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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 181 records · Page 10

Distributed Temperature Sensing within a 19-pin Wire-Wrapped Fuel Bundle Model

It has always been difficult to measure local temperature and flow velocity within fuel bundle geometries because of their complex and compact layouts. High-resolution mapping of the flow field is especially challenging. High-resolution data is typically obtained using optical instruments but optical access to the interior regions of a bundle is severely limited. Velocity fields within fuel bundle models have been mapped with particle image velocimetry (PIV), an optical technique that employs lasers and cameras. Optical access to the bundle interior is obtained using transparent materials and matching the refractive index of the physical structures with that of the fluid. Testing is necessarily isothermal because refractive indices vary with temperature. However, the ultimate aim of such studies is understanding fluid dynamics and heat transfer within real reactors and so flow field mapping under nonisothermal conditions is of particular interest. Temperature fields can be mapped at high-resolution using laser-induced fluorescence (LIF). However, as an optical technique it is unsuitable for nonisothermal liquid flows. This is due to the same sort of optical distortion that restricts PIV. It is also unsuitable for opaque fluids and setups with restricted optical access. Fiber optic distributed temperature sensing (DTS) offers a high-resolution alternative that does not rely upon imaging. A single sensor can map temperature fields at resolutions far exceeding that achievable with conventional sensors such as thermocouples. Though fiber optic sensors cannot match the spatial resolution and bandwidth of LIF, they are suitable for nonisothermal and opaque flows. And though fibers are physical probes that perturb the flow, they can be strung across complex geometries to provide data in regions lacking the optical access necessary for techniques like LIF. Distributed temperature sensing has the potential to provide fuel bundle temperature data of a type that cannot be obtained with optical methods or conventional sensors. This paper reports on preliminary results of efforts to use fiber optic distributed temperature sensors in a fuel bundle model. We are conducting a feasibility study exploring implementation issues such as strain control in the mounting configuration and signal noise associated with flow-induced vibration. We describe here the setup and present preliminary data from our first phase testing with stagnant flow. (authors)

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Generating MCNP Input Files for Unstructured Mesh Geometries

The Los Alamos National Laboratory’s (LANL) Monte Carlo N-Particle (MCNP)1 transport code version 6.3 (also known as MCNP6.3) has the capability for tracking particles on unstructured mesh (UM) geometry models embedded into constructive solid geometry (CSG) cells. This feature has been developed for performing calculations of complex geometry models because manually creating CSG models is time-consuming and error-prone as the complexities of geometries increase. A UM geometry model is a collection of finite elements representing a solid geometry. The first step of the MCNP UM calculation is using other software packages to create a finite element mesh representation of a solid 3D geometry because the MCNP code cannot be used to generate a UM model. Computer-aided design (CAD) software is typically used to create a solid geometry model, which is later imported into mesh generation software to create a UM model. Some mesh generation software packages may also be used to create solid geometries and thus CAD files are not needed. The MCNP UM feature was originally designed for models generated by the Abaqus/CAE software suite. The MCNP code version 6.0 and later can process UM models formatted as Abaqus input files. Starting with a 6.3 version, the MCNP code can process HDF5 mesh input files. We only focus on the UM models formatted as Abaqus input files in this report since currently no external software can be used to generate HDF5 mesh input files for MCNP UM calculations. The MCNP code version 6.3 can be used to convert the Abaqus mesh input files into the HDF5 mesh input files, but this option is typically used by the MCNP code development team to test the HDF5 mesh input file feature. Several software packages (such as Abaqus, Attila4MC, or Cubit) can be used to create the Abaqus input files for MCNP UM calculations. An MCNP UM calculation using an Abaqus model requires two input file types: MCNP and Abaqus input files. The Abaqus input files needed for MCNP UM calcu lations must have the correct Abaqus syntax and meet the additional requirements by the MCNP code. The MCNP code can process only Abaqus input files that make use of part and assembly definitions, where elements in each part must be grouped into one or more element sets (i.e., elset) using *Elset keyword lines with specified naming formats. The MCNP and Abaqus input files required for MCNP UM simulations must be related; pseudo-cells in an MCNP input file must be constructed from mesh model data from an Abaqus input file. For large complex UM models, it is tedious to manually create MCNP UM input files. The um pre op (unstructured mesh pre operations) program with the -m option can be used to create a skeleton MCNP input file from an Abaqus input file [6]. Since the um pre op program was written in Fortran and was not written for optimized performance, this program is a deprecated feature in the MCNP code version 6.3 and may be removed in the next release of the code. To improve calculation flow of multiphysics calculations, a Python3 code called write mcnp um input has been developed to generate an MCNP input file instead of using the um_pre_op -m option. This Python code was initially released to the public in 2020. We have updated this Python code for MCNP6.3 and it was used to generate the MCNP input files used to verify the MCNP6.3 code. The write_mcnp_um_input code is included with the MCNP6.3 code package which will be released to the public through the Radiation Safety Information Computational Center (RSICC) at Oak Ridge National Laboratory. This report is a revision of LA-UR-20-27139 report.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗

Using CUBIT to Create Unstructured Mesh Models for MCNP Simulations

The Monte Carlo N-Particle (MCNP) transport code version 6 (also known as MCNP6) has the capability for tracking particles on unstructured mesh (UM) geometry models embedded into constructive solid geometry (CSG) cells. This feature has been developed for performing calculations of complex geometry models because creating CSG models is a time-consuming and error-prone process as the complexities of geometries increase. An MCNP UM calculation requires UM geometry input files. The UM capability was originally designed to work with UM models created with the Abaqus/CAE software and ASCII input files that it generates. The Abaqus-formatted input files needed for MCNP UM calculations must have the correct Abaqus syntax and meet the additional MCNP requirements. Several software packages can generate a UM model formatted as an Abaqus input file. Cubit, the Sandia National Laboratory automated mesh generation toolkit, can generate a UM model formatted as an Abaqus input file. However, the Abaqus input files created by Cubit cannot be used for MCNP simulations. A Python script has been developed to convert an Abaqus file created by Cubit to an Abaqus file that the MCNP code can process. This report describes the process of using Cubit to create UM models for MCNP calculations.

97 MATHEMATICS AND COMPUTING↗

Nonlinear elasticity with the Shifted Boundary Method

Here, we propose a new unfitted/immersed computational framework for nonlinear solid mechanics, which bypasses the complexities associated with the generation of CAD representations and subsequent body-fitted meshing. This approach allows to speed up the cycle of design and analysis in complex geometry and requires relatively simple computer graphics representations of the surface geometries to be simulated, such as the Standard Tessellation Language (STL format). Complex data structures and integration on cut elements are avoided by means of an approximate boundary representation and a modification (shifting) of the boundary conditions to maintain optimal accuracy. An extensive set of computational experiments in two and three dimensions is included.

97 MATHEMATICS AND COMPUTING↗

Functional fiber-optic sensors embedded in stainless steel components using ultrasonic additive manufacturing for distributed temperature and strain measurements

The nuclear industry is progressing toward microreactors that can be factory assembled and deployed to remote regions for reliable, scalable power generation. However, the reduced power output requires enhanced monitoring capabilities to reduce staffing and eventually move toward autonomous control to improve the economics of microreactors. The ability to embed sensors such as fiber-optics, which can provide spatially distributed temperature and strain measurements, within microreactor components for real-time health monitoring would be particularly advantageous. Recent advances in ultrasonic additive manufacturing (UAM) have demonstrated the successful embedding of fiber-optics in soft materials such as Al and Cu by placing the sensors in machined cavities and ultrasonically welding over the top with thin foils. This article reports the first successful embedment of fiber-optic sensors and thermocouples within a common nuclear reactor material, SS304, via UAM. UAM parameters were first explored with simple plate geometries before moving to more complex geometries, such as pipes and other test articles for heat pipe–based microreactors. Select samples were sectioned for microscopy to evaluate the sensor/foil and foil/foil interfaces from samples fabricated by using 100% SS304 foils vs. foils plated with a Ni coating to improve UAM bonding. Furthermore, embedding metal-coated, low-bend loss fibers resulted in greatly reduced signal attenuation and adequate compressive residual strain in the embedded region to ensure successful strain coupling. Pipe specimen functional testing was performed by monitoring temperature and strain during transient and steady-state thermal testing.

