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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 199 records · Page 11

Fuel cells for single-aisle regional aircraft: System configuration, performance and cost

A hydrogen fuel cell propelled electric aircraft can compete with incumbent turbofan technologies for single-aisle regional aircraft by coupling design of stack, air handling, thermal management, propulsion, and airframe to optimize performance. The stack operates at 95°C to facilitate heat rejection during take-off and below 75°C during cruise to extend lifetime and is oversized to satisfy power requirements at end of life. A multi-stage turbocompressor with a compression ratio >10 is selected to reach high stack power density at 11,300-m cruise altitude. The propulsion system is configured to accommodate air handling within the core duct, an inclined heat exchanger in the outer duct to limit the nacelle size, and variable area nozzles to independently control mass flows through the core and bypass ducts. The airframe is modified for maximum lift coefficient and longer balanced field length for dramatically reduced thrust during take-off, and the fuselage is stretched by 20% to store liquid hydrogen (LH 2 ). Modularization of power systems promotes safety in one engine inoperative scenarios and allows reaching specific power metrics for stack, balance-of-plant and fuel cell system (FCS), necessary for acceptable take-off weight. In conclusion, cost parity requires increase in FCS lifetime, LH 2 cost reduction, and improved FCS specific power.

Catalyst durability↗

Effects of collisional ion orbit loss on neoclassical tokamak radial electric fields

We report that ion orbit loss is considered important for generating the radially inward electric field E r in a tokamak edge plasma. In particular, this effect is emphasized in diverted tokamaks with a magnetic X point. In neoclassical equilibria, Coulomb collisions can scatter ions onto loss orbits and generate a radially outward current, which in steady state is balanced by the radially inward current from viscosity. To quantitatively measure this loss-orbit current in an edge pedestal, an ion-orbit-flux diagnostic has been implemented in the axisymmetric version of the gyrokinetic particle-in-cell code XGC. As the first application of this diagnostic, a neoclassical DIII-D H-mode plasma is studied using gyrokinetic ions and adiabatic electrons. The validity of the diagnostic is demonstrated by studying the collisional relaxation of E r in the core. After this demonstration, the loss-orbit current is numerically measured in the edge pedestal in quasisteady state. In this plasma, it is found that the radial electric force on ions from E r approximately balances the ion radial pressure gradient in the edge pedestal, with the radial force from the plasma flow term being a minor component. The effect of orbit loss on E r is found to be only mild.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

Effects of collisional ion orbit loss on neoclassical tokamak radial electric fields

Ion orbit loss is considered important for generating the radially inward electric field Er in a tokamak edge plasma. In particular, this effect is emphasized in diverted tokamaks with a magnetic X point. In neoclassical equilibria, Coulomb collisions can scatter ions onto loss orbits and generate a radially outward current, which in steady state is balanced by the radially inward current from viscosity. To quantitatively measure this loss-orbit current in an edge pedestal, an ion-orbit-flux diagnostic has been implemented in the axisymmetric version of the gyrokinetic particle-in-cell code XGC. As the first application of this diagnostic, a neoclassical DIII-D H-mode plasma is studied using gyrokinetic ions and adiabatic electrons. The validity of the diagnostic is demonstrated by studying the collisional relaxation of Er in the core. After this demonstration, the loss-orbit current is numerically measured in the edge pedestal in quasisteady state. In this plasma, it is found that the radial electric force on ions from Er approximately balances the ion radial pressure gradient in the edge pedestal, with the radial force from the plasma flow term being a minor component. The effect of orbit loss on Er is found to be only mild.

gyrokinetic simulations↗

From pools to flow: The PROMISE framework for new insights on soil carbon cycling in a changing world

