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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 271 records · Page 15
All sourcesNASA NTRSDOE OSTI
DOE OSTI2021

Dielectric Fluids for the Direct Forced Convection Cooling of Power Electronics

The future of electrification of vehicles and other systems will require the creation of high-power density power electronics with low junction-to-fluid thermal resistance cooling solutions. One way to create this solution is to move high-heat-flux liquid cooling (single- or two-phase) as close to the power electronics components as possible. One novel approach involves submersion in dielectric fluids as the cooling solution. We first provide the range of fluid properties and develop a figure of merit (FOM) to aid in dielectric fluid selection. Next, we perform computational fluid dynamics/heat transfer (CFD/HT) modeling using single-phase cooling (submerged jet impingement on an enhanced surface) to validate the dielectric fluid FOM. Results of the study show that the developed FOM is a good representation of the performance of the fluids when compared to the results of the CFD/HT analysis. Both FOM and the CFD/HT analysis show that based on pure thermohydraulic considerations, several commercially available fluids present higher performance, on the order of 5% of water. Finally, the FOM can be used to quickly assess the thermohydraulic performance of a dielectric fluid, as well as the secondary application-specific properties such as boiling point, saturation pressure, flash point, and global warming potential, thereby allowing for fluid candidates to be readily compared.

computational fluid dynamics↗
DOE OSTI2022

Single-Phase Dielectric Fluid Thermal Management for Power-Dense Automotive Power Electronics

This paper describes the design and performance of a dielectric fluid cooling concept for automotive power electronics. The concept combines a low-thermal-resistance package (which eliminates metalized ceramic substrates) with a high-performance convective cooling strategy (slot jets impinging on finned surfaces). Modeling was first used to design the cooling system to maximize thermal performance and minimize pumping power. Additionally, a prototype was then fabricated, and experiments were conducted to validate the model predictions using three fluids at various fluid flow rates (16.7 cm 3 /s [1 L/min] to 68.3 cm 3 /s [4.1 L/min]) and inlet temperatures (30C and 70C). The final design was compact (120-cm 3 total volume, including heat exchanger and conceptual power modules) and cooled 12 devices (e.g., silicon carbide). The validated model was then used to predict the junction-to-fluid thermal resistance and pumping power for various conditions, including 40C fluid temperature. The results predict thermal resistance values as low as 19 mm 2 K/W are possible using the dielectric fluid cooling approach. The dielectric fluid cooling system is predicted to provide thermal resistance and pumping power values that are approximately 56% and 90% lower, respectively, compared to an automotive power electronics cooling system.

30 DIRECT ENERGY CONVERSION↗
DOE OSTI2020

Comparison of Thin Film Heat Flux Gauge Technologies Emphasizing Continuous-Duration Operation

Abstract Thin-film heat flux gauges (HFGs) have been used for decades to measure surface temperatures and heat flux in test turbines with the majority being used in facilities that are short-duration. These gauges are typically composed of two resistive temperature devices deposited on opposing sides of a dielectric. However, because these sensors have been traditionally applied for measurements in transient-type facilities, the challenges facing adaptation of this technology for a steady facility warrant investigation. These challenges are highlighted, and the solutions are presented throughout the paper. This paper describes the nanofabrication process for heat flux gauges and a new calibration method to address the potential deterioration of gauges over long runtimes in continuous-duration facilities. Because the primary uncertainty of these sensors arises from the ambiguity of the thermal properties, the emphasis is placed on the property determination. Also, this paper presents a discussion on the use of impulse response theory to process the data showing the feasibility of the method for steady-duration facilities after an initial settling time. The latter portion of the paper focuses on comparing well-established heat flux gauges developed for short-duration turbine test facilities to recently developed gauges fabricated using modern nanofabrication techniques for a continuous turbine test facility. The gauges were compared using the test case of an impinging jet over a range of Reynolds numbers. The comparison between the PSU gauge and the reference device indicated agreement within 14%, and similar results were achieved through comparison with established sensors from partner institutions.

Engineering↗
DOE OSTI2024

Effect of Wettability Gradient on the Scale Formation in Falling Film Flow

Mitigation of scale formation and performance degradation remains a vital challenge for falling film evaporators in various industries. In this work, an experimental study of falling film flow on a horizontal tube is conducted to investigate the effects of wettability gradients on thermal, hydraulic, and fouling behavior. It is revealed that certain hydrophobic coating patterns, such as strip, ring, and grid patterns, lead to unwetted heat transfer area, which results in decreased heat transfer compared to fully wetted plain tube. By adjusting the geometry and position of the wettability gradient, the hybrid coating demonstrates improved heat transfer performance. Based on the characteristics of horizontal tube falling film flow, impinging jet, thin film flow, and liquid retention at the tube bottom, a hybrid coating pattern is developed to improve surface wetting and mitigate the scaling coverage. It is revealed that scale deposition is regulated by wettability gradient. Crystals tend to be dense and compact in hydrophilic areas, while they appear scattered or even absent in hydrophobic regions, depending on the dimension of the hydrophobic area. While at the hydrophilic/hydrophobic boundary, a noticeable scale thickness step is observed, which raises the potential for self-cleaning. Furthermore, the balance of minimization of scaling layer coverage and maximization of wetting area requires an optimal design in coating dimensions, for which a systemic study of both flow dynamics and fouling characteristics on the falling film is necessary in the future.

