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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 19 records
All sourcesNASA NTRSDOE OSTI
DOE OSTI2026

Filament extension atomizers: A study of integration potential into spray dryers for high-viscosity and non-Newtonian fluids

Filament extension atomizers (FEAs) are an emerging class of spray nozzles designed to atomize high-viscosity and non-Newtonian fluids that are challenging for conventional pressure or two-fluid nozzles. In this study, we investigate the influence of roller geometry, surface velocity, roller material, and fluid rheology on the atomization performance of FEA systems using concentrated whey protein suspensions (50–70 wt. %). Extensional and shear rheology experiments, along with high-speed imaging and particle image velocimetry, reveal that filament breakup dynamics are governed by competition between inertial, capillary, and viscoelastic stresses. High roller rotational velocity leads to narrower spray cones, contradicting rheology experiments and suggests a significant inertial contribution to filament breakup. Smaller rollers operating at the same rotational velocity led to broader spray cones consistent with expectations. An FEA nozzle was integrated into a conventional dryer producing particles in the 100 μm range. Results suggest that FEA technology enables atomization of highly viscous fluids at industrially relevant spray cone angles similar to those generated by pressure nozzles, offering a pathway to improve energy efficiency in spray drying by enabling higher solids loading feedstocks. Furthermore, these insights provide critical guidance for optimizing FEA nozzle designs and process parameters across a range of applications.

Energy efficiency↗
NASA NTRS1956

Friction factors for flow of non-newtonian materials in pipelines

In many industries, non-Newtonian material, such as oils, lubricants, foods, cosmetics, and solid-liquid suspensions, are passed through pipelines during manufacture, application, or transportation. For the proper design of the pipelines, and evaluation of the flow resistance of the materials when flowing in these pipelines is essential. The pressure loss Δ p , due to a material flowing through a straight pipeline can be expressed as a function of a friction factor, φ, so that Δ p = ( pv 2 )/2 L/D φ where φ is a function of the flow properties of the material v is the mean velocity of the material and can be determined from the mas-flow rate, L is the length and D is the diameters of the pipeline, and p is the density of the material. The purpose of this paper is to present a generalized friction diagram, which can be used to determine φ for any material and flow condition, provided the flow properties of the material and the mean flow velocity in the pipeline are known. In composing this diagram generous use is made of the literature and only parts of the diagram and the presentation can claim originality.

Ruth N Weltmann↗
DOE OSTI2025

Compositing and Characterization of SE Quadrant Waste Exemplars

This report outlines the experimental investigation and characterization of transport properties in Hanford SE quadrant High-Level Waste (HLW). The goal of the study was to establish baseline behaviors of bulk composite rheology and settling characteristics to facilitate waste treatment process design for the Waste Treatment and Immobilization Plant (WTP) and avoid waste conditions and properties favorable to bubble cascade gas release events. The study focused on two major objectives: 1) identifying, obtaining, and preparing relevant Hanford tank waste samples for evaluation and 2) quantifying the “as-received” rheology and transport properties of the samples. Twenty-three centrifuged core segments originating from tanks AN-101, AN-106, and AW-105 were selected based on compositional relevance to SE quadrant PUREX cladding waste. These materials were composited into five waste composites enriched with target analytes: aluminum (Al), iron (Fe), phosphate (PO 4 ), uranium (U), and zirconium (Zr). Physical property and transport testing examined particle size distributions, bulk densities, settling behaviors, rheological properties, shear strengths, and just-suspended mixing speeds (NJS). Testing revealed two distinct composite classifications based on rheological characteristics: non-Newtonian composites (Fe and PO 4 ) and Newtonian composites (Al, U, and Zr). The Fe and PO 4 composites exhibited slow settling rates and reduced mobilization proclivity, attributable to strong particle-particle interactions and the formation of yield structures within non-Newtonian slurries. In contrast, the Al, U, and Zr composites displayed rapid settling and dense compaction behaviors, indicative of minimal structuring and interactions. Shear strengths for all composites were generally low relative to prior studies of SE quadrant waste, with only the U composite showing elevated strength approaching values reported in previous literature. Repeat shear strength measurements revealed contributions from dense granular material in the U composite and stronger cohesive properties in the Al composite. Settling data highlighted hindered settling behavior, with rates falling more than one order of magnitude below estimates based on Stokes’ law and rate decreasing as composite UDS content increased. NJS testing demonstrated different mobilization behaviors between cohesive and granular composites. The Fe composite required the highest mixing rate for resuspension, while the Al composite was the easiest to resuspend. Comparison of measured NJS against predictions made using the Zwietering correlation suggests non-Newtonian behavior alters resuspension mechanics, rendering non-Newtonian systems more stable against resuspension lift forces relative to their granular counterparts.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2026

