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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 307 records · Page 17
All sourcesNASA NTRSDOE OSTI
DOE OSTI2023

Modeling Heat Pipes with Non-Condensable Gases

The report showcases advancements in modeling heat pipes, considering both scenarios with and without non-condensable gases. To achieve this, two distinct modeling approaches are juxtaposed. Firstly, the effective conduction model, implemented in the MOOSE-based code Sockeye, is employed. Secondly, a first-of-a-kind two-phase Euler-Euler Computational Fluid Dynamics (CFD) model is developed using the STAR-CCM+ code. Both models undergo validation against experimental data, acknowledging the inherent uncertainties associated with each modeling assumption. Interestingly, the non-tuned CFD model surpasses the performance of the calibrated conduction model for heat pipes operating under both conditions: with and without non-condensable gases. It's worth noting, however, that the CFD models entail significantly longer runtimes compared to the conduction models. Nevertheless, the insights garnered from the CFD model shed invaluable light on the intricate operational dynamics of heat pipes. Future work involves broadening the validation scope of these models and continuing their development to enhance their utility as robust tools for heat pipe design and operational support.

42 ENGINEERING↗
DOE OSTI2022

QUIC-URB and QUIC-fire extension to complex terrain: Development of a terrain-following coordinate system

Ensemble-based approaches to prescribed fire planning cannot be supported by CFD-based models like FIRETEC and WFDS because they are too computationally expensive and cannot leverage LES approaches like CAWFE and WRF-SFIRE because too coarse of resolution. QUIC-Fire was developed to fill this gap but it cannot currently address complex terrain, typical for instance of the Western United States. In this paper, we describe the extension of the diagnostic wind model QUIC-URB, the wind engine of QUIC-Fire, to a terrain-following coordinate system. In particular, the paper presents the mathematical derivation of the wind solver leading to a linear system of equations that are solved through the successive over-relaxation method. The model is validated against a standard test used in previous works (the Askervein Hill) and against a new dataset from measurements in the Socorro Mountains, New Mexico. The terrain-following implementation captured the correct phenomenology for the isolated Askervein Hill, with a wind speed up at the top of the hill. We report the model agreed well with measurements on the upwind side of the peak, but overestimated speed-up on the downwind side of the hill. This is due to the inability of the model to generate flow separation and wake-eddy dynamics. On a common laptop, the divergence-free wind field was obtained in 6 s, making the solver appealing for coupled fire–atmosphere simulations. The Socorro Mountain was highly complex, with many cliff faces, peaks, and valleys. Although the model captures the magnitude and direction of inlet and outlet areas of the domain, it performs rather poorly in the valley region and in the regions near the steep cliffs. Hence, the model shows good agreement with data in areas of open sloped terrain but lacks in areas where flow separation and thermally driven effects may be present (neither effect was addressed in this work). Results highlight that future work should focus on the implementation of parameterizations of wake-eddies, similar to QUIC-URB’s building parameterizations, and on thermodynamic-driven flow.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2022

Learning high-dimensional parametric maps via reduced basis adaptive residual networks

We propose a scalable framework for the learning of high-dimensional parametric maps via adaptively constructed residual network (ResNet) maps between reduced bases of the inputs and outputs. When just few training data are available, it is beneficial to have a compact parametrization in order to ameliorate the ill-posedness of the neural network training problem. By linearly restricting high-dimensional maps to informed reduced bases of the inputs, one can compress high-dimensional maps in a constructive way that can be used to detect appropriate basis ranks, equipped with rigorous error estimates. A scalable neural network learning framework is thus to learn the nonlinear compressed reduced basis mapping. Unlike the reduced basis construction, however, neural network constructions are not guaranteed to reduce errors by adding representation power, making it difficult to achieve good practical performance. Inspired by recent approximation theory that connects ResNets to sequential minimizing flows, we present an adaptive ResNet construction algorithm. This algorithm allows for depth-wise enrichment of the neural network approximation, in a manner that can achieve good practical performance by first training a shallow network and then adapting. We prove universal approximation of the associated neural network class for $L^2_v$ functions on compact sets. Our overall framework allows for constructive means to detect appropriate breadth and depth, and related compact parametrizations of neural networks, significantly reducing the need for architectural hyperparameter tuning. Numerical experiments for parametric PDE problems and a 3D CFD wing design optimization parametric map demonstrate that the proposed methodology can achieve remarkably high accuracy for limited training data, and outperformed other neural network strategies we compared against.