Soils represent the largest terrestrial reservoir of organic carbon, and the balance between soil organic carbon (SOC) formation and loss will drive powerful carbon-climate feedbacks over the coming century. To date, efforts to predict SOC dynamics have rested on pool-based models, which assume classes of SOC with internally homogenous physicochemical properties. However, emerging evidence suggests that soil carbon turnover is not dominantly controlled by the chemistry of carbon inputs, but rather by restrictions on microbial access to organic matter in the spatially heterogeneous soil environment. The dynamic processes that control the physicochemical protection of carbon translate poorly to pool-based SOC models; as a result, we are challenged to mechanistically predict how environmental change will impact movement of carbon between soils and the atmosphere. In this study, we propose a novel conceptual framework to explore controls on belowground carbon cycling: Probabilistic Representation of Organic Matter Interactions within the Soil Environment (PROMISE). In contrast to traditional model frameworks, PROMISE does not attempt to define carbon pools united by common thermodynamic or functional attributes. Rather, the PROMISE concept considers how SOC cycling rates are governed by the stochastic processes that influence the proximity between microbial decomposers and organic matter, with emphasis on their physical location in the soil matrix. We illustrate the applications of this framework with a new biogeochemical simulation model that traces the fate of individual carbon atoms as they interact with their environment, undergoing biochemical transformations and moving through the soil pore space. We also discuss how the PROMISE framework reshapes dialogue around issues related to SOC management in a changing world. We intend the PROMISE framework to spur the development of new hypotheses, analytical tools, and model structures across disciplines that will illuminate mechanistic controls on the flow of carbon between plant, soil, and atmospheric pools.

54 ENVIRONMENTAL SCIENCES↗

Ideal internal kink stability in presence of plasma flow and neoclassical toroidal viscosity due to energetic particles

Abstract The influence of energetic particles (EPs) on the ideal internal kink mode, in rotating tokamak plasmas, is numerically investigated by simultaneously solving MHD-kinetic hybrid equations together with a toroidal momentum balance equation utilizing the MARS-Q code (Liu et al 2013 Phys. Plasmas 20 042503). The neoclassical toroidal viscous (NTV) torque, induced by precessional drift resonances of trapped energetic particles, acts as the momentum sink term to damp the plasma flow. Quasi-linear initial value simulations show local reduction of the flow amplitude and enhancement of the flow shear near the q = 1 rational surface ( q is the safety factor) due to EP induced NTV. Both effects in turn destabilize the internal kink mode. These numerical findings are robust against the initial linear stability of internal kink, the initial plasma flow profile, as well as the equilibrium distribution model for EPs.

Physics↗

The Large-Scale Vorticity Balance of the Antarctic Continental Margin in a Fine-Resolution Global Simulation

The depth-integrated vorticity budget of a global, eddy-permitting ocean/sea ice simulation over the Antarctic continental margin (ACM) is diagnosed to understand the physical mechanisms implicated in meridional transport. The leading-order balance is between the torques due to lateral friction, nonlinear effects, and bottom vortex stretching, although details vary regionally. Maps of the time-averaged depth-integrated vorticity budget terms and time series of the spatially averaged, depth-integrated vorticity budget terms reveal that the flow in the Amundsen, Bellingshausen, and Weddell Seas and, to a lesser extent, in the western portion of East Antarctica, is closer to an approximate topographic Sverdrup balance (TSB) compared to other segments of the ACM. Correlation and coherence analyses further support these findings, and also show that inclusion of the vorticity tendency term in the response (the planetary vorticity advection and the bottom vortex stretching term) increases the correlation with the forcing (the vertical net stress curl), and also increases the coherence between forcing and response at high frequencies across the ACM, except for the West Antarctic Peninsula. Finally, these findings suggest that the surface stress curl, imparted by the wind and the sea ice, has the potential to contribute to the meridional, approximately cross-slope, transport to a greater extent in the Amundsen, Bellingshausen, Weddell, and part of the East Antarctic continental margin than elsewhere in the ACM.

58 GEOSCIENCES↗

Public Reference Data for Megawatt-Scale Hydrogen Electrolysis - Simulated Marine Hydrokinetic Tidal Turbine

