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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 235 records · Page 13
All sourcesNASA NTRSDOE OSTI
DOE OSTI2021

An Overview of Non-LWR Vessel Cooling Systems for Passive Decay Heat Removal (Technical Letter Final Report)

The following report provides a technical review of various reactor vessel cooling system (VCS) concepts under consideration for decay heat removal (DHR) in non-light water advanced reactor designs. This review focuses on ex-vessel designs, including the Reactor Cavity Cooling System (RCCS), the Reactor Vessel Auxiliary Cooling System (RVACS), and hybrid iterations, using both air and water cooling to achieve their heat removal function. Based on a literature review of publicly available sources published between 1979 and 2021, a technical summary is presented detailing existing and planned VCS design options, their applicability to specific reactor type, and review of authored research and development studies. Following an assessment of the availability of data and modeling tools, an evaluation was performed analyzing their likely performance during normal, degraded, and accident conditions, including reliability, stability, and longevity. With renewed consideration of air-based DHR systems by some US vendors, there is a need to fully understand the complexities inherent to natural circulation systems, and more importantly, how they may influence safety-related heat removal functions and system performance. For DHR systems that rely on air-based mode of cooling, this entails quantification of the impacts of low flow conditions during start-up, relative elevations of inlet and outlet ducts for below-grade installations, effects of the use of multiple parallel chimneys for redundancy, and impact of weather conditions at the plant site. For systems relying on water-based mode cooling, reliance on limited coolant inventory in an event of pipe break or extended duration accident scenarios, sensitivities related to stability of boiling flow and heat transfer conditions, and quantification of full-scale structural vibrations on balance of plant structures are among the complicating factors.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2024

Q1 Report for FY25 Theory and Simulation Performance Target: Development of an integrated modeling framework for fusion reactor design and assessment

This report describes the work and activities carried out towards the completion of each of the following milestones in FY25 Q1: 1. Demonstrate workflow for generating self-consistent CESOL plasma profiles + first wall and divertor loading prediction and generate the CAT plasma and neutron loading needed for further engineering analysis: $/circ$ Initially run CESOL with SOLPS and map heat flux using simple HEAT method: ▪ Generate SOLPS grid for CAT reference case, ▪ Implement and apply ‘lower’ fidelity method of using HEAT-like analytic method to map SOLPS heat flux from charged particles to first wall, and ▪ Provide initial heat flux + neutron loading for further engineering analysis. 2. Demonstrate multiphysics magnet analysis: $/circ$ Demonstrate validation of the Elmer workflow by comparing induced stresses due to EM forces generated by TF coils using multiple codes.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2020

Revisiting the first Sandia Fracture Challenge with transient deformation heating and strain localization considerations

In this study, we present a systematic experimental study and accompanying theoretical analysis of the dependence of ductile fracture on strain localization, strain hardening rates, deformation-induced thermal softening, and transient heat conduction under spatially uniform as well as spatially heterogeneous deformation. Spatially uniform cases are studied via standard dogbone shaped specimens subject to uniaxial tension. Spatially heterogeneous deformation is studied via the so-called Sandia Fracture Challenge (SFC) specimen, which is a standard compact tension specimen modified with three machined holes in front of a blunt notch. We utilize the same precipitation hardened martensitic stainless steel used in the first SFC experiments, i.e. 15-5 PH with an H1075 heat treatment. We also study 15-5 PH in Condition A and with the H900 heat treatment, each of which has a different hardening behavior and ductility. We find that the ductility does not correlate with the deformation to first crack initiation in the SFC specimen. Instead, hardening rates are better correlated. Moreover, a re-examination finds that an accurate calibration of the hardening rates is strongly correlated with accurate blind predictions of ductile fracture in the SFC specimens. Given that thermal softening can greatly affect hardening rates, we provided a thermographic analysis of deformation-induced heating and transient heat transfer in both the dogbone shaped samples and the SFC specimens. Transient heating in stainless steels is found to have first-order effects on the strain at the onset of necking, strain to fracture, as well as strain localization and ductile fracture in complex geometries even under so-called quasi-static loading rates.