42 ENGINEERING↗
DOE OSTI2021

The Effect of Pressure on NO x Entitlement and Reaction Timescales in a Premixed Axial Jet-In-Crossflow

This paper investigates the pressure dependency of a lean premixed jet injected into a lean vitiated crossflow with an experimentally verified detailed chemistry computational fluid dynamics (CFD) model and 53 species considered. Experimental data were taken in an axially staged combustor with an optically accessible test section, allowing the use of particle image velocimetry (PIV) and CH* chemiluminescence techniques as well as point measurement of species concentration, temperature, and pressure. The experimental data cases at one, three, and five atmospheres were selected to describe the flame stabilization dependency on pressure and gain the required knowledge for an extrapolation to engine condition. Simulated exit nitrogen oxide levels were validated with experimental emission data, and a global emission trend for the NO reduction at elevated pressure and constant turbine inlet temperature level was defined. The nitrogen oxide benefit at elevated operating pressure was justified with the significantly smaller flame surface area: the analysis of the simulated spanwise and top-view profiles showed a relatively short receded core flame with nitrogen oxide production in the center at high pressure relative to a longer and larger shear layer flame at atmospheric condition that produced NO toward the inner and outer side of the flame. Furthermore, decomposition of the Damköhler number revealed the strong influence of the reaction timescales with higher reaction rates at elevated pressure, along with a moderate influence of the turbulent timescales, showing higher turbulence intensity in the lee-side recirculation zone at lower pressure.

03 NATURAL GAS↗
DOE OSTI2020

Coupling of Laminar-Turbulent Transition with RANS Computational Fluid Dynamics

This project combines several new concepts to create a boundary layer transition prediction capability that is suitable for analyzing modern hypersonic flight vehicles. The first new concept is the use of ''optimization'' methods to detect the hydrodynamic instabilities that cause boundary layer transition; the use of this method removes the need for many limiting assumptions of other methods and enables quantification of the interactions between boundary layer instabilities and the flow field imperfections that generate them. The second new concept is the execution of transition analysis within a conventional hypersonics CFD code, using the same mesh and numerical schemes for the transition analysis and the laminar flow simulation. This feature enables rapid execution of transition analysis with less user oversight required and no interpolation steps needed.

42 ENGINEERING↗
DOE OSTI2025

Effect of Surface Roughness on Dynamic Stall in Pitching Motion

Dynamic stall plays a critical role in determining the performance and stability of a wide range of fluid-dynamics systems in various engineering applications. This unsteady aerodynamic phenomenon is particularly significant for maneuvering aircraft wings, jet aircraft subjected to gust encounters, helicopter rotor blades, and wind turbine blades [1–3]. The prediction of the dynamic stall vortex (DSV) is challenging due to factors such as unsteady aerodynamics, three-dimensional (3-D) effects, turbulence and flow separation, incoming gust, and surface impact effects [4–6]. Hence, advanced computational techniques and modeling approaches in computational fluid dynamics (CFD) would be required to enhance the accuracy and reliability of DSV predictions in dynamic stall scenarios. In the past, Batther and Lee [7] employed delayed detached eddy simulations (DDES) to understand the flow physics associated with the onset of dynamic stall. Their approach demonstrated that DDES achieves results comparable to those obtained from large-eddy simulations at a reduced computational cost. In another study, Khalifa et al. [8] examined the 3-D aspects of dynamic stall on a NACA 0012 airfoil using DES solvers. In conclusion, the findings underlined the superiority of 3-D simulations over two-dimensional approaches, particularly in predicting the lift coefficient values and capturing dynamic stall stages more precisely.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2024

A Finite Difference informed Random Walk solver for simulating radiation defect evolution in polycrystalline structures with strongly inhomogeneous diffusivity