The U.S. Department of Energy and National Laboratory of the Rockies (NLR) demonstrate hydrogen electrolysis, hydrogen compression and storage, and variable hydrogen fuel cell power production using megawatt-scale equipment at NLR’s Flatirons Campus as part of the Advanced Research on Integrated Energy Systems (ARIES) initiative. This dataset is part of that effort and is intended for academic, national laboratory, industrial, and other stakeholders to plan, design, and validate models of megawatt-scale hydrogen technologies and diverse energy infrastructure. These data provide a baseline for how existing hydrogen electrolysis technologies perform when coupled with other energy technologies. This dataset contains inputs and outputs from simulations of a floating marine hydrokinetic turbine over approximately half a tidal cycle (~6.6 hours). Inflow conditions were derived from field measurements in Alaska’s Cook Inlet and represent a tidal environment in which the current speed ramps from near 0 m/s to a peak of 3 m/s and back. The original acoustic doppler current profiler dataset is publicly available on the Marine and Hydrokinetic Data Repository. In a full tidal cycle, the flow reverses and the rotor would reorient; this reversal was not modeled. In the Cook Inlet campaign , turbulence intensity was similar in both directions. Two inflow cases are included. In the first case, labeled “raw” in the files, the measured current time series was used directly in the InflowWind module of OpenFAST. Speed and direction were applied as a function of time and elevation, uniformly in the horizontal direction. With full spatial coherence, this approach captures high turbulent variability and results in pronounced power fluctuations, so it is considered a conservative, near-worst-case representation of loading. In the second case, labeled “average” in the files, a 30-minute moving average was applied to extract the slowly varying mean speed. The residual fluctuations about this mean were used to generate spatially varying, full-field turbulence inputs with TurbSim, giving a more physically realistic representation of the inflow across the rotor disk. Two random realizations were used to produce distinct inflow conditions for two OpenFAST simulations representing a two-turbine array. The same turbulence intensity is applied across the full time series, producing larger fluctuations at the start and end, where the mean speed is low. The second case is the more appropriate framework for performance and power assessment but overpredicts turbulence at lower flow speeds and underpredicts it at higher speeds. As the floating platform moves and the rotor changes its x-position, Taylor’s frozen turbulence hypothesis used by InflowWind assumes a constant rather than a time-varying mean velocity, introducing some inaccuracy in the velocity plane sampling. The turbine modeled is the 500-kW Reference Model 1, a horizontal-axis two-bladed hydrokinetic turbine on a four-column floating semisubmersible substructure . Simulations were performed using OpenFAST v4.1 with the Reference Open Source Controller (ROSCO) v2.10. All input files required to reproduce the simulations are included. The electrolyzer is a 1.25-MW proton exchange membrane type MC250 system manufactured by Nel . This unit supports up to 2.5 MW, but NLR has only a single 1.25-MW stack. The datasets report hydrogen balance-of-plant and system data, all captured at 1 Hz, including hydrogen mass production measured with an Emerson Coriolis flow meter. The system controls hydrogen production by varying direct current applied to the stack, from a maximum of 3,000 A to a minimum safe operating current of 300 A, or 10%. Because the current–voltage characteristic changes as the stack ages and efficiency degrades, the actual minimum safe operating power changes over time. The simulated tidal turbine time series data was translated from power (kilowatts) to current (amperes) using a curve fit with calibration data and sent to the electrolyzer power supply at 1-Hz. Each zip file represents a single tidal electrolysis experiment and is named: {technology}_{inflow method}_{number of 500 kW tidal turbines connected} For instance, “tidal-500kW-RM1_average_2.zip” is a 6-hour experiment using the 500-kW tidal reference model, scaled by 2x (1-MW) to better match the electrolyzer maximum of 1.25MW, fed with the 30-minute moving average current case. Each zip folder contains the following files: A .csv file of raw data. An .xlsx file explaining all the fields in the raw data. A .png plot showing the time series of hydrogen production in kilograms per hour, electrolysis power consumption, and input wave power. A .csv file combines all tidal profiles as "combined_tidal_experiments.csv." A separate experiment, “characterization_200.zip,” shows the MC250 electrolyzer steady-state response with 30-minute load steps over 5 hours and is accessible with this entry.

08 HYDROGEN↗

ISMIP6 Antarctica: a multi-model ensemble of the Antarctic ice sheet evolution over the 21st century

