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At least 235 records · Page 13

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DOE OSTI2020

Elucidating the effect of preheating temperature on melt pool morphology variation in Inconel 718 laser powder bed fusion via simulation and experiment

In laser powder bed fusion (L-PBF) additive manufacturing, the mechanical performance, microstructure and defects of fabricated parts are closely associated with the melt pool morphology, e.g., its dimension and shape through the building process. Past studies have largely focused on how the process parameters such as laser power and scan speed affect melt pool characteristics. In this study, the melt pool morphology variation as a function of preheating temperature in the conduction, transition, and keyhole regimes and the underlying mechanisms in each regime are investigated through ex-situ sample characterization and computation thermal fluid dynamics (CtFD) simulation. Single tracks with different combinations of laser power and scan speed are deposited on an Inconel 718 bare plate preheated to a temperature range of 100–500 °C in the experiment. Significant changes are observed in melt pool morphology as a function of preheating temperature from optical measurements of melt track cross sections. The depth of melt pool in the three regimes increases monotonically with preheating temperature, e.g., at 500 °C, the experimental melt pool depth is increased by 49% in conduction regime, 34% in transition regime and 33% in keyhole regime, respectively, while the variation of melt pool width in each regime does not all follow an increasing trend but depends on the melt pool regimes. Melt pool width variation in the conduction and transition regimes is found to depend on the enhanced heat conduction directly related to temperature dependent thermal properties. Through validated CtFD simulations, it is found that in the keyhole regime the evaporation mass, recoil pressure, and laser drilling effect is enhanced with higher preheating temperature, which gives rise to a deeper melt pool. The simulations also reveal that preheating temperature significantly elongates the melt track length due to the increased flow rate and strong recoil pressure that accelerates the backward flow.

36 MATERIALS SCIENCE↗

DOE OSTI2023

Spatio-temporal patterning of extensile active stresses in microtubule-based active fluids

Abstract Microtubule-based active fluids exhibit turbulent-like autonomous flows, which are driven by the molecular motor powered motion of filamentous constituents. Controlling active stresses in space and time is an essential prerequisite for controlling the intrinsically chaotic dynamics of extensile active fluids. We design single-headed kinesin molecular motors that exhibit optically enhanced clustering and thus enable precise and repeatable spatial and temporal control of extensile active stresses. Such motors enable rapid, reversible switching between flowing and quiescent states. In turn, spatio-temporal patterning of the active stress controls the evolution of the ubiquitous bend instability of extensile active fluids and determines its critical length dependence. Combining optically controlled clusters with conventional kinesin motors enables one-time switching from contractile to extensile active stresses. These results open a path towards real-time control of the autonomous flows generated by active fluids.

36 MATERIALS SCIENCE↗

DOE OSTI2025

NEWTS Economic Data Dashboard: Critical Materials for Energy

The NEWTS Economic Data Dashboard: Critical Materials for Energy is an economic screening tool for assessing the concentration and potential value of the 18 critical materials for energy in fossil energy-related wastewater across the United States. Datasets used to develop the dashboard and complete economic calculations are available as supplementary downloads. These resources were developed primarily using geochemical composition and volume data from the NEWTS Integrated dataset (version 1.0). Energy-related wastewater types presented in the dashboard include produced water (PW), brackish groundwater (BW), acid mine drainage (AMD), coal combustion residual leachate (CCRL), power plant flue gas desulfurization wastewater (FGD), and geothermal fluids. The concentrations of the following critical minerals were included in the analysis, when available: Al, Co, Cu, Dy, F, Ga, Ge, C, Ir, Li, Mg, Mn, Nd, Ni, Pt, Pr, Si, Tb. This economic screening tool was built to support identification of promising critical mineral feedstocks and economic research targets.

