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DOE OSTI2025

Dynamic Heat Flow and Current Distribution Analysis in the Bottom Anode of an Electric Arc Furnace Using Fiber-Optic Sensors

A reliable method for monitoring bottom anode wear during DC Electric Arc Furnace (DC-EAF) operation is of critical importance for safe and efficient steel production. Underestimation of bottom wear poses a serious safety risk that must be avoided, while overestimation of bottom wear also poses challenges, as premature anode replacement is expensive and affects EAF productivity. Previously, we demonstrated that fiber-optic sensors can be successfully deployed to create a spatially distributed temperature map to monitor the health of the anode. The present work explores the heat flow and current density distribution in bottom anode pins to predict bottom wear, steel penetration events, and monitor refractory erosion. Small dynamic variations in pin temperature induced by joule heating during arcing also provide a means to observe local current flows in each pin. When mapped, these measurements provide a real-time view of the non-uniform and dynamic current flow in the bottom anode during EAF operation that can affect bottom wear.

Bottom Anode↗

NASA NTRS1987

In-situ technique for checking the calibration of platinum resistance thermometers

The applicability of the self-heating technique for checking the calibration of platinum resistance thermometers located inside wind tunnels was investigated. This technique is based on a steady state measurement of resistance increase versus joule heating. This method was found to be undesirable, mainly because of the fluctuations of flow variables during any wind tunnel testing.

Daryabeigi, Kamran↗

DOE OSTI2022

Electric current-induced precipitation hardening in advanced high-strength steel

Effect of electric current on precipitation hardening for advanced high-strength steel is investigated based on mechanical testing and microscopic observation. Complex-phase steel containing nano-sized Nb-bearing carbides was used. By comparing the flow stress between uniaxial tension with applied electric current (pulsed tension) and without electric current (nonpulsed tension) at various elevated temperatures, the influence of electric current on precipitation hardening was confirmed. A higher values of Vickers hardness and full-width-at-half-maximum were obtained in the pulsed tensile specimen compared to the identically heat treated specimen after the same deformation. Small angle neutron scattering analysis showed that the volume fraction and mean diameter of newly formed precipitates in the pulsed tensile specimen were higher and larger than those in the induction heat treated specimen, respectively. In conclusion, it clearly shows that additional precipitation hardening could be induced by the athermal effect of electric current, which is distinct from the thermal effect of Joule heating.

36 MATERIALS SCIENCE↗

NASA NTRS1979

Thermal structure and energy influx to the day- and nightside Venus ionosphere

The thermal structure of and energy influx to the dayside and nightside Venus ionosphere are discussed, based on data obtained by the Pioneer Venus spacecraft. Where the dayside ionosphere appears relatively constant in total ion concentration, ion and electron temperatures and ion composition below the ionopause, retarding potential analyzer measurements confirm the presence of strong spatial and temporal variations in nightside ion concentration. Ion temperatures on the nightside above 225 km are found to be larger by a factor of two or more than on the dayside, and comparable to electron temperatures on the day and night sides. Models of dayside and nightside ion temperatures consistent with observations require the heat input of 0.003 erg/sq cm sec and 0.005 erg/sq cm sec, respectively, to the ion gas to raise the ion temperature above that of the neutral gas, presumably by means of Joule heating.

Knudsen, W. C.↗

NASA NTRS1992

Dynamical interactions between the middle atmosphere and thermosphere

Based on modeling some interactions between the middle atmosphere and thermosphere are presented. The interactions studied include the thermospheric circulations driven by radiative and auroral heating affecting the O concentration and temperature of the upper mesosphere through the exchange of chemical energy. Considering Kellog's mechanism, an interaction between the mesosphere and thermosphere that is driven by Joule heating is discussed.