36 MATERIALS SCIENCE↗

DECA: Discrete Event inspired Cellular Automata for grain structure prediction in additive manufacturing

Microstructure largely dictates macroscopic material properties and is strongly affected by processing. Therefore, the simulation of microstructure evolution in response to thermal fields during processing is of significant interest within the computational materials science community. Additive manufacturing (AM) has emerged as a technique for producing complex geometries and unique microstructures. Yet, complex and rapid thermal cycles in AM pose computational challenges for existing microstructure models. This work proposes a discrete event inspired cellular automata (CA) approach, titled DECA, to accelerate simulation of grain structure evolution in AM. In contrast to conventional time-stepped CA models, this model directly solves the times capture events would take place allowing for stepping in events rather than time (a technique also found in the field of discrete-event simulation). In comparison to purely serial discrete-event models, DECA allows for temporary violation of the causality constraint, but detects and corrects these violations, leading to an emergent phenomenon dubbed causality rippling, in which previously calculated capture events are overwritten. The amount of repeated calculations, defined by the capture ratio, is taken as a measure of computational inefficiency, and the model parameters that affect this ratio are evaluated. The new DECA approach was found to be more computationally efficient than conventional time-stepped CA models while guaranteeing an accurate solution, which can only be achieved in the conventional models for vanishingly small time steps. Finally, opportunities for parallelization and scaling of the new approach are discussed.

36 MATERIALS SCIENCE↗

Application of a full potential method for computation of three-dimensional supersonic flows

A nonlinear aerodynamic analysis technique based on the full potential equation in conservative form has been modified to permit treatment of supersonic flows with embedded subsonic regions (typically near the fuselage-canopy juncture and the wing leading edge). Solution procedures for the equations do not require any specific form of geometry or physical grid system. This results in the capability to analyze easily very complex geometries provided the posed problem lies within the isentropic restrictions of the full potential theory. Characteristic signal propagation theory is used to monitor the type dependent flow and a conservative switching scheme is employed to transition from the supersonic marching algorithm to a subsonic relaxation procedure and vice versa. An implicit approximate factorization scheme is used to solve the finite-difference equations. These modifications now permit analysis of fully three-dimensional flowfields including the interference effects due to lifting surface wakes. Improved grid generation capability allows analysis of complete complex aircraft geometries (fuselage, wing, tail, wing wake, and tail wake). Results are presented showing very good correlations with experimental surface pressure data and aerodynamic force data at both design and off-design operating points. Configurations examined include several waverider concepts, an arrow wing-body with wake, an advanced tactical fighter concept, and a fighter forebody-canard configuration.

Jones, K. M.↗

An interactive graphics program for manipulation and display of panel method geometry

Modern aerodynamic panel methods that handle large, complex geometries have made evident the need to interactively manipulate, modify, and view such configurations. With this purpose in mind, the GEOM program was developed. It is a menu driven, interactive program that uses the Tektronix PLOT 10 graphics software to display geometry configurations which are characterized by an abutting set of networks. These networks are composed of quadrilateral panels which are described by the coordinates of their corners. GEOM is divided into fourteen executive controlled functions. These functions are used to build configurations, scale and rotate networks, transpose networks defining M and N lines, graphically display selected networks, join and split networks, create wake networks, produce symmetric images of networks, repanel and rename networks, display configuration cross sections, and output network geometry in two formats. A data base management system is used to facilitate data transfers in this program. A sample session illustrating various capabilities of the code is included as a guide to program operation.