Abstract. Ice flow models of the Antarctic ice sheet are commonly used to simulate its future evolution in response to different climate scenarios and assess the mass loss that would contribute to future sea level rise. However, there is currently no consensus on estimates of the future mass balance of the ice sheet, primarily because of differences in the representation of physical processes, forcings employed and initial states of ice sheet models. This study presents results from ice flow model simulations from 13 international groups focusing on the evolution of the Antarctic ice sheet during the period 2015–2100 as part of the Ice Sheet Model Intercomparison for CMIP6 (ISMIP6). They are forced with outputs from a subset of models from the Coupled Model Intercomparison Project Phase 5 (CMIP5), representative of the spread in climate model results. Simulations of the Antarctic ice sheet contribution to sea level rise in response to increased warming during this period varies between −7.8 and 30.0 cm of sea level equivalent (SLE) under Representative Concentration Pathway (RCP) 8.5 scenario forcing. These numbers are relative to a control experiment with constant climate conditions and should therefore be added to the mass loss contribution under climate conditions similar to present-day conditions over the same period. The simulated evolution of the West Antarctic ice sheet varies widely among models, with an overall mass loss, up to 18.0 cm SLE, in response to changes in oceanic conditions. East Antarctica mass change varies between −6.1 and 8.3 cm SLE in the simulations, with a significant increase in surface mass balance outweighing the increased ice discharge under most RCP 8.5 scenario forcings. The inclusion of ice shelf collapse, here assumed to be caused by large amounts of liquid water ponding at the surface of ice shelves, yields an additional simulated mass loss of 28 mm compared to simulations without ice shelf collapse. The largest sources of uncertainty come from the climate forcing, the ocean-induced melt rates, the calibration of these melt rates based on oceanic conditions taken outside of ice shelf cavities and the ice sheet dynamic response to these oceanic changes. Results under RCP 2.6 scenario based on two CMIP5 climate models show an additional mass loss of 0 and 3 cm of SLE on average compared to simulations done under present-day conditions for the two CMIP5 forcings used and display limited mass gain in East Antarctica.

54 ENVIRONMENTAL SCIENCES↗

Computational and numerical analysis of AC optimal power flow formulations on large-scale power grids

We report that alternating current optimal power flow (AC-OPF) is a fundamental tool in electric utilities to determine optimal operation of the various resources. Typically, the AC-OPF problem uses power balance formulation containing voltages and power equations. Yet, there is no comprehensive comparison of the different AC-OPF formulations, especially for large-scale networks. This paper presents a detailed comparative evaluation of different formulations of the AC-OPF problem on networks ranging from 9-bus to 25,000 buses. Three different formulations: 1) power balance with polar voltages, 2) power balance with Cartesian voltages, and 3) current balance with Cartesian voltages are discussed in detail by comparing their characteristics, and numerical and computational performance.

24 POWER TRANSMISSION AND DISTRIBUTION↗

Dimits shift, avalanche-like bursts, and solitary propagating structures in the two-field flux-balanced Hasegawa–Wakatani model for plasma edge turbulence

We show that the recently introduced two-field flux-balanced Hasegawa–Wakatani (BHW) model captures the key features of drift-wave turbulent transport mediated by zonal flows observed in more complete and accurate gyrokinetic simulations, such as the existence of a nonlinear upshift of the threshold for drift wave turbulence driven transport, often called the Dimits shift, as well as non-local transport with avalanche bursts and solitary propagating structures. Because of the approximations made in the BHW model, these observations are made for the particle flux instead of the heat flux more commonly studied in ion temperature gradient (ITG) driven turbulence in fluid or gyrokinetic codes. Many of these features are not seen in other Hasegawa–Wakatani models, which confirm the critical role of the electron dynamics parallel to the magnetic field lines. To address questions regarding the role of boundary conditions on the drift-wave zonal flow dynamics, we apply our model to both a channel domain geometry and the more typical doubly periodic geometry. We only observe strong soliton-like solutions in the particle flux for the channel geometry, in the vicinity of the boundaries, where strong velocity shear and density gradients are generated, which are absent in the doubly periodic simulations. Changing the aspect ratio of the simulation domain also has a significant effect. In domains which are elongated in the radial direction, more complex multi-scale dynamics takes place, with multiple zonal jets interacting with each other, and large scale avalanches.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

Atmospheric pressure plasma functionalization of polystyrene

Atmospheric pressure plasma jets (APPJs) are used to improve the adhesive and hydrophilic properties of commodity hydrocarbon polymers such as polypropylene, polyethylene, and polystyrene (PS). These improvements largely result from adding oxygen functional groups to the surface. PS functionalization is of interest to produce high value biocompatible well-plates and dishes, which require precise control over surface properties. In this paper, we discuss results from a computational investigation of APPJ functionalization of PS surfaces using He/O 2 /H 2 O gas mixtures. A newly developed surface reaction mechanism for functionalization of PS upon exposure to these plasmas is discussed. A global plasma model operated in plug-flow mode was used to predict plasma-produced species fluxes onto the PS surface. A surface site balance model was used to predict oxygen-functionalization of the PS following exposure to the plasma and ambient air. We found that O-occupancy on the surface strongly correlates with the O-atom flux to the PS, with alcohol groups and cross-linked products making the largest contributors to total oxygen fraction. Free radical sites, such as alkoxy and peroxy, are quickly consumed in the post-plasma exposure to air through passivation and cross-linking. O-atom fluences approaching 10 17 cm -2 saturate the O-occupancy on the PS surface, creating functionality that is not particularly sensitive to moderate changes in operating conditions.

