Engineering topics

Thornton, Aaron

Publications and source records attributed to Thornton, Aaron.

4 records

DOE OSTI2024

Integrated top-down process and voxel-based microstructure modeling for Ti-6Al-4V in laser wire direct energy deposition process

Laser-wire metal additive manufacturing (AM) is one of the ideal direct energy deposition (DED) processes for creating large-scale parts with a medium level of complexity. However, the DED process involves complex thermal signatures and wide length scales making the fabrication of realistic AM components and part qualification often reliant on experimental trial-and-error optimization. While experimental measurements over the full volume of a part are valuable and necessary, measuring the entire area of a part is significantly laborious and practically infeasible, particularly for large parts in terms of cost and rapid qualification. Therefore, in this work, we developed an effective thermal and microstructure modeling framework based on the Johnson–Mehl-Avrami-Kolmogorov (JMAK) and Koistinen & Marburger (KM) models through a top-down approach that considers plate distortion-affected thermal profiles. A voxel-by-voxel simulation method is used to predict individual phase fractions of Ti-6Al-4 V. The predicted results were validated through detailed metallurgical measurements. A combined voxel-by-voxel approach with a sparse data reconstruction technique produced a near-perfect reconstruction of the original data. This approach anticipates a significant reduction in data points and computation time and resources. Lastly, we conclude with potential extensions of this work to other modeling efforts.

36 MATERIALS SCIENCE↗

DOE OSTI2024

BTRIC Technical Support for Appalachia: FY 2024 Summary Report on Net Negative Carbon Building Demonstration with AgPod

This report investigates the effects of various concentrations of CO 2 on the photosynthesis and biomass accumulation of crops growing in an AgPod, using kale as the test crop. In the first year of the study, increasing the CO 2 concentration in the AgPod was found to promote higher photosynthetic rates in kale plants up to 1,300 ppm (the highest CO 2 concentration measured). An interesting finding was that net photosynthetic rates of kale leaves remain unsaturated until reaching unusually high levels of photosynthetically active radiation (PAR, > 1,200 µmol m -1 s -1 ) and CO 2 concentration (> 1,100 ppm). Such high levels of saturating PAR and CO 2 concentration values rarely occur under natural conditions, suggesting a promising potential for carbon capture via enriched controlled environment agriculture (ECEA). During the second year of the study, a second crop was planted to confirm the actual effects on growth with increased CO 2 concentrations. Our results suggest that growing kale plants in the AgPod system at higher CO 2 levels resulted in a successful and highly productive crop, up to three times the amount grown at 415 CO 2 . Further, the kale plants grown under higher CO 2 conditions (1000 ppm) are not CO 2 saturated and can potentially further improve yield at even higher CO 2 environments.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2024

Liquid Piston with Spray Cooling Near-Isothermal Compressor

The goal of this project was to prototype and characterize the performance of a liquid-piston spray-cooled gas compressor. The working principle of the compressor enables optimized high-efficiency operation over a very wide range of operating conditions, unlike conventional compressors that are optimized for a narrow range of operating conditions. The compressor technology is suitable for many applications, such as gas pipeline transport, gas storage, and commercial and residential heat pumps. Both physical testing and computational fluid dynamics (CFD) modeling of the processes using the Oak Ridge National Laboratory high-performance computing center were completed. The experimental and CFD studies focused on a near-isothermal liquid-piston compressor (LPC) that uses propylene glycol to compress CO 2 . The first prototype demonstrated isothermal operation during several sequentially executed cycles of CO 2 compression and raised the temperature of the compressed CO 2 by only 2 K, compared with approximately 6 K when the gas was compressed non-isothermally. Isothermal operation was demonstrated at CO 2 flow rates of up to 2 L/min. The second prototype was designed with two compression chambers to allow continuous flow of high-pressure CO 2 . However, the design of the valve train to direct flow between the compression chambers was not sufficient to allow demonstration of CO 2 compression. Numerical simulations of the LPC in which the compression chamber was filled with propylene glycol injected from the bottom inlet were performed using large eddy simulation (LES) with the wall-adapting local eddy-viscosity subgrid-scale model coupled with the multiphase volume of fluid (VOF) model to simulate the transient interface between gas and liquid and to capture the heat and mass transfers within the compression chamber. In this effort, the effects of boundary conditions applied to the LES-VOF calculations (i.e., no wall, an adiabatic wall, and a wall with a heat flux subscribed) on the overall pressure and temperature of the CO 2 gas as well as the transient evolution of flow and heat transfer within the compression chamber were investigated and are discussed in this report. The LES calculation with no wall showed no dynamical flow patterns, and the volume-averaged temperature of CO 2 increased from 305 to 392.7 K, whereas LES calculations with a constant wall temperature or a wall heat flux had similar increases of CO 2 temperatures. The results of the LES simulation using a wall heat flux showed different stages in the compression process and revealed dynamical formation and interaction of CO 2 gas layers and circulation flow patterns within the chamber that contributed to the overall heat transfer between the solid wall, gas, and liquid surface in the compressor. Though an industrial partnership for commercializing the compressor was not secured, the technology was attractive for an industrial partner to use in two research proposals in response to US Department of Energy funding opportunity announcements.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2023

BTRIC Technical Support for Appalachia: FY 2023 Summary Report on Net Negative Carbon Building Demonstration with AgPod

This study investigates the effects of various concentrations of carbon dioxide (CO 2 ) on the photosynthesis and biomass accumulation of crops growing in an Agricultural Pod (AgPod). The initial test crop was kale. It has been found that increasing the CO 2 concentration in the AgPod promotes higher photosynthetic rates in kale plants up to 1300 ppm (highest CO 2 concentration). An interesting finding was that net photosynthetic rates of kale leaves remain unsaturated until unusually high levels of photosynthetically active radiation (PAR, > 1200 µmolm-2s-1) and CO 2 concentration (> 1100 ppm) are reached. Such high levels of saturating PAR and CO 2 concentration values rarely occur under natural conditions, suggesting a promising potential for carbon capture via enriched greenhouse crop production. This task is one part of an overall plan to incorporate an AgPod to utilize carbon captured from the atmosphere to achieve net negative carbon emissions in a small neighborhood or community.

54 ENVIRONMENTAL SCIENCES↗