42 ENGINEERING↗
DOE OSTI2024

Preliminary Design of Nuclear Reactor Heat Delivery Systems: Integration with Reference Oil Refinery, Methanol Synthesis, and Hydrogen Production

The Department of Energy’s (DOE) Integrated Energy Systems (IES) program is generating comprehensive analyses validating the opportunity for using nuclear energy in a variety of applications including future clean grids, providing heat for direct use, and providing heat to help reduce emissions in chemical commodities. This work focuses on the preliminary designs of thermal delivery systems that can integrate heat produced from a nuclear core to industrial processes. The key research question that needs to be answered is: what is the prospective method for integrating nuclear generated heat energy into non-electric applications that can facilitate combined heat and power operations by advanced nuclear reactor systems? This research is a composition of case studies showing preliminary conceptual designs for thermal delivery systems integrating advanced nuclear systems with a few industrial systems including high temperature steam electrolysis, a reference oil refinery, and potential future methanol systems that supplant some natural gas use with nuclear energy. Piping and instrumentation diagrams have been developed to show the conceptual integration of nuclear systems with representative industrial systems. Different features of the configurations are dependent on the specific integration requirements including energy source conditions, demand quantity, and require energy application conditions. Design concepts are validated using thermodynamic balance calculations to verify system performance including calculating system losses during transport. Key components: pumps and compressors, heat exchangers, and network piping are reported with key design information and sizing.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2023

Strongly Heated Turbulent Flow in a Channel with Pin Fins

Large-eddy simulations (LES) were performed to study the turbulent flow in a channel of height H with a staggered array of pin fins with diameter D = H/2 as a function of heating loads that are relevant to the cooling of turbine blades and vanes. The following three heating loads were investigated—wall-to-coolant temperatures of Tw/Tc = 1.01, 2.0, and 4.0 - where the Reynolds number at the channel inlet was 10,000 and the back pressure at the channel outlet was 1 bar. For the LES, two different subgrid-scale models—the dynamic kinetic energy model (DKEM) and the wall-adapting local eddy-viscosity model (WALE)—were examined and compared. This study was validated by comparing with data from direct numerical simulation and experimental measurements. The results obtained show high heating loads to create wall jets next to all heated surfaces that significantly alter the structure of the turbulent flow. Results generated on effects of heat loads on the mean and fluctuating components of velocity and temperature, turbulent kinetic energy, the anisotropy of the Reynolds stresses, and velocity-temperature correlations can be used to improve existing RANS models.

42 ENGINEERING↗
DOE OSTI2023

Fluid dynamic and thermal performance of a slotted cylinder at low Reynolds number

The fluid dynamic and thermal performance of a circular cylinder with a slot parallel to the flow is numerically investigated. The study utilized the semi-implicit finite volume multi-material algorithm MPM-ICE, a component of the Uintah framework. The normalized slot width s/D ranges from 0.1 - 0.3, introducing an additional heat transfer surface area between ~ 10 and ~ 50%, and a mass reduction between ~ 13 and ~ 38% in the cylinder. We assumed two-dimensional incompressible flow and simulated a Reynolds number Re D between 100 and 1000. The slotted cylinders are found to have a total drag force reduction up to ~ 45%, compared to a solid cylinder despite the additional viscous drag force in the slot. Convection heat transfer is enhanced up to ~ 70%. Further, the slotted cylinder performance index, defined as the ratio of the heat rate to the drag force, increases up to maximum of ~ 3, indicating better overall thermal fluid performance. An entropy analysis showed the best performance index occurs at the highest Re D . Correlations for drag coefficient and Nusselt number are proposed along with an entropy optimization method.

