terms. A small difference is observed between the new and old splittings which increases with higher levels of ionization.

Hatfield, John A.↗