42 ENGINEERING↗
DOE OSTI2025

Corrosion of Rare-Earth Disilicate Environmental Barrier Coatings in Gas Turbine Environments—Part 2: Microstructure Model

A model for the volatization of ytterbium disilicate (YbDS) by water vapor is developed. The new model is based on the Deal & Grove theory of the thermal oxidation of silicon [1], generalized here to account for the multi-step, second-order chemical reactions for silica depletion, multi-component mixture effects, and the unsteady porous microstructural evolution of the corroded inner zone. With the new model, the fundamental kinetic rate and standard porous media parameters are determined using the atmospheric steam jet impingement experiment of Ridley & Opila [2] and compared to results from the original Deal & Grove model. Fixing the input parameters in each respective model, a validation study (blind prediction) is presented for the high Reynolds number (1 × 105) and high pressure (14.7 atm) burner rig experiment of Wan et al. [3].

Cha, Chong M [Rolls Royce]↗
DOE OSTI2024

Multiphysics Co-Optimization Design and Analysis of Double-Side Cooled Silicon Carbide-Based Power Module: Preprint

With the rapid growth of Electric Vehicles (EVs) and Hybrid Electric Vehicles (HEVs), much more rigorous design targets have been set for automotive power electronics, including high power density, high reliability, and low cost. Novel power module and inverter technologies based on wide bandgap (WEG) semiconductors have been developed to meet these design targets, while providing optimal power semiconductor operating temperature and promising thermomechanical performance. Compared with conventional cooling techniques which are normally applied only on one side of power module, double-side cooling approach is now believed to be the solution to enable high power density and low thermal resistance of WEG semiconductor-based power electronics. In this work, we develop a three-phase power module that is double-sided cooled using dielectric fluid jet impingement. In each phase, four silicon carbide (SiC) power semiconductors are bonded to copper busbars without electrical insulation layers. A finite element analysis (FEA) model is created for thermal and thermomechanical analysis. Based on FEA modeling results, we select particular dimensions for a parametric study to optimize thermal and mechanical performance. Using a multi-objective genetic algorithm (MOGA)-based optimization method, we have minimized the maximum junction temperature and thermal stresses within the power module. The multiphysics co-optimization approach has enabled an efficient design process of power modules with greatly reduced computational cost, as compared to conventional processes that rely on exhaustive numerical simulations and iterations.

ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2021

A Multi-physics Computational Investigation of Droplet Pathogen Transport Eminating from Synthetic Coughs and Breathing

In response to the global SARS-CoV-2 transmission pandemic, Sandia National Laboratories Rapid Lab-Directed Research and Development (LDRD) COVID-19 initiative has deployed a multi-physics, droplet-laden, turbulent low-Mach simulation tool to model pathogen-containing water droplets that emanate from synthetic human coughing and breathing. The low-Mach turbulent Eulerian/point-particle Lagrangian methodology directly couples mass, momentum, energy, and species to capture droplet evaporation physics that supports the ability to distinguish between droplets that deposit and those that persist in the environment. Additionally, the cough mechanism is modeled as a pulsed-spray with a prescribed log-normal droplet size distribution. Simulations demonstrate direct droplet deposition lengths in excess of three meters while the persistence of a droplet nuclei entrained within a buoyant plume is noted. Including the effect of protective barriers demonstrates effective mitigation of large-droplet transport. For coughs into a protective barrier, jet impingement and large-scale re-circulation can drive droplets vertically and back towards the subject while supporting persistence of droplet nuclei. Simulations in quiescent conditions demonstrate droplet preferential concentrations due to the coupling between vortex ring shedding and the subsequent advection of a series of three-dimensional rings that tilt and rise vertically due to a misalignment between the initial principle vortex trajectory and gravity. These resolved coughing simulations note vortex ring formation, roll-up and breakdown, while entraining droplet nuclei for large distances and time scales.

42 ENGINEERING↗
DOE OSTI2021

Verification of Data-Driven Models of Physical Phenomena using Interpretable Approximation

Machine-learned models, specifically neural networks, are increasingly used as “closures” or “constitutive models” in engineering simulators to represent fine-scale physical phenomena that are too computationally expensive to resolve explicitly. However, these neural net models of unresolved physical phenomena tend to fail unpredictably and are therefore not used in mission-critical simulations. In this report, we describe new methods to authenticate them, i.e., to determine the (physical) information content of their training datasets, qualify the scenarios where they may be used and to verify that the neural net, as trained, adhere to physics theory. We demonstrate these methods with neural net closure of turbulent phenomena used in Reynolds Averaged Navier-Stokes equations. We show the types of turbulent physics extant in our training datasets, and, using a test flow of an impinging jet, identify the exact locations where the neural network would be extrapolating i.e., where it would be used outside the feature-space where it was trained. Using Generalized Linear Mixed Models, we also generate explanations of the neural net (à la Local Interpretable Model agnostic Explanations) at prototypes placed in the training data and compare them with approximate analytical models from turbulence theory. Finally, we verify our findings by reproducing them using two different methods.