Insights into mixing of non-isothermal multi-polymer melts for complex plastics recycling

Catalytic recycling or upcycling of plastics is often limited not by catalyst performance, but by transport, arising from highly viscous, non-Newtonian polymer melts. In this work, we develop a reactor-scale framework that integrates rheological measurements, constitutive modeling, computational fluid dynamics (CFD), and experiments to quantify mixing, heat transfer, and dispersion in surrogate hydrocarbon melts representing mixed plastics systems. Temperature- and shear rate-dependent viscosity of low-density polyethylene (LDPE) and high-density polyethylene (HDPE) is measured to create two surrogate polymers (PLD and PHD) that capture the dominant shear-thinning flow behavior while neglecting strong elastic effects, enabling tractable simulation of non-isothermal, polymer-melt mixing using a Carreau-Arrhenius generalized Newtonian framework. Three-dimensional CFD simulations are employed to evaluate impeller performance in PLD using mixing time, cavern volume, thermal uniformity, and interfacial area for regimes in which viscoelastic effects are not dominant. We show that magnetic stir bars commonly used in lab-scale studies produce large thermal gradients (~60 °C) and poor mixing, even under idealized power delivery and polymer flow conditions. In contrast, close-clearance anchor impellers achieve near-isothermal operation, reduce mixing times by up to 5×, and provide >90% active circulation volume. We further demonstrate that, at low pseudo-Deborah number (De*), motor power requirements can be predicted directly from shear rate-dependent rheology using the Carreau-Arrhenius framework, enabling rational selection of operating conditions. Extension to surrogate immiscible multi-polymer systems based on PLD and PHD shows that interfacial area is highly sensitive to operating conditions and impeller design, with coaxial anchor-turbine configurations enhancing dispersion by up to 4 × .

Close-clearance impellers↗
DOE OSTI2025

Tomographic Volumetric Additive Manufacturing of Silica Glass with In Situ Error Calculation and Projection Tiling

The optical, thermal, and chemical properties of glass make it an ideal material for use in a wide range of applications, from optics and chemistry reactionware to consumer products. Tomographic volumetric additive manufacturing (tVAM) creates 3D objects by selectively gelling material within a rotating vial of photo-sensitive material by exposure to a series of tomographically-determined images. Here, in this study, tVAM is investigated for fabrication of complex, centimeter-scale, 3D silica glass parts. By optimizing the post-processing procedure, fully-dense glass parts with up to 2 cm 2 cross sectional area are achieved. The changes in optical properties during printing are leveraged for in situ metrology during printing, and the non-Newtonian nature of the glass-filled photoresin system to facilitate larger fabrication volumes via tiled projections. Printed structures are finally demonstrated for applications as MEMS components, optics, fluidics, and consumer products.

Materials science↗
DOE OSTI2025

Nucleation rate controlled grain boundary and lattice creep

Nucleation versus diffusion rate-limited bicrystal and single crystal creep exhibit different scaling dependencies that enable the mechanisms to be isolated when measured as a function of sample size. It has recently been suggested that nucleation rate-limited kinetic models generally describe the non-Newtonian portion of the creep response well, but more direct evidence is required. This work analyzes the grain boundary creep response of UO 2 , a pyrochlore high entropy oxide, silver, and palladium, along with the lattice creep of silver using small-scale in situ loading in the transmission electron microscope. At small sizes, each system exhibits scale dependence associated with nucleation rate-limited kinetics. Fits of the data produce activation volumes on the order of a few Burgers vectors cubed with positive temperature coefficients as expected for nucleation kinetics. The activation enthalpies fall in the range of about 0.4 eV to 1.7 eV, being lower for the metals and higher for the oxides.

36 MATERIALS SCIENCE↗
DOE OSTI2025

3D polycatenated architected materials

Architected materials derive their properties from the geometric arrangement of their internal structural elements. Their designs rely on continuous networks of members to control the global mechanical behavior of the bulk. Here, in this study, we introduce a class of materials that consist of discrete concatenated rings or cage particles interlocked in three-dimensional networks, forming polycatenated architected materials (PAMs). We propose a general design framework that translates arbitrary crystalline networks into particle concatenations and geometries. In response to small external loads, PAMs behave like non-Newtonian fluids, showing both shear-thinning and shear-thickening responses, which can be controlled by their catenation topologies. At larger strains, PAMs behave like lattices and foams, with a nonlinear stress-strain relation. At microscale, we demonstrate that PAMs can change their shapes in response to applied electrostatic charges. The distinctive properties of PAMs pave the path for developing stimuli-responsive materials, energy-absorbing systems, and morphing architectures.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Pre-metered coating flow models with Goma 7: Workflow Tutorial

Tutorials for modeling of slot-die and slide-die coating flows with Goma 7, an open source finite element code, are presented. The tutorials cover the workflow to attaining steady state solutions for these flows, and continuation strategies for navigating the operating windows. Advanced topics of coating window prediction, automated multiparameter continuation, non-Newtonian rheology, dynamic contact line modeling, and some more solution strategies are also covered.