36 MATERIALS SCIENCE↗

Multiscale thermal hydraulic coupling methods for boiling water reactor simulation

During the last two years, the Virtual Environment for Reactor Applications (VERA) has been extended to simulate boiling water reactors (BWRs). The thermal hydraulic effects present in BWRs are far more complex than those in pressurized water reactors (PWRs). Therefore, the runtime is significantly increase and convergence behavior worse compared to PWRs. Most of the additional runtime is spent during the first few coupled iterations, when the power shape is still rapidly evolving, dramatically affecting the thermal hydraulics (TH). To alleviate the increased computational expense, a multiscale TH coupling approach was developed in VERA in which a highly efficient, simplified TH model is solved for several coupled iterations until the power shape is partially converged. The simplified solution is used to inform the assembly-wise flow distribution in the high-fidelity TH solver CTF, reducing the amount of work required to properly balance the pressure drop in each channel and reducing runtime for the couple calculation. Because the final TH calculations are performed with CTF, there is ultimately no impact on the accuracy of the converged solution. This paper presents the details of this multiscale TH coupling approach, along with results for a 4x4 array of GE-14 fuel bundles and whole-core coupled simulations of the Hatch core. These two cases show that the multiscale approach dramatically reduces the runtime of coupled BWR simulations. (authors)

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

Population balance modeling of polyurethane foam formation with pressure‐dependent growth kernel

Abstract Polyurethane foams are widely used materials often chosen for their useful characteristics such as low thermal conductivity, ease of application, and high strength‐to‐weight ratios. Computational models are needed to predict the dynamics of the flow and expansion, and the resulting material properties, to improve manufacturing processes. In this paper, a model for PMDI, a water‐blown polyurethane foam, is presented. By extending a kinetics‐based approach by adding bubble‐scale information via a population balance equation (PBE) using the quadrature method of moments, we can track bubble size distributions during foaming. We present results from a three‐dimensional computational fluid dynamics model using arbitrary Lagrangian–Eulerian interface tracking implemented in finite element software. The model compares favorably with experimental data, including dynamics, bubble distributions measured by both camera and diffusion wave spectroscopy, and post‐test bubble size from scanning electron microscopy and density measurements from x‐ray computed tomography.

Ortiz, Weston↗

Machine-learned closure of URANS for stably stratified turbulence: connecting physical timescales & data hyperparameters of deep time-series models

Stably stratified turbulence (SST), a model that is representative of the turbulence found in the oceans and atmosphere, is strongly affected by fine balances between forces and becomes more anisotropic in time for decaying scenarios. Moreover, there is a limited understanding of the physical phenomena described by some of the terms in the Unsteady Reynolds-Averaged Navier–Stokes (URANS) equations—used to numerically simulate approximate solutions for such turbulent flows. Rather than attempting to model each term in URANS separately, it is attractive to explore the capability of machine learning (ML) to model groups of terms, i.e. to directly model the force balances. We develop deep time-series ML for closure modeling of the URANS equations applied to SST. We consider decaying SST which are homogeneous and stably stratified by a uniform density gradient, enabling dimensionality reduction. We consider two time-series ML models: long short-term memory and neural ordinary differential equation. Both models perform accurately and are numerically stable in a posteriori (online) tests. Furthermore, we explore the data requirements of the time-series ML models by extracting physically relevant timescales of the complex system. We find that the ratio of the timescales of the minimum information required by the ML models to accurately capture the dynamics of the SST corresponds to the Reynolds number of the flow. The current framework provides the backbone to explore the capability of such models to capture the dynamics of high-dimensional complex dynamical system like SST flows.