Diffusivity of species and defects on grain boundaries is usually several orders of magnitude larger than that inside grains. Such strongly inhomogeneous diffusivity requires prohibitively high computational demands for modeling microstructural evolution. Here, this paper presents a highly-efficient numerical solver, combining the Finite Difference method and Random Walk model, designed for accurately modeling strongly inhomogeneous diffusion within polycrystalline structures. The proposed solver, termed Finite Difference informed Random Walk (FDiRW), integrates a customized Finite Difference (cFD) scheme tailored for fast diffusion along thin grain boundaries represented by a single-layer of nodes. Numerical experiments demonstrate that the FDiRW solver achieves an impressive efficiency gain of 1560x compared to traditional Finite Difference methods while maintaining accuracy, making it feasible for personal computer machines to handle diffusional systems with strongly inhomogeneous diffusivity across static polycrystalline microstructures. The model has been successfully applied to simulate radiation defect evolution, showcasing its scalability to engineering scales in both length and time dimensions.

36 MATERIALS SCIENCE↗
DOE OSTI2023

A Computational Investigation of Engine Heat Transfer with Ducted Fuel Injection

Ducted fuel injection (DFI) is an innovative method that curtails or prevents soot formation in direct-injection compression-ignition engines. DFI uses a simple duct, positioned outside each injector hole, facilitating the fuel/charge gas mixing before ignition. This reduces the equivalence ratio below two, in the autoignition zone, which in turn decreases soot formation. But this method also reduces fuel-conversion efficiency. This study investigates the effects of DFI on in-cylinder heat transfer. Experiments with conventional diesel combustion (CDC) and DFI were performed at four different dilution levels. Computational fluid dynamics (CFD) simulations were carried out at conditions matching those of the experiments, and the simulations were validated by the experimental data. The CFD simulations enabled to examine of in-cylinder heat release and temperature distributions. The heat transfer to the piston, head, and cylinder was investigated. The results show that DFI increased the heat transfer to the walls compared to CDC under the same conditions. This could help explain why DFI has been observed to reduce fuel-conversion efficiency by approximately 1% (absolute) relative to CDC under certain conditions. The efficiency loss typically decreases with dilution, such that DFI can improve fuel-conversion efficiencies relative to CDC at higher dilution levels.

Şener, Ramazan↗
DOE OSTI2022

Modeling of Supercritical CO2 Shell-and-Tube Heat Exchangers Under Extreme Conditions: Part II: Heat Exchanger Model

Abstract Heat exchangers play a critical role in supercritical CO2 Brayton cycles by providing necessary waste heat recovery. Supercritical CO2 thermal cycles potentially achieve higher energy density and thermal efficiency operating at elevated temperatures and pressures. Accurate and computationally efficient estimation of heat exchanger performance metrics at these conditions is important for the design and optimization of sCO2 systems and thermal cycles. In this paper (Part II), a computationally efficient and accurate numerical model is developed to predict the performance of shell-and-tube heat exchangers (STHXs). Highly accurate correlations reported in Part I of this study are utilized to improve the accuracy of performance predictions, and the concept of volume averaging is used to abstract the geometry and reduce computation time. The numerical model is validated by comparison with computational fluid dynamics (CFD) simulations and provides high accuracy and significantly lower computation time compared to existing numerical models. A preliminary optimization study is conducted and the advantage of using supercritical CO2 as a working fluid for energy systems is demonstrated.

Engineering↗
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 OSTI2021

Exploring the Effects of Piston Bowl Geometry and Injector Included Angle on Dual-Fuel and Single-Fuel RCCI