Critical Minerals; Critical Minerals and Materials↗

DOE OSTI2022

Design and Technoeconomic Analysis of High-Temperature Particle Conveyance Components for a 100 MW e Concentrating Solar Power Plant

Levelized costs of electricity (LCOE) approaching the U.S. Department of Energy Solar Energy Technologies Office 2030 goal of 0.05 $/kWh may be achievable using Brayton power cycles that use supercritical CO2 as the working fluid and flowing solid particles with temperatures >700° C as the heat transfer media. The handling and conveyance of bulk solid particles at these temperatures in an insulated environment is a critical technical challenge that must be solved for this approach to be used. A design study was conducted at the National Solar Thermal Test Facility (NSTTF) at Sandia National Laboratories in Albuquerque, NM, with the objective of identifying the technical readiness level, performance limits, capital and O&M costs, and expected thermal losses of particle handling and conveyance components in a particle-based CSP plant. Key findings indicated that chutes can be a low-cost option for particle handling but uncertainties in tower costs make it difficult to know whether they can be cost effective in areas above the receiver if tower heights must then be increased. Skips and high temperature particle conveyance technology are available for moving particles up to 640° C. This limits the use of mechanical conveyance above the heat exchanger and suggests vertical integration of the hot storage bin and heat exchanger to facilitate direct gravity fed handling of particles.

14 SOLAR ENERGY↗

DOE OSTI2024

Photovoltaic device for enhancing power output of concentrating solar thermal power plants

A photovoltaic retrofit device for a concentrating solar thermal power plant having a parabolic trough reflector, and a fluid receiver with working fluid therein spaced from the reflector and positioned at a focal point of the reflector. The photovoltaic device includes a plurality of adjustable angle dichroic mirrors positioned between the parabolic trough reflector and the fluid receiver. A photovoltaic receiver assembly has multiple photovoltaic panels in angular relationship to each other. A photovoltaic temperature regulating system includes a fluid medium to regulate temperature of the photovoltaic panels.

Otanicar, Todd↗

DOE OSTI2025

The Co-Firing of Pine Biomass and Waste Coal in 100 and 600 MW Power Plants: A Sustainable Approach to Reduce GHG Emissions

Climate change is a global issue that has gained much attention recently. Co-firing biomass with coal/waste coal reduces the electricity sector’s GHG emissions sustainably. This study uses commercial software to model waste coal and biomass co-firing in 100 MW and 600 MW power plants. The objective is to assess the effects of fluid types (subcritical and supercritical), plant capacities (100 MW and 600 MW), boiler types (pulverized coal and circulating fluidized bed boilers), biomass and waste coal co-firing ratios (0:100, 20:80, 40:60, 60:40, 80:20, and 100:0), and carbon capture and storage efficiencies (0%, 90%, 95%, and 97%) on performance parameters such as net plant efficiency, heat rate, net plant CO2 and SO2, and particulate matter emissions. The feedstocks selected for this investigation include anthracite waste coal and loblolly pine biomass. As the biomass fraction increases from 0% to 100%, co-fired power plants net efficiency increases by 3–8%. Supercritical plants had a 6% higher net plant efficiency than the subcritical plants. The study found that the biomass’s high heating value decreased the fuel flow rate and reduced plant CO2 emissions by 10–16%. With 100% biomass power plant feed and 90% carbon capture and storage efficiency, CO2 emissions drop by 83% and SO2 and PM emissions drop to zero.

Bhoi, Prakashbhai R. (ORCID:0000000333104888)↗

DOE OSTI2021

Active liquid crystals powered by force-sensing DNA-motor clusters

Significance Single-molecule techniques have elucidated how isolated molecular motors generate piconewton forces with unprecedented detail. However, in diverse biological and synthetic settings, force-generating proteins collectively power nonequilibrium dynamics, including continuous large-scale rearrangements and persistent fluid flows. Characterizing motor-generated forces in these dense and dynamical environments remains a challenge. We assembled a reversible DNA-based force-sensing probe that, by an optical readout, reveals the molecular arrangements and the force loads experienced by kinesin motors. These probes provide insight into motor-generated forces that collectively power the unique dynamics of microtubule-based active nematics, a noteworthy example of an internally driven active matter system. DNA-based force probes can be extended to study forces and stresses in various synthetic systems as well as diverse cellular environments.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗

DOE OSTI2022

Numerical fluid dynamics for FRG flow equations: Zero-dimensional QFTs as numerical test cases. I. The O ( N ) model

The functional renormalization group (FRG) approach is a powerful tool for studies of a large variety of systems, ranging from statistical physics over the theory of the strong interaction to gravity. The practical application of this approach relies on the derivation of so-called flow equations, which describe the change of the quantum effective action under the variation of a coarse-graining parameter. In the present work, we discuss in detail a novel approach to solve such flow equations. This approach relies on the fact that RG equations can be rewritten such that they exhibit similarities with the conservation laws of fluid dynamics. This observation can be exploited in different ways. First of all, we show that this allows to employ powerful numerical techniques developed in the context of fluid dynamics to solve RG equations. In particular, it allows us to reliably treat the emergence of nonanalytic behavior in the RG flow of the effective action as it is expected to occur in studies of, e.g., spontaneous symmetry breaking. Second, the analogy between RG equations and fluid dynamics offers the opportunity to gain novel insights into RG flows and their interpretation in general, including the irreversibility of RG flows. Further, we work out this connection in practice by applying it to zero-dimensional quantum-field theoretical models. The generalization to higher-dimensional models is also discussed. Our findings are expected to help improving future FRG studies of quantum field theories in higher dimensions both on a qualitative and quantitative level.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗

DOE OSTI2022

Monitoring of Temperature Measurements for Different Flow Regimes in Water and Galinstan with Long Short-Term Memory Networks and Transfer Learning of Sensors

Temperature sensing is one of the most common measurements of a nuclear reactor monitoring system. The coolant fluid flow in a reactor core depends on the reactor power state. We investigated the monitoring and estimation of the thermocouple time series using machine learning for a range of flow regimes. Measurement data were obtained, in two separate experiments, in a flow loop filled with water and with liquid metal Galinstan. We developed long short-term memory (LSTM) recurrent neural networks (RNNs) for sensor predictions by training on the sensor’s own prior history, and transfer learning LSTM (TL-LSTM) by training on a correlated sensor’s prior history. Sensor cross-correlations were identified by calculating the Pearson correlation coefficient of the time series. The accuracy of LSTM and TL-LSTM predictions of temperature was studied as a function of Reynolds number (Re). The root-mean-square error (RMSE) for the test segment of time series of each sensor was shown to linearly increase with Re for both water and Galinstan fluids. Using linear correlations, we estimated the range of values of Re for which RMSE is smaller than the thermocouple measurement uncertainty. For both water and Galinstan fluids, we showed that both LSTM and TL-LSTM provide reliable estimations of temperature for typical flow regimes in a nuclear reactor. The LSTM runtime was shown to be substantially smaller than the data acquisition rate, which allows for performing estimation and validation of sensor measurements in real time.

Pantopoulou, Stella↗

DOE OSTI2024

Advanced Power Electronics and Electric Machines

The advanced power electronics and electric machines (APEEM) research group at the National Renewable Energy Laboratory (NREL) has developed world-class experimental and modeling capabilities for designing and evaluating efficient and reliable power electronics and electric machines thermal management systems. They also design, fabricate and characterize advanced power electronics packaging, and are developing state-of-health monitoring techniques. These researchers deliver safe, reliable, high performing, power-dense components that allow seamless integration between renewable energy sources, electric transportation, and the grid, helping to make widespread electric vehicle (EV) adoption and greenhouse gas emissions reduction more feasible. This document outlines the group's major capabilities in the areas of power electronics; module development and characterization; thermal modeling and management; thermomechanical reliability analysis of devices, modules, inverters/converters, and electric machines; physics-of-failure-based reliability analysis; and microelectronics. It also overviews the group's state-of-the-art equipment for fluid-based thermal management; thermal measurement & characterization; thermomechanical reliability analysis; micro- and power electronics measurement & characterization; and prototype fabrication, as well as the group's world-class modeling and simulation capabilities.