Mayr, H. G.↗

NASA NTRS2014

Forcing of the Coupled Ionosphere-Thermosphere (IT) System During Magnetic Storms

Poynting flux shows peaks around auroral zone AND inside polar cap. Energy enters IT system at all local times in polar cap. Track-integrated flux at DMSP often peaks at polar latitudes- probably due to increased area of polar cap during storm main phases. center dot lon temperatures at DMSP show large increases in polar region at all local times; cusp and auroral zones do not show distinctively high Ti. center dot I on temperatures in the polar cap are higher than in the auroral zones during quiet times. center dot Neutral densities at GRACE and GOCE show maxima at polar latitudes without clear auroral signatures. Response is fast, minutes from onset to density peaks. center dot GUVI observations of O/N2 ratio during storms show similar response as direct measurements of ion and neutral densities, i.e. high temperatures in polar cap during prestorm quiet period, heating proceeding from polar cap to lower latitudes during storm main phase. center dot Discrepancy between maps of Poynting flux and of ion temperatures/neutral densities suggests that connection between Poynting flux and Joule heating is not simple.

Magnetic Storms↗

NASA NTRS1992

Nonadiabatic heating of the central plasma sheet at substorm onset

Heating events in the plasma sheet boundary layer and central plasma sheet are found to occur at the onset of expansive phase activity. The main effect is a dramatic increase in plasma temperature, coincident with a partial dipolarization of the magnetic field. Fluxes of energetic particles increase without dispersion during these events which occur at all radial distances up to 23 RE, the apogee of the ISEE spacecraft. A major difference between these heating events and those observed at geosynchronous distances lies in the heating mechanism which is nonadiabatic beyond 10 RE but may be adiabatic closer to earth. The energy required to account for the increase in plasma thermal energy is comparable with that required for Joule heating of the ionosphere. The plasma sheet must be considered as a major sink in the energy balance of a substorm. Lobe magnetic pressures during these events are estimated. Change in lobe pressure are generally not correlated with onsets or intensifications of expansive phase activity.

Huang, C. Y.↗

DOE OSTI2025

Advanced Computational Modeling of High-Level Waste Vitrification at the Hanford Site

The U.S. Department of Energy (DOE) has selected vitrification for stabilizing legacy tank waste at the Hanford site, where radioactive waste from plutonium production was historically stored in underground tanks. This waste will be separated into low-activity waste (LAW) and high-level waste (HLW) fractions and processed at the Waste Treatment and Immobilization Plant (WTP). At WTP, glass melters are used for the vitrification of radioactive tank waste, transforming it into a stable borosilicate glass form for safe long-term storage. The melter vessel is constructed from highly durable and heat-resistant materials, where the vitrification process occurs. The main regions that are modeled are the melt pool, plenum, cold cap, riser/discharge chamber, and surrounding structure with insulation layers. Forced convection induced by air bubblers at the base of the melter ensure uniform temperature distribution and provide heat to the cold cap layer. The cold cap is a region of reacting batch feed that floats on top of the molten glass and is where the batch-to-glass reactions occur. Joule heating provided by electrodes mounted along the vertical walls of the melter and immersed directly in the glass, generates the necessary heat for the net endothermic conversion processes that occur in the cold cap. The high temperatures, radioactivity, and opaque nature of the glass prevent direct observation inside the melters. Therefore, computational models are essential for providing insight into factors that affect melter throughput. Thermocouples in the plenum provide operators with plenum temperature measurements. Operational adjustments include bubbling rate, voltage supplied to the electrodes, feed adjustments, and glass removal rate. Different computational fluid dynamics (CFD) models have been developed, each serving a specific purpose. There are CFD models of different scale melters, as well as models that capture the two-phase flow interfaces of rising bubbles in the molten glass or models with a simplified molten glass region so that the surrounding structure and plenum can be feasibly incorporated. Pilot-scale melter models have been developed to serve as validation of the methods employed in the simulation of the full-scale WTP melters. Models incorporating resolved bubbling are used to develop momentum source terms to implement into a single phase, multi-region, steady-state flow model that is being validated by measured process parameters such as glass production rate, voltage, input power, plenum temperatures, etc. The resolved bubbling model uses the multiphase volume of fluid approach to model the system with a high-resolution interface capturing scheme to maintain sharp interfaces between the molten glass and the air phase. The suite of CFD models is continually being improved to incorporate more realistic physics and achieve faster turnaround time. For example, an incremental controller is implemented to automatically adjust electrode voltage within the simulation to a molten glass set point temperature of 1150°C. Newer models feature improved meshes to ensure conformal meshes between regions and eliminate unnecessary mesh refinement in areas that are not of interest (such as boundary layers in offgas ports). Instead of explicitly modeling the structural, refractory, and insulation layers of the melter, a thermal resistance approach is used with published correlations used for boundary conditions. The development of robust and efficient CFD models will be instrumental in enabling the WTP to successfully fulfill its mission of safely stabilizing legacy nuclear waste.