42 ENGINEERING↗
DOE OSTI2022

In Tube Condensation Heat Transfer and Pressure Drop for R454B and R32—Potential Replacements for R410A

The heating, ventilation and air conditioning (HVAC) industry in the United States seeks near-term alternative refrigerants to replace R-410A in unitary equipment. Two potential replacement refrigerants are R-454B and R-32. It is of interest to investigate the capability and accuracy of existing heat exchanger design methods when applied to these replacement refrigerants. To that end, this work presents empirical condensation quasi-local heat transfer coefficient and pressure drop data for R-454B and R-32. These data were obtained in a $\frac{3}{8}$ in. (9.52 mm) outside diameter (OD) smooth copper tube with a wall thickness of 0.032 in. (0.81 mm). The experimental variables and their ranges included refrigerant absolute pressure ( 1960 ≤ P a b s ≤ 3196 kPa), condensation temperature ( 35 ≤ T c o n d ≤ 50 °C), mass flux ( 100 ≤ G ≤ 200 kg m -2 s -1 ), vapor quality ( 0 ≤ x ≤ 1 ), and heat flux ( 32.9 ≤ q ″ ≤ 62.97 kW m -2 ). It was found that the heat transfer correlation developed by Cavallini et al. Cavallini et al. (2006) predicted the experimental condensation heat transfer data, for both R-454B and R-32, with the greatest accuracy. Using the Cavallini et al. correlation, it was found that the mean absolute percentage error (MAPE) was 10.5% and 15.1% for R-454B and R-32, respectively. Additionally, the pressure drop correlation developed by Friedel Friedel (1979) predicted the experimentally determined pressure gradient with a MAPE of 7.7% and 5.5% for R-454B and R-32, respectively. These results will assist the practicing thermal engineer to choose the most appropriate design correlation for these near-term replacement refrigerants.

42 ENGINEERING↗
DOE OSTI2020

A novel shallow bore ground heat exchanger for ground source heat pump applications—Model development and validation

A novel ground heat exchanger design, the Underground Thermal Battery (UTB), was proposed as a low-cost alternative to the conventional vertical bore ground heat exchanger (VBGHE) for the application of ground source heat pumps (GSHPs). The UTB is designed to be installed in a shallow borehole (less than 6 m deep) and thus could cost much less than the conventional VBGHE, which usually is installed in vertical bores 60 m deep. By utilizing natural convection of water and phase change materials, the UTB tempers its temperature change in response to thermal loads, which helps improve the efficiency of GSHPs. A one-dimensional (1D) model of the UTB has been developed and validated with the measured performance data of a small-scale UTB, as well as the simulation results of a more detailed three dimensional (3D) numerical model, which accounts for both heat transfer and fluid dynamics in the UTB. Further, this 1D model is computationally much more efficient than the 3D model and thus can simulate the annual performance of the UTB with acceptable computation time. The 1D model has been used to evaluate the performance of the UTB so that it can be compared with the conventional VBGHE.

42 ENGINEERING↗
DOE OSTI2023

Design, modeling and simulation of nuclear-powered integrated energy systems with cascaded heating applications

Nuclear-renewable integrated energy systems (IES) consist of a variety of energy generation and conversion technologies and can be used to meet heterogeneous end uses (e.g., electricity, heat, and cooling demands). In addition to supply-demand balance, end-use heat demands usually require heat supply of certain temperature ranges. The effective and efficient utilization of heat produced within an IES is, therefore, a critical challenge. Here, this paper examines design options of an IES that includes heating processes of multiple temperature grades. We investigate a cascaded design configuration, where the remaining residual heat after high-grade heating processes [e.g., hydrogen production through high-temperature steam electrolysis (HTSE)] is recovered to meet the low-grade heating needs [e.g., district heating (DH)]. Additionally, a thermal energy storage system is integrated into the DH system to address the imbalance between heat supply and demand. This paper primarily focuses on the design and modeling of the proposed system and evaluates its operation with a 24-h transient process simulation using a DH demand profile with hourly resolution. The results indicate that the residual heat from the HTSE exhaust is insufficient for the DH demand, and additional topping heat directly from the reactor process steam is needed. Furthermore, the inclusion of thermal energy storage within the DH system provides the necessary balance between thermal generation and demand, thereby ensuring a consistent rated temperature of the DH supply water. This approach helps minimize the control actions needed on the reactor side.