Abstract Reactivity control compression ignition (RCCI) is a low-temperature combustion technique that has been proposed to meet the current demand for high thermal efficiency and low engine-out emissions. However, its requirement of two separate fuel systems (i.e., a low-reactivity fuel system and a high-reactivity fuel system) has been one of its major challenges in the last decade. This leads to the single-fuel RCCI concept, where the secondary fuel (reformates of diesel) is generated from the primary fuel (diesel) through catalytic partial oxidation reformation. Following the in-depth analysis of the reformate fuel (reformates of diesel) and its benefit as the low-reactivity fuel with diesel, the effects of the start of injection (SOI) timing of diesel and the energy-based blend ratio were also studied in detail. In this study, the effects of piston profile and the injector included angles were experimentally examined using both conventional fuel pairs (gasoline—diesel and natural gas—diesel) and reformate RCCI. A validated computational fluid dynamics (CFD) model was also used for a better understanding of the experimental trends. Comparing a reentrant bowl piston with a shallow bowl piston at a constant compression ratio and SOI, the latter showed better thermal efficiency, regardless of the fuel combination, due to its 10% lower surface area for the heat transfer. Comparing the 150-degree included angle and 60-degree included angle on the shallow bowl piston, the latter showed better combustion efficiency, regardless of the fuel combination, due to its earlier combustion phasing (at constant SOI timing). The effect was particularly prominent on reformate RCCI because of its incredibly high diluent concentration, which retards the combustion further for the 150-deg injector. Later, using convergecfd, seven different injector included angles were studied at a constant SOI. With the change in injector included angle, the region of the cylinder targeted by the fuel spray varies significantly, and it was found to have a significant impact on the combustion efficiency and the engine-out emissions. As the injector included angle changed from 60-deg to 150-deg, the combustion efficiency increased by 15% and the CO, NOx, and HC emissions decreased by 96%, 70%, and 86%, respectively.

Engineering↗
DOE OSTI2026

Surrogates for Valve-Controlled Pipe Flow: Accelerating Nuclear Reactor Design

Neural surrogate models are developed to replace expensive steady-state RANS CFD simulations for valve-controlled pipe flow in nuclear reactor design. Using parametric CFD data generated with MOOSE Pronghorn across a range of valve geometry and flow conditions, three approaches are compared: a POD-based reduced-order model, a structured UNet on a cylindrical grid, and unstructured models (DeepONet and BiStride MeshGraphNet) on nondimensionalized point clouds. POD achieves the highest accuracy (99%) with fast inference but requires storing all solution snapshots, while the DeepONet and BSMS-GNN both achieve ~89% accuracy at sub-second inference, with the BSMS-GNN offering superior geometric generalizability. These surrogates enable rapid ranking of candidate valve designs and can warm-start CFD solvers to accelerate convergence, supporting agentic design iteration on the Prometheus platform.

42 - ENGINEERING↗
DOE OSTI2020

Comparison of Single-Phase Convection in Additive Manufactured Versus Traditional Metal Foams

Abstract Metal foams have been often used for thermal management due to their favorable characteristics including high specific surface area (SSA), high thermal conductivity, and low relative density. However, they are accompanied by shortcomings including the significant contact resistances due to attachment method, as well as the need for characterization of foam parameters such as pore diameter and SSA. Additive manufactured (AM) metal foams would eliminate the substrate/foam thermal resistance, decrease the need for pre-usage characterization, and allow for tailoring structures, while also taking advantage of the characteristics of traditionally manufactured foams. A commercial, aluminum foam (nominally 5 pores per inch (PPI), 86.5% porosity) was analyzed using X-ray microcomputed tomography, and a custom-designed metal foam based on the cell diameter and porosity of the commercial sample was subsequently manufactured. Reduced domain computational fluid dynamics/heat transfer (CFD-HT) models were compared against experimental data. Postvalidation, the flow behavior, effect of varying attachment thermal conductivities, and thermal performance were numerically investigated, demonstrating the usefulness of validated pore-scale models, as well as the potential for improved performance using AM metal foams over traditionally manufactured foams.

Engineering↗
DOE OSTI2025

Q3 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 Q3: 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. • Benchmark between two first wall heat flux mapping methods, identify importance of various heat flux sources and physics impact of using fully coupled CESOL vs post-analysis evaluation. 2. Generate medium fidelity parametrized CAD. • Generate parametrized CAD components for the CAT example case via either user-defined modules called within the geometry generation or by defeatured/parametrized CAD, including DCLL blanket matched to divertor boundary and magnets. Define materials, labels, and boundary conditions for passing the mesh to CFD tools. 3. Demonstrate multiphysics magnet analysis. • Demonstrate magnet analysis workflow called from the FREDA workflow, and 4. Demonstrate nuclear analysis. • Add model to OpenFOAM and/or other codes possibly including Diablo to account for tritium diffusion in solids.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2021