97 MATHEMATICS AND COMPUTING↗

Scale-Up Studies for the Dehydration of C 4+ Alcohols into Drop-In Diesel Fuel

Herein, we demonstrate the production of liter quantities of drop-in diesel-range ethers from biomass-derived alcohols. We report scale-up resultsfor the dehydration of a mixture of C 4+ alcohols using powder and pellet zeolite Ycatalyst in continuous flow and batch reactors. The activity of zeolite Y decreaseswith the introduction of an alumina binder. Large alcohols, as well as branchedand secondary alcohols, increase the coke content over the pellet Y catalyst. Thepellet formulation had lower carbon balances and selectivity to C 10+ ethers,suggesting that the pellet formulation increases alcohol absorption and cokeproduction. Crushing the pellet Y catalyst to smaller particle sizes does notrecover the activity of zeolite Y in its powder form. Cold flow experiments showthat particle agglomeration contributes to pressure buildup in the continuous flowreactor. C 10+ ether blends can be produced in batch reactors at high alcohol conversion regimes. One liter of a diesel #2 blend wasproduced by scaling up this reaction. The final blend consists of a substantial portion of C 10+ ethers (63.7 wt %), followed by heavyunknown products (27.4 wt %). Furthermore, the final alcohol and butyl ether concentration values were 7.3 and 1.5 wt %, respectively. Theblendstock reported in this paper can satisfy diesel #2 ASTM standards for density, cloud point, flashpoint, and cetane number.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

The advancing wave front on a sloping channel covered by a rod canopy following an instantaneous dam break

The drag coefficient Cd for a rigid and uniformly distributed rod canopy covering a sloping channel following the instantaneous collapse of a dam was examined using flume experiments. The measurements included space x and time t high resolution images of the water surface h(x, t) for multiple channel bed slopes So and water depths behind the dam Ho along with drag estimates provided by sequential load cells. Using these data, an analysis of the Saint-Venant equation (SVE) for the front speed was conducted using the diffusive wave approximation. An inferred Cd=0.4 from the h(x, t) data near the advancing front region, also confirmed by load cell measurements, is much reduced relative to its independently measured steady-uniform flow case. This finding suggests that drag reduction mechanisms associated with transients and flow disturbances are more likely to play a dominant role when compared to conventional sheltering or blocking effects on Cd examined in uniform flow. The increased air volume entrained into the advancing wave front region as determined from an inflow–outflow volume balance partly explains the Cd reduction from unity.

Mechanics↗

Localized mix-induced radiative cooling in a capsule implosion at the National Ignition Facility

In this work, w present direct measurements of electron temperature variations within an inertially confined deuterium-tritium plasma caused by localized mix of higher-Z materials into the central hot spot. The data are derived from newly developed differentially filtered penumbral imaging of the bremsstrahlung continuum emission. Our analysis reveals distinct localized emitting features in the stagnated hot-spot plasma, and we infer spatial variations in the electron temperature: the mixed region is 660±130eV colder than the surrounding hot-spot plasma at 3.26±0.11keV. Our analysis of the energy flow shows that we measure approximately steady-state conditions where the radiative losses in the mix region are balanced by heat conduction from the surrounding hot deuterium-tritium plasma.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

Application of a Distributed Element Roughness Model to Additively Manufactured Internal Cooling Channels

Abstract Design for cooling effectiveness in turbine blades relies on accurate models for dynamic losses and heat transfer of internal cooling passages. Metal additive manufacturing (AM) has expanded the design space for these configurations, but can give rise to large-scale roughness features. The range of roughness length scales in these systems makes morphology resolved computational fluid dynamics (CFD) impractical. However, volumetric roughness models can be leveraged, as they have computational costs orders of magnitude lower. In this work, a discrete element roughness model (DERM), based on the double-averaged Navier–Stokes equations, is presented and applied to additively manufactured rough channels, representative of gas turbine blade cooling passages. Unique to this formulation of DERM is a generalized sheltering-based treatment of drag, a two-layer model for spatially averaged Reynolds stresses, and explicit treatment of dispersion. Six different AM rough surface channel configurations are studied, with roughness trough to peak sizes ranging from 15% to 60% nominal channel passage half-width, and the roughness Reynolds number ranges from Rek = 60 to 300. DERM predictions for spatially and temporally averaged mean flow quantities are compared to previously reported direct numerical simulation results. Good agreement in the mean velocity profiles, stress balances, and drag partitions are observed. While DERM models are typically calibrated to specific deterministic roughness morphologies at comparatively small roughness Reynolds numbers, the present more generalized DERM formulation has wider applicability. Here, it is demonstrated that the model can accommodate random roughness of large scale, typical of AM.

Engineering↗