Hall, J. F.↗

Insights into scale translation of methane transport in nanopores

Accurate prediction of flow behavior in shale matrix is critical for efficient development of shale gas reservoirs. In these systems, the majority of pores are in the nano-size range. As a result, continuum-based approaches may not be appropriate to simulate flow in such systems. Molecular dynamics (MD) simulations are capable of capturing the relevant microscale physics. Their relatively high computational expense, however, restricts MD simulations to rather small systems and domains. This limitation creates a gap between computational need of macroscale systems and capabilities of MD simulations. The lattice Boltzmann method (LBM) is a suitable candidate to bridge this gap. In this work, the multiple-relaxation-time (MRT)-LBM is used to study methane transport in nano-size pores. Adsorption effects near solid boundaries, as well as non-ideal behavior of fluids, are accounted for via incorporating appropriate force terms in LBM. In this work, parameters associated with the force terms in the equation of state are studied in detail, and a workflow is proposed to determine optimal values of these parameters for gas flow in slit pores. Specifically, we establish these parameters such that the range of density values that the model is able to simulate is maximized. We demonstrate this workflow by simulating gas flow where velocity and density profiles from MD simulations are used as reference data. Results from LBM simulations are in good agreement with MD reference data for pores that are 4 nm in width or larger. Moreover, we propose a preconditioning scheme to improve the stability of LBM in dealing with complex geometries. The robustness of this scheme is demonstrated by simulating several roughness geometries. This work motivates the use of LBM in scale translation of the physics of mass transport in more complex permeable media.

03 NATURAL GAS↗

Development of a Robust and Efficient Parallel Solver for Unsteady Turbomachinery Flows

The traditional design and analysis practice for advanced propulsion systems relies heavily on expensive full-scale prototype development and testing. Over the past decade, use of high-fidelity analysis and design tools such as CFD early in the product development cycle has been identified as one way to alleviate testing costs and to develop these devices better, faster and cheaper. In the design of advanced propulsion systems, CFD plays a major role in defining the required performance over the entire flight regime, as well as in testing the sensitivity of the design to the different modes of operation. Increased emphasis is being placed on developing and applying CFD models to simulate the flow field environments and performance of advanced propulsion systems. This necessitates the development of next generation computational tools which can be used effectively and reliably in a design environment. The turbomachinery simulation capability presented here is being developed in a computational tool called Loci-STREAM [1]. It integrates proven numerical methods for generalized grids and state-of-the-art physical models in a novel rule-based programming framework called Loci [2] which allows: (a) seamless integration of multidisciplinary physics in a unified manner, and (b) automatic handling of massively parallel computing. The objective is to be able to routinely simulate problems involving complex geometries requiring large unstructured grids and complex multidisciplinary physics. An immediate application of interest is simulation of unsteady flows in rocket turbopumps, particularly in cryogenic liquid rocket engines. The key components of the overall methodology presented in this paper are the following: (a) high fidelity unsteady simulation capability based on Detached Eddy Simulation (DES) in conjunction with second-order temporal discretization, (b) compliance with Geometric Conservation Law (GCL) in order to maintain conservative property on moving meshes for second-order time-stepping scheme, (c) a novel cloud-of-points interpolation method (based on a fast parallel kd-tree search algorithm) for interfaces between turbomachinery components in relative motion which is demonstrated to be highly scalable, and (d) demonstrated accuracy and parallel scalability on large grids (approx 250 million cells) in full turbomachinery geometries.

West, Jeff↗

SU-F-J-74: High Z Geometric Integrity and Beam Hardening Artifact Assessment Using a Retrospective Metal Artifact Reduction (MAR) Reconstruction Algorithm

Purpose: To test the efficacy of a retrospective metal artifact reduction (MAR) reconstruction algorithm for a commercial computed tomography (CT) scanner for radiation therapy purposes. Methods: High Z geometric integrity and artifact reduction analysis was performed with three phantoms using General Electric’s (GE) Discovery CT. The three phantoms included: a Computerized Imaging Reference Systems (CIRS) electron density phantom (Model 062) with a 6.5 mm diameter titanium rod insert, a custom spine phantom using Synthes Spine hardware submerged in water, and a dental phantom with various high Z fillings submerged in water. Each phantom was reconstructed using MAR and compared against the original scan. Furthermore, each scenario was tested using standard and extended Hounsfield Unit (HU) ranges. High Z geometric integrity was performed using the CIRS phantom, while the artifact reduction was performed using all three phantoms. Results: Geometric integrity of the 6.5 mm diameter rod was slightly overestimated for non-MAR scans for both standard and extended HU. With MAR reconstruction, the rod was underestimated for both standard and extended HU. For artifact reduction, the mean and standard deviation was compared in a volume of interest (VOI) in the surrounding material (water and water equivalent material, ∼0HU). Overall, the mean value of the VOI was closer to 0 HU for the MAR reconstruction compared to the non-MAR scan for most phantoms. Additionally, the standard deviations for all phantoms were greatly reduced using MAR reconstruction. Conclusion: GE’s MAR reconstruction algorithm improves image quality with the presence of high Z material with minimal degradation of its geometric integrity. High Z delineation can be carried out with proper contouring techniques. The effects of beam hardening artifacts are greatly reduced with MAR reconstruction. Tissue corrections due to these artifacts can be eliminated for simple high Z geometries and greatly reduced for more complex geometries.