12 - MGMT OF RADIOACTIVE AND NON-RADIOACTIVE WASTE↗

NASA NTRS1996

Evaluation of high temperature superconductive thermal bridges for space borne cryogenic detectors

Infrared sensor satellites are used to monitor the conditions in the earth's upper atmosphere. In these systems, the electronic links connecting the cryogenically cooled infrared detectors to the significantly warmer amplification electronics act as thermal bridges and, consequently, the mission lifetimes of the satellites are limited due to cryogenic evaporation. High-temperature superconductor (HTS) materials have been proposed by researchers at the National Aeronautics and Space Administration Langley's Research Center (NASA-LaRC) as an alternative to the currently used manganin wires for electrical connection. The potential for using HTS films as thermal bridges has provided the motivation for the design and the analysis of a spaceflight experiment to evaluate the performance of this superconductive technology in the space environment. The initial efforts were focused on the preliminary design of the experimental system which allows for the quantitative comparison of superconductive leads with manganin leads, and on the thermal conduction modeling of the proposed system. Most of the HTS materials were indicated to be potential replacements for the manganin wires. In the continuation of this multi-year research, the objectives of this study were to evaluate the sources of heat transfer on the thermal bridges that have been neglected in the preliminary conductive model and then to develop a methodology for the estimation of the thermal conductivities of the HTS thermal bridges in space. The Joule heating created by the electrical current through the manganin wires was incorporated as a volumetric heat source into the manganin conductive model. The radiative heat source on the HTS thermal bridges was determined by performing a separate radiant interchange analysis within a high-T(sub c) superconductor housing area. Both heat sources indicated no significant contribution on the cryogenic heat load, which validates the results obtained in the preliminary conduction model. A methodology was presented for the estimation of the thermal conductivities of the individual HTS thermal bridge materials and the effective thermal conductivities of the composite HTS thermal bridges as functions of temperature. This methodology included a sensitivity analysis and the demonstration of the estimation procedure using simulated data with added random errors. The thermal conductivities could not be estimated as functions of temperature; thus the effective thermal conductivities of the HTS thermal bridges were analyzed as constants.

Scott, Elaine P.↗

NASA NTRS1982

Computer modeling of thermoelectric generator performance

Features of the DEGRA 2 computer code for simulating the operations of a spacecraft thermoelectric generator are described. The code models the physical processes occurring during operation. Input variables include the thermoelectric couple geometry and composition, the thermoelectric materials' properties, interfaces and insulation in the thermopile, the heat source characteristics, mission trajectory, and generator electrical requirements. Time steps can be specified and sublimation of the leg and hot shoe is accounted for, as are shorts between legs. Calculations are performed for conduction, Peltier, Thomson, and Joule heating, the cold junction can be adjusted for solar radition, and the legs of the thermoelectric couple are segmented to enhance the approximation accuracy. A trial run covering 18 couple modules yielded data with 0.3% accuracy with regard to test data. The model has been successful with selenide materials, SiGe, and SiN4, with output of all critical operational variables.