42 ENGINEERING↗
NASA NTRS1972

Peak axial-velocity decay with single- and multi-element nozzles

Jet peak-velocity decay data were obtained for a variety of circular and noncircular single-element and multi-element nozzles for application to externally-blown-flap (EBF) STOL aircraft. These data permit a rational approach, in terms of element type and element spacing, to nozzles designed to promote mixing of the jet exhaust with the surrounding air. Rapid mixing and the resulting lower axial jet velocity decreases the noise caused by the interaction of jet impingement on the flap assembly of EBF STOL aircraft. Empirical relationships are presented that permit the prediction of peak axial-velocity decay curves for a wide spectrum of mixer-type nozzles. The data are useful also in the design of ejector-type noise suppressors and for the suppression of VTOL downwash velocities caused by vertically oriented exhaust nozzles.

Vonglahn, U. H.↗
NASA NTRS1972

Peak axial-velocity decay with single- and multi-element nozzles.

Jet peak-velocity decay data were obtained for a variety of circular and noncircular single-element and multi-element nozzles for application to externally-blown-flap STOL aircraft. These data permit a rational approach, in terms of element type and element spacing, to nozzles designed to promote mixing of the jet exhaust with the surrounding air. Rapid mixing and the resulting lower axial jet velocity decreases the noise caused by the interaction of jet impingement on the flap assembly of EBF STOL aircraft. Empirical relationships are presented that permit the prediction of peak axial-velocity decay curves for a wide spectrum of mixer-type nozzles. The data are useful also in the design of ejector-type noise suppressors and for the suppression of VTOL downwash velocities caused by vertically oriented exhaust nozzles.

Von Glahn, U. H.↗
NASA NTRS1973

A visual study of radial inward choked flow of liquid nitrogen

A visual study of the radial inward choked flow of liquid nitrogen was conducted. Data and high speed moving pictures were obtained. The study indicated the following: (1) steady radial inward choked flow seems equivalent to steady choked flow through axisymmetric nozzles, (2) transient choked flows through the radial gap are not uniform and the discharge pattern appears as nonuniform impinging jets, and (3) the critical mass flow rate data for the transient case appear different from those of the steady case.

Hendricks, R. C.↗
NASA NTRS1973

Externally blown flap dynamic loads

Some of the principal results obtained in three series of measurements of fluctuating surface pressures induced on externally blown flaps by jet impingment are presented. Large- and small-scale models and hot- and cold-flow tests are considered. The discussion sets forth scaling parameters and consistent features of the root-mean-square values and spectra of the loading. Implications of these results with regard to sonic fatigue are indicated.

Lansing, D. L.↗
NASA NTRS1973

A visual study of radial inward choked flow of liquid nitrogen.

Data and high speed movies were acquired on pressurized subcooled liquid nitrogen flowing radially inward through a 0.0076 cm gap. The stagnation pressure ranged from 0.7 to 4 MN/sq m. Steady radial inward choked flow appears equivalent to steady choked flow through axisymmetric nozzles. Transient choked flows through the radial gap are not uniform and the discharge pattern appears as nonuniform impinging jets. The critical mass flow rate data for the transient case appear different from those for the steady case. On the mass flow rate vs pressure map, the slope and separation of the isotherms appear to be less for transient than for steady radial choked flow.

Hendricks, R. C.↗
NASA NTRS1973

Effect of gage size on the measurement of local heat flux

General formulas are derived for determining gage averaging errors of strip-type heat flux meters used in the measurement of one-dimensional heat flux distributions. In addition, a correction procedure is presented which allows a better estimate for the true value of the local heat flux. As an example of the technique, the formulas are applied to the cases of heat transfer to air slot jets impinging on flat and concave surfaces. It is shown that for many practical problems, the use of very small heat flux gages is often unnecessary.

Baumeister, K. J.↗
NASA NTRS1974

Cross-correlation methods for studying near- and far-field noise characteristics of several flow-surface interaction problems

Systematic methods based on cross-correlation techniques are presented for experimental studies of near- and far-field noise characteristics of airflow-surface interaction problems. By cross-correlating any two of three-kinds of microphone measurements: one flush-mounted on the surface, one located in the near field, and one placed in the far field, far-field noise intensities and near-field acoustic energy fluxes can be determined. In both near and far fields, the noise characteristics due to the flow turbulence and surface fluctuating pressure contributions can be evaluated separately. Specific applications to the noise field generated by impinging jets, by surface blowing jets, and by turbulent flow over trailing edges are discussed.

Pan, Y. S.↗