08 HYDROGEN↗
DOE OSTI2023

Heat Exchanger Intensification Through Powder Processing and Enhanced Design (HIPPED)

High intensity, supercritical CO 2 heat exchangers capable of operating at temperatures between 800 and 1100 ˚C and pressures greater than 80 bar are considered a critical component for high efficiency power generation and a range of next-generation industrial processes. A novel heat exchanger concept was proposed in this project. The proposed concept involved a plate-type architecture with three-dimensional fins, called twisted s-shaped fins, that capitalize on additive manufacturing. Four manufacturing processes were studied to realize the complex envisioned design: press and sinter of metallic powders, directed energy deposition, laser powder bed fusion, and a novel powder bed process involving a photoreactive polymer called SEAM (scalable expeditious additive manufacturing), that later was developed at MSU. The team was able to manufacture subscale heat exchangers using laser powder bed fusion (LPBF) and SEAM. The team settled on using SEAM as a final manufacturing approach due to its very low cost. The SEAM-manufactured heat exchanger, however, when tested under pressure, exhibited leaks and the process still requires further development beyond the timeline of the project. To support the heat exchanger design and testing, the team developed a new high temperature flow loop allowing testing under high temperature and pressure. Computational modeling of the heat exchanger was also performed for the twisted s-shaped fins and the computations were validated with experimental data. The new twisted fins resulted in enhanced heat transfer and reduced pressure drop. To further minimize pressure drop in the plate heat exchanger, the team also developed a simplified model for flow maldistribution in the manifolds, providing a new tool for designers that eliminates the need for complex CFD calculations. A technoeconomic analysis was also developed to contrast SEAM with LPBF, this tool indicated that SEAM is several times less costly and offer significant promises as a rapid low cost additive manufacturing process for metallic systems.

30 DIRECT ENERGY CONVERSION↗
DOE OSTI2023

Thermal Extraction and Delivery from Advanced Reactor Systems

This document presents preliminary thermodynamic analysis of thermal extraction and delivery from advanced nuclear reactors. Light-water, high temperature gas, sodium fast, and molten salt reactors are templated and analyzed for thermal extraction from nominal steam production conditions. Uncontrolled, controlled, and partial admission steam extraction methods are described and analyzed to show the differences in system impact from the various methods. Thermal delivery modeling results show comparisons that have become possible through the computational capabilities of the thermal delivery model. Due to the significant degrees of freedom of the problem, specific cases are used to compare the thermodynamic costs of heat transport using various heat transfer fluids. All this work is done using Modelica models, allowing for the future application of models in dynamic analyses beyond the steady-state calculations presented in this report. Appendices describe additional capabilities and methods that can help users analyze complex problems using HYBRID models developed in Modelica.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2025

Overcoming the thermal conductivity versus oxidation resistance barrier in high-temperature steels

Heat-resistant steels with high chromium additions (≥5 weight percent) are critical for many high temperature energy and manufacturing applications, including heat exchangers, pistons for engines, and dies for metal working and casting. However, while high chromium additions increase oxidation resistance at elevated temperatures, they also compromise thermal conductivity, resulting in a metallurgical trade-off between these two important properties. Here we show that a microstructure with both higher thermal conductivity and improved oxidation resistance at elevated temperatures is achieved in a unique steel with only 1 weight percent chromium, thereby overcoming the long-standing metallurgical trade-off. This is accomplished through a tailored thermal treatment that produces a tempered martensitic matrix with low solute content and a fine dispersion of copper precipitates and molybdenum enriched carbides. A further discovery is that the resultant thermally grown oxide includes an iron-copper-manganese-enriched outer layer that provides high-temperature oxidation protection equivalent to heat-resistant steels with five times the chromium content and 25% lower thermal conductivity.