advanced gate drivers↗

DOE OSTI2024

Analysis and Optimization of the Recompression Cycle with High Temperature Recuperator Bypass for Concentrating Solar Power Applications

This work analyzes the sCO2 recompression with high temperature recuperator (HTR) bypass power cycle for use in concentrating solar power (CSP) systems. CSP operation differs from other thermal power plants in that CSP must balance between maximizing the heat transfer fluid (HTF) temperature difference and maximizing the cycle thermal efficiency, which typically are inversely related. Large HTF temperature differences reduce the size and cost of thermal energy storage (TES), improve the solar receiver efficiency, and require lower mass flow rates that reduce pumping power required to elevate the HTF to the receiver. The recompression cycle with HTR bypass potentially offers improved thermal efficiency with larger HTF temperature differences as compared to the recompression cycle, and it has fewer turbomachinery components than the partial cooling cycle. The recompression with HTR bypass cycle adds a second lower temperature primary heat exchanger which transfers heat from the HTF to the fraction of sCO2 flow that bypasses the HTR. We developed a model to compare the recompression with HTR bypass cycle to the recompression and partial cooling cycles. A sweep of design parameters including bypass fraction, recompression fraction, recuperator conductance, and pressure ratio is used to form a pareto-optimal front with the cycle thermal efficiency and HTF temperature difference as objectives. An optimization routine has also been developed to find optimal design point parameters for a target HTF temperature difference. The performance of the recompression with HTR bypass cycle is compared with recompression and partial cooling cycles.

concentrating solar power↗

DOE OSTI2024

Impedance Emulation Control of Wave Energy Converters

Modeling and control of wave energy conversion (WEC) systems for maximum power extraction is challenging due to complex multiphysics that include fluids, mechanics, and machine drives. To uncover an intuitive model that clearly depicts WEC system operation, we utilize a force-current equivalent circuit framework which then enables us to design an impedance emulation control strategy. To provide context for our framework, we focus on a standard reference model-3 (RM3) point absorber device coupled to a permanent magnet synchronous generator. After the proposed extremum seeking controller is computed, we experimentally validate its performance on a platform that consists of two back-to-back connected inverters that emulate the WEC system.

wave energy conversion, impedance emulation, machi↗

DOE OSTI2024

High-Temperature Oxidation Behavior of Wrought and Additive Manufactured H282 in Direct-Fired Supercritical CO2 Power Cycle Environments

Materials selection is a key concern for corrosion resistance in high temperature and pressure direct-fired supercritical CO2 power cycles. The effect of elevated pressure on corrosion resistance can be critical, as impurities within the supercritical fluid such as H2O and O2 can result in additional corrosion behaviors. Utilizing additive manufacturing (AM) methods for construction of power cycle components requiring both compact and complex designs could be advantageous. AM H282 produced by laser powder bed fusion was exposed to direct-fired conditions (95CO2 – 4H2O – 1 O2) at 750 °C at both atmospheric pressure and supercritical conditions (20 MPa) for up to 4,000 hours. Oxidation behavior, sub-surface carbide formation, and chromia scale volatilization was dependent upon AM preparation techniques and surface modifications. These results are discussed in terms of the potential compatibility issues that may arise when using AM alloys in high temperature regions of direct-fired sCO2 power cycles, particularly for thin-walled components.