Numerical Study and Validation of Melting and Solidification in PCM Embedded Heat Exchangers with Straight Tube

Latent heat thermal energy storage (LHTES) systems have shown great potential to enable reliable use of renewable energy and load shifting. LHTES offer high storage density and release energy at near constant temperature because of its use of phase change materials (PCMs). The cylindrical PCM heat exchangers (PCMHX) are one of the most used technologies due to their simplicity. Numerical models for such PCMHX enable engineers to estimate their performance for different design parameters and operating conditions without having to test them all. However, modeling the phase change phenomena can be challenging. To better understand the difficulties involving accurate modeling of PCMHX, a cylindrical latent storage unit filled with PCM and water as in-tube heat transfer fluid (HTF) is numerically investigated. This paper presents a study based on a 2D-axisymmetric model of a straight tube embedded in PCM in a cylindrical container. CFD is used to study the charging (melting) and discharging (solidification) phenomena. The models are validated against experimental and numerical data from the literature. The predicted local PCM temperature profile over time agrees within 2K compared to the experimental values. The paper also presents a simple method to estimate the melting and solidification phase change temperature range from limited data provided by PCM manufacturers.

PCM, melting, solidification, CFD, heat exchanger↗
DOE OSTI2022

Computational Fluid Dynamics analysis of a jet-induced attrition

The flow dynamics, collisional behavior and attrition rates of a grid jet attrition unit are computationally investigated using a kinetic theory-based approach. Profiles of the flow statistical properties are presented and discussed to describe the jet dynamics. Attrition behavior and rates are analyzed from the local reconstruction of the collision energy spectra. The commonly used jet-induced attrition mechanisms which involve the entrainment of the particles into the jet followed by their acceleration and collision at the jet tip is reproduced by the CFD calculations in this work. Here, supported by the local attrition rates, it is shown that the shear-based collisions around the jets, due to counter-current particle axial motions, are an additional jet-induced mechanism generating more fines than at the jet tips.

42 ENGINEERING↗
DOE OSTI2024

Percheron Power Archimedes Screw Turbine Analysis (Abstract)

The development of the Percheron Power (Percheron) composite Archimedes screw turbine (AST) is based upon employing newly developed theoretical mathematical models for optimizing the water volume carried through the AST for a given diameter, combined with minimizing efficiency losses due to bypass flow and friction. The key feasibility issues associated with producing the composite blades will be to understand the strength, fatigue, and wear performance of the AST blades and associated components, and how these factors change along the length of the turbine. To get to this understanding of material property requirements, Percheron needs free-surface computational fluid dynamics (CFD) models of the AST designs and to perform interactive modeling between the turbine blade optimization and component design based on finite element method stress analysis (FEA). The workscope and analyses requested by Percheron in the Small Business Voucher (SBV) program are well aligned with PNNL capability and recent work experience in performing CFD and FEA analysis for hydropower and marine energy turbines. The CFD analysis will provide estimates of power, efficiency, and surface forces on the blades. The forces on the blade will be transferred to the FEA analysis that will be used to evaluate the material stresses. The CFD and FEA analyses will be repeated for different AST designs provided to PNNL by Percheron. The work conducted in this SBV project will complement the existing Percheron FOA project by providing better defined parameters for design and material selection for the turbine unit prior to manufacture of initial test units.

42 ENGINEERING↗
DOE OSTI2025

Validation of RANS Models for Predicting Bypass Flow in Prismatic VHTRs

In prismatic Very-High Temperature Reactors (VHTRs), gaps occur between neighboring fuel assemblies referred to as bypass gaps. This work aims to measure the flow distribution between the bypass gaps between neighboring assemblies and the coolant channels within the assemblies. Computational fluid dynamics (CFD) was done using Reynolds-Averaged Navier Stokes (RANS) modeling in STAR-CCM+ to assess the ability of RANS models to accurately capture this phenomena. The RANS results were compared to experimental worked performed by Seoul National University (SNU) and Korea Atomic Energy Research Institute (KAERI) for validation. The CFD results showed good comparison with the experimental data available from SNU and flow split was characterized for multiple configurations, inlet mass flow rates, and bypass gap sizes.

22 - GENERAL STUDIES OF NUCLEAR REACTORS↗