08 HYDROGEN↗
NASA NTRS1959

Some effects of vibration and rotation on the drift of gyroscopic instruments

It is the purpose of this paper to describe and indicate possible analytical approaches to some of the most significant mechanisms by which vibration induced drifts may occur, and to indicate, where possible, some means of alleviating them. In all cases we will not consider gimbal bearing friction, mass unbalance or other sources of steady extraneous torques on the gyro rotor. The mechanisms to be discussed are: Non-Newtonian viscosity in single degree of freedom (SDF) integrating-rate gyros, nonisoelasticity in SDF gyros, noncommutative effects for SDF stabilized platform, gimbal inertia effects, 2 DF gyros, and spin axis torque coupling in 2 DF gyros. High-frequency elastic resonances are not discussed explicitly in detail, because they are a more familiar problem and one which depends strongly on the details of each particular gyro design.

Viscous Torque↗
NASA NTRS2004

Lunar and Planetary Science XXXV: Icy Worlds: Moving and Grooving

Reports from the conference session entitled Icy Worlds: Moving and Grooving, include:Mass Anomalies on Ganymede; Europan Chaos and Lenticulae: A Synthesis of Size, Spacing, and Areal Density Analyses; Thermal and Topographic Tests of Europa Chaos Formation Models; Flexure of Europa s Lithosphere Due to Ridge-Loading; Ridges on Europa: Origin by Incremental Ice-Wedging ; Convergent Boundaries on Europa: a Numerical Approach to Euler Pole Analysis and Its' Implications for Plate Reconstruction; Numerical Simulations of Subsolidus Convection in the Ice Shell of Europa: Implications for the Thermal Evolution and Present State; Effects of Plasticity on Convection in an Ice Shell: Implications for Europa; Non-Newtonian Convection and Compositional Buoyancy: Advances in Modeling Convection and Dome Formation on Europa; Convective Instability in Ice I: Application to Callisto and Ganymede; Crater Size Distributions on Callisto: A Galileo SSI Summary; Neutron Diffraction Studies of Planetary Ices; and H2O2 Synthesis Induced by Irradiation of H2O with Energetic H+ and Ar+ Ions at Various Temperatures.

Source record↗
DOE OSTI2025

High-Fidelity CFD Modeling of Cryogenic Hydrogen Isotope Extrusion for Fusion Reactor Pellet Fueling

This study investigates the extrusion processes of deuterium and protium using ANSYS-Polyflow. The geometries and computational fluid dynamics (CFD) settings closely replicate the experimental setups and data acquired from the extruder experiments at Oak Ridge National Laboratory (ORNL) for validation purposes. We explore the impacts of (1) slip versus non-slip boundary conditions and (2) the use of constant, temperature-, and shear rate–dependent viscosities, concluding that the implementation of non-slip wall boundary conditions combined with shear rate–dependent viscosity produced more accurate predictions. The simulations achieved excellent agreement with the experimental data, with relative differences of only 5% for deuterium, and 3% to 6% for protium. This is the first time that experimental extrusion data at ORNL have been accurately predicted through high-fidelity CFD modeling. In conclusion, the advancements offer valuable insights and a foundational modeling tool for optimizing pellet injectors for ITER and other future reactor-scale devices.

ANSYS-Polyflow↗
DOE OSTI2025

Flow-Driven Stretch Fluctuations Govern the Nonlinear Viscoelasticity of Elongating Associative Polymer Networks

We use nonequilibrium molecular dynamics simulations to verify recent tube-model predictions that associative polymer networks exhibit broad stretch fluctuations during elongational flow. Simulations further show that these fluctuating dynamics give rise to the rate-dependent extensional viscosity 𝜂 𝐸 measured in filament stretching experiments on H-bonding networks. Simulations model bivalent associative networks with a reactive bead-spring model for varying association strength and extensional strain rate. We observe that stretch fluctuations are driven by a new form of chain tumbling, where chains continually collapse and elongate as their associations break and reform within the advecting network. This produces a broad, nearly uniform distribution of chain stretch over a wide range of strain rates, manifesting as a rate-independent plateau in the extensional stress. Our results show that the nonlinear viscoelasticity of associative networks is dominated by large fluctuations in molecular response, which cannot be captured by current mean-field models.

biomimetic & bio-inspired materials↗