Carney, Casey↗

DOE OSTI2020

Final Report for Tech-X Corporations’s contribution to Enhancing Understanding of High Energy Density Plasmas from Wire Array and Solid Liner Implosions Using Fluid Modeling with Kinetic Closures

Recent results from experiments and simulation of magnetically driven pulsed power liners have explored the role of the early-time electrothermal instability in the evolution of the magneto-Rayleigh-Taylor instability. Our focus will be on understanding the development of such instabilities and the potential stabilization mechanisms via electron thermal conduction, viscosity, and large magnetic fields which we expect could play a significant role in supporting the success of the MagLIF program. Experiments have shown that studies of high-energy density plasmas from wire-array implosions require physics modeling that goes well beyond simple models such as ideal magnetohydrodynamics. The goal of this work is to provide increased understanding of these experiments by employing simulations with a multi-fluid extended-MHD model which uses kinetic closures for thermal conduction, resistivity and viscosity. We will use codes easily available to the wider research community, including university students, with a secondary goal of providing the community with well-benchmarked tools capable of advanced modeling of high-energy-density plasmas.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2022

Surface fluctuating hydrodynamics methods for the drift-diffusion dynamics of particles and microstructures within curved fluid interfaces

Here we introduce fluctuating hydrodynamics approaches on surfaces for capturing the drift-diffusion dynamics of particles and microstructures immersed within curved fluid interfaces of spherical shape. We take into account the interfacial hydrodynamic coupling, traction coupling with the surrounding bulk fluid, and thermal fluctuations. For fluid-structure interactions, we introduce Immersed Boundary Methods (IBM) and related Stochastic Eulerian-Lagrangian Methods (SELM) for curved surfaces. We use these approaches to investigate the statistics of surface fluctuating hydrodynamics and microstructures. For velocity autocorrelations, we find characteristic power-law scalings $τ^{-1}, τ^{-2}$, and plateaus can emerge. This depends on the physical regime associated with the geometry, surface viscosity, and bulk viscosity. This differs from the characteristic $τ^{-3/2}$ scaling for bulk three dimensional fluids. We develop theory explaining these observed power-laws associated with time-scales for dissipation within the fluid interface and coupling to the surrounding fluid. We then use our introduced methods to investigate a few example systems and roles of hydrodynamic coupling and thermal fluctuations including for the kinetics of passive particles and active microswimmers in curved fluid interfaces.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2020

Molten Chloride Thermophysical Properties, Chemical Optimization, and Purification

Next-generation concentrating solar power (CSP) technology requires high-temperature heat-transfer fluids and thermal energy storage that can operate in the temperature range of 500°–720°C. This high temperature demands a new chemistry for the heat-transfer fluids that must have high-temperature thermal and chemical stabilities, high energy density, and low corrosion rate on metallic materials used in the heat exchangers, piping, and thermal energy storage tanks. A ternary MgCl 2 -KCl-NaCl chloride-salt system has been proposed to achieve such goals, given its high-temperature thermal stability. The chloride-salt-based systems have been used by the metallurgy industry as the electrolyte to electrolytically extract metallic magnesium. They have also attracted attentions from the nuclear industry for developing the molten salt fast reactors that can operate at close to atmospheric pressure and at higher temperature than traditional light-water reactors. However, the corrosion properties of the ternary salt are not well known. The corrosion mechanism is believed to be correlated to the presence of MgOHCl impurity at the operation temperature. MgOHCl is fundamentally caused by the hygroscopic nature of the MgCl 2 component. Therefore, the first key objective of this project is to understand the nature of the corrosiveness of the ternary chloride-salt system and its prevention by designing new lab-scale purification processes. Because of its importance, a working group called the Chloride Salt Collective across multiple U.S. Department of Energy national laboratories is established to gain experimental agreement on the corrosion behaviors. In addition, water generation during salt dehydration could lead to highly corrosive HCl/water mixture via a hydrolysis process between water and anhydrous MgCl 2 or MgCl 2 hydrates. MgOHCl will eventually be converted to MgO particulates regardless of the chemical path chosen (i.e., by thermal decomposition, chemical purification with an active metal, or electrochemical purification utilizing the reduction power of electron flows). Large MgO particles with high hardness can wear out bearing and bushing and even clog the delicate channels in the primary heat exchanger. Because of this, a second objective is to understand the chemistry behind salt purification and transfer the scientific understanding to a set of engineering know-how for large-scale salt melter design. Because there is limited information on the thermophysical properties and the sensitivity of these properties around the targeted salt composition, a third objective is to measure thermophysical properties relevant to system and component design and support Topic 1 Liquid Pathway development. For example, composition shift due to salt reaction with water can be a potential issue because it can lead to changes of thermophysical properties, such as (1) melting point (or freeze point), which can jeopardize safe operation of the supercritical CO 2 power cycle proposed for next-generation CSP, and (2) heat capacity and density, which can decrease the overall power-generation capability of the plants. The value of the thermal conductivity of the selected salt composition is also a critical criterion for the solar receiver design.