Chmielewski, A. B.↗

NASA NTRS1976

The critical currents in superconducting tin films

The nonlinear current-voltage curves exhibited by tin films in the flux flow state have made studies of the amount of heating present in the sample necessary. The samples in this work consisted of an evaporated tin film on one side of a 2 mm thick crystal quartz substrate and a carbon film of the same configuration as the tin film on the back of the substrate. The carbon film was used as a thermometer to measure the temperature rise of the tin film above the bath temperature. The heating results indicate negligible effects in the samples. Temperature ratios as small as 0.80 for the tin samples have been investigated and the current-voltage characteristics are still nonlinear, indicating that the source of the nonlinearity is not Joule heating in the samples.

Payne, J. E.↗

NASA NTRS1979

The heating of the temperature minimum region in solar flares - A reassessment

The paper discusses and evaluates the suggestions made by Machado et al. (1978) on how to reconcile the observed temperature enhancements at temperature-minimum levels in solar flares with some theoretical heating mechanism. The objective is to gain deeper insight into the nature of the photospheric flare. The discussion focuses on the validity of the assumption of H(-) LTE at temperature-minimum levels, as well as on EUV irradiation and Joule heating by steady currents as heating mechanisms. It is found that, unless there are strong inhomogeneities associated with either heating mechanism, neither can reasonably be reconciled with observations. It is concluded that detailed high-resolution (both spatial and temporal) measurements are necessary to further the present understanding of the flare process at temperature-minimum levels.

Emslie, A. G.↗

DOE OSTI2021

Large-scale additive manufacturing of self-heating molds

Large-scale material extrusion additive manufacturing technology is becoming the new mainstream technology for scaled-up composite mold and die applications. This paradigm shift in composite processing technology is primarily driven by out-of-autoclave tooling applications, in which fiber reinforced composite molds with scaled-up sizes and embedded heating elements are attractive. The present research describes the design, manufacturing, and testing of self-heating composite molds fabricated via a large-scale pellet extrusion 3D printing machine with an integrated wire co-extrusion tool. Polycarbonate (PC) composites reinforced with carbon fiber (PC/CF; 20 wt.%) and glass fiber (PC/GF; 20 wt.%) were used to fabricate mold parts. Joule heating thermal test results showed that uniform temperatures (~100 °C) were achieved for both PC/CF and PC/GF mold surfaces, using a custom-made feedback control power supply and infrared thermography. Mechanical characterizations, including tensile and flexural testing were performed on the wire-embedded and un-wired PC/CF and PC/GF base specimens to investigate the impact of the fiber reinforcement as well as the embedded wires. In the direction of extrusion, the ultimate tensile stress of PC/CF was 105 MPa, and that of PC/GF was 73 MPa, while the neat PC value was 64 MPa. Inner-bead voids and interfacial gaps were observed and characterized via optical and scanning electron microscopy. The embedded wires and inner bead impacted the mechanical properties of the composites. Furthermore, the stiffness of the wire-embedded mold was still satisfactory, proving that the technology can be used to fabricate additively manufactured out-of-oven/autoclave molds.

36 MATERIALS SCIENCE↗

NASA NTRSDate not supplied

Atmospheric Escape from Magnetized Rocky Exoplanets

Recent Kepler and TESS observations discovered many rocky exoplanets in habitable zones around active main-sequence stars. The upper atmospheres of exoplanets are subject to two important energy sources derived from their host stars. First, the stellar photon flux in the X-ray and XUV bands ionizes and heats the upper atmosphere, driving atmospheric heating, affecting the conductance, and enhancing atmospheric escape. Second, the stellar wind’s interaction with the exoplanet’s intrinsic magnetic field transfers energy to the atmosphere through field aligned currents and Poynting flux. That energy is dissipated in the high latitude cusp and auroral regions through Joule heating which can inflate the atmosphere and also enhance the atmospheric escape rate. This presentation will discuss recent advances in modeling these energy inputs and their consequences for exoplanetary habitability. Also, I will discuss the development of a new model, the (exo) PLANETary Ionosphere-Thermosphere Tool for Research (PLANET-ITTR) and some early results from it.