Pierce, Dean T. [Oak Ridge National Laboratory (OR↗
DOE OSTI2021

An Approach to High-Performance Affordable Housing Using Point-Source Space Conditioning

This project explored the use of minisplit ductless heat pumps in combination with small through-wall transfer fans to provide space conditioning in small single-story homes, including manufactured homes and homes built by Habitat for Humanity. The objectives were to reduce space-conditioning energy consumption by 50% compared to the 2009 International Energy Conservation Code (ICC 2009) while maintaining home affordability and thermal comfort. The strategy to achieve this goal also included a highly efficient thermal envelope to reduce space-conditioning loads.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2020

Geometrical quasi-ballistic effects on thermal transport in nanostructured devices

In this work, we employ thermoreflectance thermal imaging to directly measure the steady-state two-dimensional (2D) temperature field generated by nanostructured heat sources deposited on silicon substrate with different geometrical configurations and characteristic sizes down to 400nm. The analysis of the results using Fourier’s law not only breaks down as size scales down, but it also fails to capture the impact of the geometry of the heat source. The substrate effective Fourier thermal conductivities fitted to wire-shaped and circular-shaped structures with identical characteristic lengths are found to display up to 40% mismatch. Remarkably, a hydrodynamic heat transport model reproduces the observed temperature fields for all device sizes and shapes using just intrinsic Si parameters, i.e., a geometry and size-independent thermal conductivity and nonlocal length scale. The hydrodynamic model provides insight into the observed thermal response and of the contradictory Fourier predictions. We discuss the substantial Silicon hydrodynamic behavior at room temperature and contrast it to InGaAs, which shows less hydrodynamic effects due to dominant phonon-impurity scattering.

42 ENGINEERING↗
DOE OSTI2026

Thermal Management Solution for an Integrated Outer-Rotor Motor Drive: Opportunities and Challenges

This work highlights an integrated thermal management solution for the outer-rotor motor (ORM) drive. The integrated ORM drive utilizes water-ethylene glycol coolant for power electronics and stator cooling. Air cooling is used for rotor laminations, magnets and outer-rotor structures, and the rotor shaft. To fully understand the performance of the integrated ORM drive and thermal management coupling effects, a full drive conjugate heat transfer model has been developed to investigate coupled cooling performance of various components of the ORM drive. Various motor rotational speeds, power output scenarios, and cooling options for the integrated ORM drive have been investigated. The model estimates the operating window for the ORM drive while keeping component operating temperatures below prescribed limits. The model also highlights the importance of windage losses at higher rotational speeds for this ORM design, which involves higher rotor surface area per unit width of the rotor. Different designs are also investigated, particularly focusing on rotor cooling with air either naturally induced by rotor spin or forced airflow with the help of a blower, to circumvent challenges imposed by higher windage losses. The work highlights motor rotational speed limitations and the need for potential liquid cooling options for desired rotor performance at higher rotational speeds. Liquid cooling for the rotor may even become more critical for nonuniform rotor-stator gaps, leading to even higher and uneven windage losses across the full circumference of the motor, consequentially, more heating for the rotor.

30 DIRECT ENERGY CONVERSION↗
DOE OSTI2025

Design of Novel Hot Gas Component for Gas Turbine Engines Enabled by Materials and Additive Manufacturing Process Development

This CRADA project was the result of a project award under FOA-DOE-0001980. The overarching FOA project team consisted of researchers from Carpenter Technology Corporation (CTC), Solar Turbines Incorporated (Solar), Pennsylvania State University (PSU), University of California-Santa Barbara (UCSB), and Oak Ridge National Laboratory (ORNL). Evaluations were conducted on two high-γ’ superalloys that were designed by CTC and the UCSB. One alloy named GammaPrint-700 (GP-700) is a cobalt-base superalloy. The other alloy named GammaPrint-1100 (GP-1100) is a nickel-base (Ni-base) superalloy. PSU provided expertise and experimental testing of the thermal performance of AM micro-cooling architectures. ORNL provided expertise with the AM superalloy materials characterization and AM processing science. Solar provided turbine component design expertise. The focus of this CRADA report is to document the efforts between ORNL and CTC towards the development of superalloys designed for AM. The project goal was to use an AM processable high-temperature superalloy and design for Additive Manufacturing (DfAM) techniques to design an efficient turbine component (i.e. a turbine tip shoe) with enhanced cooling features that can only be fabricated through additive manufacturing (AM). The efficiencies of existing combined heat and power (CHP) engines are capped by both component design and materials limitations. However, AM of a tip shoe component from a γ’strengthened superalloy offers the design flexibility to increase the efficiency and power of an industrial gas turbine. This project brought about advancements in the DfAM tip shoe design space and in the area of high temperature superalloys processable through laser powder bed fusion (LPBF) AM. State of art computation design tools were utilized to optimize unique cooling features into a tip shoe component design. A two-prong materials development approach was taken to support development of the AM tip shoe geometry. The first approach centered on investigating the processability and the appropriate process science for the industry standard high-γ’ nickel-base (Ni-base) superalloy Mar-M247. This superalloy is typically cast and considered non-weldable by traditional welding standards. In the course of this work, the alloy was not deemed feasible for process scale-up due to significant cracking issues during printing. The second approach focused on the development and evaluation of a novel cobalt-base superalloy, GammaPrint™-700 (GP-700 and a Ni-base superalloy, GammaPrint™-1100 (GP-1100) designed to mitigate the significant AM processing issues with Mar-M247. The processability of these two alloys were investigated through electron beam melting (EBM) binder-jet AM (BJAM), and LPBF as a risk mitigation for manufacturability. To be considered a candidate material for down-selection to proceed to full-scale AM tip shoe engine testing trials, the high temperature creep rupture strength was required to achieve at a minimum, a Larsen Miller Parameter (LMP) increase of 10.9% over the baseline material LPBF AM Hastelloy X.