14 SOLAR ENERGY↗

DOE OSTI2021

Stopping-power enhancement from discrete particle-wake correlations in high-energy-density plasmas

Three-dimensional (3D) simulations of electron beams propagating in high-energy-density plasmas using the quasistatic Particle-in-Cell (PIC) code QuickPIC demonstrate a significant increase in stopping power when beam electrons mutually interact via their wakes. Each beam electron excites a plasma wave wake of wavelength ~ 2 π c / ω p e , where c is the speed of light and ω p e is the background plasma frequency. Here we show that a discrete collection of electrons undergoes a beam-plasma-like instability caused by mutual particle-wake interactions that causes electrons to bunch in the beam, even for beam densities n b for which fluid theory breaks down. This bunching enhances the beam's stopping power, which we call “correlated stopping,” and the effect increases with the “correlation number” N b ≡ n b ( c / ω p e ) 3 . For example, a beam of monoenergetic 9.7 MeV electrons with N b = 1 / 8 , in a cold background plasma with n e = 10 26 cm – 3 (450 g cm – 3 DT), has a stopping power of 2.28 ± 0.04 times the single-electron value, which increases to 1220 ± 5 for N b = 64 . The beam also experiences transverse filamentation, which eventually limits the stopping enhancement.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2020

Fluid Dynamics Effects on Microstructure Prediction in Single-Laser Tracks for Additive Manufacturing of IN625

Single-track laser fusion were simulated using a heat-transfer-solidification-only (HTS) model and its extension with fluid dynamics (HTS_FD) model using a parallel open-source code, which included laminar fluid dynamics, flat-free surface of the molten alloy, heat transfer, phase-change, evaporation, and surface tension phenomena. The results illustrate that the fluid dynamics affects the solidification and ensuing microstructure. For the HTS_FD simulations, thermal gradient, G was found to exhibit a maximum at the extremity of the solidified pool ( i.e. , at the free surface), while for HTS simulations, G exhibited a maximum around the entire edge of the solidified pool. HTS_FD simulations predicted a wider range of cooling rates than the HTS simulations, exhibited an increased spread in the solidification speed, V variation within the melt-pool with respect to the HTS model results. Primary dendrite arm spacing (PDAS) were evaluated based on power law correlations and marginal stability theory models using the ( G , V ) from HTS and HTS_FD simulations to quantify the effect of the fluid dynamics on the microstructure. At low-laser powers and low-scan speeds, the PDAS obtained with the fluid dynamics model (HTS_FD) was larger by more than 30 pct with respect to the PDAS calculated with the simple HTS model. A new PDAS correlation, i.e. , $ \lambda_{1} \left[ {\mu {\text{m}}} \right] = 832\;G\left[ {\text{K/m}} \right]^{ - 0.5} V\left[ {\text{m/s}} \right]^{ - 0.25} $ , which uses the ( G , V ) results from the HTS_FD model was developed and validated against experimental results.

36 MATERIALS SCIENCE↗