William Danchi↗

DOE OSTI2024

Real‐Time Observation of Slowed Charge Density Wave Dynamics in Thinned 1T‐TaS 2

Abstract Transient electrical pulsing is used to investigate the slowed charge density wave (CDW) kinetics of 1T‐TaS 2 . These measurements distinguish a fast response of the material, consistent with the onset of self‐heating, from much slower transients that occur on timescales orders of magnitude longer than this. The latter variations appear consistent with slow configurational changes in the CDW, which, due to the thin nature of the 1T‐TaS 2 , can be distinguished from the much faster dynamics of Joule heating. Experiments in which the cooling of the material is interrupted, demonstrate the possibility of “programming” it in different, strongly nonequilibrium, CDW phases. Collectively, the results point to the existence of a complex free‐energy space for the thinned material, whose multi‐valley structure and hidden metastable states govern the resulting thermal and field‐driven dynamics. Crucially, this work demonstrates that while the CDW dynamics in this material may have a thermal character, the timescales associated with these motions can be very different from those on which self‐heating occurs. This discovery will be important for efforts to implement active devices that utilize the CDW states of thinned 1T‐TaS 2 .

Yin, Shenchu↗

NASA NTRS1983

Amalthea - Implications of the temperature observed by Voyager

The temperature profile of Amalthea's surface layer is modeled as a function of location and time of day, assuming a triaxial ellipsoid shape and thermal properties similar to those of the lunar soil. Although the major heat source is direct insolation, temperatures are slightly increased by thermal radiation from Jupiter, sunlight reflected from the planet, and charged particle bombardment. Possible sources of error in the model are discussed in detail, including satellite shape effects, unusually low emissivity, uncommonly rough surface, abnormal thermal inertia, charged particle flux variability, and Joule heating. Voyager 1 IRIS observations suggest that the Amalthean surface has an emissivity near unity, but cannot put any useful limits on the thermal inertia of the Amalthean surface layer.

Simonelli, D. P.↗

NASA NTRS2016

Modeling and Simulation of Radiative Compressible Flows in Aerodynamic Heating Arc-Jet Facility

Numerical simulations of an arc heated flow inside NASA's 20 [MW] Aerodynamics heating facility (AHF) are performed in order to investigate the three-dimensional swirling flow and the current distribution inside the wind tunnel. The plasma is considered in Local Thermodynamics Equilibrium(LTE) and is composed of Air-Argon gas mixture. The governing equations are the Navier-Stokes equations that include source terms corresponding to Joule heating and radiative cooling. The former is obtained by solving an electric potential equation, while the latter is calculated using an innovative massively parallel ray-tracing algorithm. The fully coupled system is closed by the thermodynamics relations and transport properties which are obtained from Chapman-Enskog method. A novel strategy was developed in order to enable the flow solver and the radiation calculation to be preformed independently and simultaneously using a different number of processors. Drastic reduction in the computational cost was achieved using this strategy. Details on the numerical methods used for space discretization, time integration and ray-tracing algorithm will be presented. The effect of the radiative cooling on the dynamics of the flow will be investigated. The complete set of equations were implemented within the COOLFluiD Framework. Fig. 1 shows the geometry of the Anode and part of the constrictor of the Aerodynamics heating facility (AHF). Fig. 2 shows the velocity field distribution along (x-y) plane and the streamline in (z-y) plane.

Pasma flows↗

NASA NTRS1980

Model calculations of the dayside ionosphere of Venus - Energetics

A model of the energy balance of the dayside ionosphere of Venus is presented. Calculations of the dayside electron and ion temperature profiles are carried out and compared with data from experiments on the Pioneer Venus orbiter. The coupled heat conduction equations for electrons and ions are solved for several values of the solar zenith angle. It is shown that thermal conductivities are inhibited by the presence of a horizontal magnetic field. A realistic model of the magnetic field that includes fluctuations is employed in deriving an appropriate expression for the thermal conductivity. The contributions of photoelectrons, ion chemistry, Joule heating, and solar wind heating to the energy balance of the ionosphere are considered.

Cravens, T. E.↗