99 GENERAL AND MISCELLANEOUS↗
DOE OSTI2025

Design of Novel Hot Gas Component for Gas Turbine Engines Enabled by Materials and Additive Manufacturing Process Development

This CRADA project was the result of a project award under FOA-DOE-0001980. The overarching FOA project team consisted of researchers from Carpenter Technology Corporation (CTC), Solar Turbines Incorporated (Solar), Pennsylvania State University (PSU), University of California-Santa Barbara (UCSB), and Oak Ridge National Laboratory (ORNL). Evaluations were conducted on two high-γ’ superalloys that were designed by CTC and the UCSB. One alloy named GammaPrint-700 (GP-700) is a cobalt-base superalloy. The other alloy named GammaPrint-1100 (GP-1100) is a nickel-base (Ni-base) superalloy. PSU provided expertise and experimental testing of the thermal performance of AM micro-cooling architectures. ORNL provided expertise with the AM superalloy materials characterization and AM processing science. Solar provided turbine component design expertise. The focus of this CRADA report is to document the efforts between ORNL and CTC towards the development of superalloys designed for AM. The project goal was to use an AM processable high-temperature superalloy and design for Additive Manufacturing (DfAM) techniques to design an efficient turbine component (i.e. a turbine tip shoe) with enhanced cooling features that can only be fabricated through additive manufacturing (AM). The efficiencies of existing combined heat and power (CHP) engines are capped by both component design and materials limitations. However, AM of a tip shoe component from a γ’strengthened superalloy offers the design flexibility to increase the efficiency and power of an industrial gas turbine. This project brought about advancements in the DfAM tip shoe design space and in the area of high temperature superalloys processable through laser powder bed fusion (LPBF) AM. State of art computation design tools were utilized to optimize unique cooling features into a tip shoe component design. A two-prong materials development approach was taken to support development of the AM tip shoe geometry. The first approach centered on investigating the processability and the appropriate process science for the industry standard high-γ’ nickel-base (Ni-base) superalloy Mar-M247. This superalloy is typically cast and considered non-weldable by traditional welding standards. In the course of this work, the alloy was not deemed feasible for process scale-up due to significant cracking issues during printing. The second approach focused on the development and evaluation of a novel cobalt-base superalloy, GammaPrint™-700 (GP-700 and a Ni-base superalloy, GammaPrint™-1100 (GP-1100) designed to mitigate the significant AM processing issues with Mar-M247. The processability of these two alloys were investigated through electron beam melting (EBM) binder-jet AM (BJAM), and LPBF as a risk mitigation for manufacturability. To be considered a candidate material for down-selection to proceed to fullscale AM tip shoe engine testing trials, the high temperature creep rupture strength was required to achieve at a minimum, a Larsen Miller Parameter (LMP) increase of 10.9% over the baseline material LPBF AM Hastelloy X.

36 MATERIALS SCIENCE↗