60 APPLIED LIFE SCIENCES↗

Development of a gas pressure bonded four-pole alternator rotor

Methods were developed for fabrication of a solid four pole alternator rotor by hot isostatic pressure welding. The rotor blanks welded in this program had complex geometrical mating interfaces and were of considerable bulk, being approximately 3-1/2 inches (0.089 meters) in diameter and 14 inches (0.356 meters) long. Magnetic end pieces were machined from AlSl 4340 steel, while the non-magnetic central section was of Inconel 718. Excellent welds were produced which were shown to be responsive to post weld heat treatments which substantially improved joint strength. Prior to welding the rotors, test specimens of complex geometry were welded to demonstrate that complex surfaces with intentional mechanical misfit could be readily joined using HIP welding. This preliminary work demonstrated not only that interface compliance is achieved during welding but that welding pressure is developed in these thick sections sufficient to produce sound joints. Integral weld-heat treatment cycles were developed that permitted the attainment of magnetic properties while minimizing residual stress associated with the allotropic transformation of 4340 steel.

Lessmann, G. G.↗

Performance of Advanced Signal Processing and Pattern Recognition Algorithms Using Raw Data from Ultrasonic Guided Waves and Fiber Optics Transducers

The Light Water Reactor Sustainability Program was initiated to evaluate technologies that could be used to perform online monitoring of piping and other secondary system structural components in commercial nuclear power plants. These online monitoring systems have the potential to identify when a more detailed inspection is needed using real-time measurements, rather than at a pre-determined inspection interval. This transition to condition-based, risk-informed automated maintenance will contribute to a significant reduction of operations and maintenance costs that account for most nuclear power generation costs. This report describes the current state of research related to ultrasonic guided wave testing and its application to detecting defects in commercial nuclear power plants. The report analyzes the applicability of the guided wave technology to secondary piping systems, as well as studying the potential for expanding the range of guided wave technology to include bent piping and other piping components. The ultrasonic guided waves can inspect long stretches of straight piping; however, more complex geometries such as elbows, welds, and tees are causing spurious reflections and coherent noise, which significantly decreases the sensitivity of the technique. To deal with these limitations, high-definition fiber optic sensors are applied to complex piping geometries, and advanced machine learning algorithms are used to detect deviations from healthy states. This report also analyzes the performance of advanced signal processing and machine learning-based pattern recognition algorithms in detecting defects in secondary structures. It is demonstrated on guided wave data collected at nuclear power plants that the independent component analysis can separate different coherent noise components and segregate them from useful signals. It also demonstrates that advanced machine learning techniques, such as neural networks, support vector machines, and deep learning networks, can detect minor defects present in inspected structures. Recommendation about the applicability of advanced machine learning techniques to online piping monitoring are also given.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Atmospheric and Science Complexity Effects on Surface Bidirectional Reflectance

Among the tools used in passive remote sensing of Earth resources in the visible and near-infrared spectral regions are measurements of spectral signature and bidirectional reflectance functions (BDRFs). Determination of surface properties using these observables is complicated by a number of factors, including: (1) mixing of surface components, such as soil and vegetation, (2) multiple reflections of radiation due to complex geometry, such as in crop canopies, and (3) atmospheric effects. In order to bridge the diversity in these different approaches, there is a need for a fundamental physical understanding of the influence of the various effects and a quantiative measure of their relative importance. In particular, we consider scene complexity effects using the example of reflection by vegetative surfaces. The interaction of sunlight with a crop canopy and interpretation of the spectral and angular dependence of the emergent radiation is basically a multidimensional radiative transfer problem. The complex canopy geometry, underlying soil cover, and presence of diffuse as well as collimated illumination will modify the reflectance characteristics of the canopy relative to those of the individual elements.

Diner, D. J.↗

Continuous and Smooth Envelopes of Topological Algebras. Part 1

Since the first optical instruments were invented, an idea that the visible image of an object under observation depends on tools of observation became commonly assumed in physics. A way of formalizing this idea in mathematics is the construction that assigns to an arbitrary object A in a category K its envelope Env{sub Φ}{sup Ω}A in a given class of morphisms (a class of representations) Ω with respect to a given class of morphisms (a class of observation tools) Φ. It turns out that if we take a sufficiently wide category of topological algebras as K, then each choice of the classes Ω and Φ defines a “projection of functional analysis into geometry,” and the standard “geometric disciplines,” like complex geometry, differential geometry, and topology, become special cases of this construction. This gives a formal scheme of “categorical construction of geometries” with many interesting applications, in particular, “geometric generalizations of the Pontryagin duality” (to the classes of noncommutative groups). In this paper we describe this scheme in topology and in differential geometry.

97 MATHEMATICS AND COMPUTING↗

Continuous and Smooth Envelopes of Topological Algebras. Part 2

Since the first optical instruments were invented, the idea that the visible image of an object under observation depends on tools of observation became commonly assumed in physics. A way of formalizing this idea in mathematics is the construction that assigns to an arbitrary object A in a category K its envelope Env{sub Φ}{sup Ω} A in a given class of morphisms (a class of representations) Ω with respect to a given class of morphisms (a class of observation tools) Φ. It turns out that if we take a sufficiently wide category of topological algebras as K, then each choice of the classes Ω and Φ defines a “projection of functional analysis into geometry,” and the standard “geometric disciplines,” like complex geometry, differential geometry, and topology, become special cases of this construction. This gives a formal scheme of “categorical construction of geometries” with many interesting applications, in particular, “geometric generalizations of the Pontryagin duality” (to the classes of noncommutative groups). In this paper we describe this scheme in topology and in differential geometry.

97 MATHEMATICS AND COMPUTING↗

Numerical Study of Base Pressure Characteristic Curve for a Four-Engine Clustered Nozzle Configuration

Excessive base heating has been a problem for many launch vehicles. For certain designs such as the direct dump of turbine exhaust in the nozzle section and at the nozzle lip of the Space Transportation Systems Engine (STME), the potential burning of the turbine exhaust in the base region has caused tremendous concern. Two conventional approaches have been considered for predicting the base environment: (1) empirical approach, and (2) experimental approach. The empirical approach uses a combination of data correlations and semi-theoretical calculations. It works best for linear problems, simple physics and geometry. However, it is highly suspicious when complex geometry and flow physics are involved, especially when the subject is out of historical database. The experimental approach is often used to establish database for engineering analysis. However, it is qualitative at best for base flow problems. Other criticisms include the inability to simulate forebody boundary layer correctly, the interference effect from tunnel walls, and the inability to scale all pertinent parameters. Furthermore, there is a contention that the information extrapolated from subscale tests with combustion is not conservative. One potential alternative to the conventional methods is computational fluid dynamics (CFD), which has none of the above restrictions and is becoming more feasible due to maturing algorithms and advancing computer technology. It provides more details of the flowfield and is only limited by computer resources. However, it has its share of criticisms as a predictive tool for base environment. One major concern is that CFD has not been extensively tested for base flow problems. It is therefore imperative that CFD be assessed and benchmarked satisfactorily for base flows. In this study, the turbulent base flowfield of a experimental investigation for a four-engine clustered nozzle is numerically benchmarked using a pressure based CFD method. Since the cold air was the medium, accurate prediction of the base pressure distributions at high altitudes is the primary goal. Other factors which may influence the numerical results such as the effects of grid density, turbulence model, differencing scheme, and boundary conditions are also being addressed. Preliminary results of the computed base pressure agreed reasonably well with that of the measurement. Basic base flow features such as the reverse jet, wall jet, recompression shock, and static pressure field in plane of impingement have been captured.

Wang, Ten-See↗