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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 343 records · Page 19

Metal additively manufactured wavy fin cold-plate architecture for improved thermal-hydraulic performance

Rapid growth in artificial intelligence and data center workloads demands high-performance liquid cooling to manage increasing chip power. This study presents two metal-additive-manufactured cold plates with sinusoidal fins, constant-amplitude wavy fins and linearly variable-amplitude wavy fins and compares them against metal-additive-manufactured straight fins using experiments conducted at 1 kW heat dissipation as well as high-fidelity 3D conjugate computational fluid dynamic simulations. The cold plates were printed in AlSi10Mg material and underwent design using a Python-automated workflow prior to manufacture and testing. The experiments show that wavy fins reduce the normalized thermal resistance by 35 to 45 % at water flow rates from 1 to 4 LPM. At a fixed 20 kPa pressure drop, the variable-waviness design lowered peak surface temperature by 9 °C and thermal resistance by 51 %, while edge-channel maldistribution in the constant wavy fin design limited gains. A thermal resistance breakdown revealed that 55–63 % of the total thermal resistance in wavy designs comes from base heat conduction, 27–33 % from fin heat conduction, and 9–13 % from fin heat convection, indicating the need to address conduction bottlenecks. Parametric sweeps identify a 3 mm fin pitch as optimal, and that horizontal inlet/outlet manifolds further reduce pressure drop by 30–60 % and thermal resistance by 9–16 % relative to vertical inlet-outlet manifolds. The results yield comprehensive guidelines for fin geometry, manifold alignment, material selection and additive-manufacturing constraints to realize high-performance liquid-cooled cold plates for power-dense electronics.

3d printing↗

1 / ω electric-field noise in surface ion traps from correlated adsorbate dynamics

Ion traps are promising architectures for implementing quantum computers, but they suffer from excessive “anomalous” ion motional heating that limit their overall coherence and practicality for scalable quantum computing. The exact microscopic origins of anomalous heating remain an open question, but experiments point to adsorbates on trap electrodes as one likely source. Many different models of anomalous heating have been proposed, but these models have yet to pinpoint the atomistic origin of the experimentally observed 1/ω electric-field noise scaling seen in ion traps at frequencies between 0.1–10 MHz. In this work, we show that a model based on previously proposed surface-induced dipole fluctuations on adsorbates, but which also incorporates interparticle interaction dynamics through molecular dynamics simulations of up to multiple monolayers of adsorbates, gives rise to 1/ω frequency scaling at the MHz frequencies typically employed in ion traps. Overall, these results demonstrate that moderate-to-high densities of adsorbates can give rise to a set of activated motions that produce the 1/ω noise observed in ion traps and that collective adsorbate motions produce the observed noise spectra that a noninteracting model does not capture.

36 MATERIALS SCIENCE↗

Unlocking the Path to Decarbonized Building Thermal Systems: Strategies for Designers and Contractors: Preprint

The design and construction community plays a pivotal role in facilitating the transition to decarbonized thermal systems that maintain human comfort while reducing building emissions. Through the U.S. Department of Energy Better Buildings initiative's Design and Construction Allies, a cohort of leading architecture, engineering, and construction firms have identified top ranked barriers that designers and contractors face when implementing solutions for building owners. These barriers to decarbonizing thermal - especially heating - systems include equipment availability; electrical capacity constraints; space allocations; complex system configurations; and lack of experience in designing, installing, and maintaining heat pumps. These impediments significantly amplify the risk and financial burden associated with the adoption of decarbonized solutions. The barriers also decrease the likelihood that designers, contractors, and owners will adopt decarbonization strategies without clear plans and guidance on how to implement these solutions, mitigate risk, and overcome the identified barriers. The National Renewable Energy Laboratory, the Design and Construction Allies, and the American Society of Heating, Refrigerating, and Air-Conditioning Engineers have developed "how to" thermal decarbonization guidance based on best practices. The subjects covered range from the role of energy efficiency in facilitating decarbonized heating solutions to strategies for decarbonizing new and existing heating, ventilating, and air-conditioning systems. The focus is on overcoming barriers so that energy-efficient, electrified buildings - both new and retrofit - become the industry standard. This paper outlines 1) the method used to collect and organize this guidance, 2) industry barriers to decarbonization, and 3) decarbonization techniques that have broad market applicability.

building heating↗

Thermal-shock experiments for separate-effects validation of UO 2 fuel fracture models

Because of the important role that fracture plays in the behavior of ceramic UO2 fuel in a nuclear reactor environment, fracture models are a major component of fuel performance codes. As with any aspect of fuel performance, it is crucial to validate these fracture models against experimental data; however, obtaining well-controlled data for conditions representative of a reactor environment is difficult. Quenching is proposed here as a relatively simple approach for using a laboratory environment to achieve conditions that approximate those of a reactor environment. In this paper, an experimental apparatus containing a single instrumented fuel pellet in a sealed section of copper tubing is developed. It is then applied to a series of seven experiments in which the apparatus is first heated to a high temperature (580-680°C) by immersion in a molten salt bath, then quenched in a cold bath (-10-4 °C). Development of these experiments was guided by numerical simulations, and post-test simulations were performed to aid in understanding the experimental behavior and assessing the accuracy of the predictions of fracture initiation and propagation. In addition, similar experiments were performed on solid copper rods to provide temperature-dependent heat transfer coefficients for use in simulations of these experiments. Here, this study demonstrates that quenching is a viable approach for generating thermal gradients representative of those in prototypical light-water reactor conditions at powers of about 5–10 kW/m. Fracture is expected to begin at these power levels, and moderate amounts of radial and axial cracking was observed in these quenching tests.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Where Are White Roofs More Effective in Cooling the Surface?

Solar reflective roofs (also called white or cool roofs) are a common heat mitigation strategy. By reflecting more sunlight than regular roofs, cool roofs experience lower surface temperatures and produce less heating of the surrounding air. The effectiveness of cool roofs, quantified by the surface temperature difference between cool roofs and regular roofs ??????, is known to vary spatially. A common perception is that ?????? is controlled by solar radiation that reaches the roof surface. Here we use an Earth System Model and a surface energy balance model to show that the spatial variability of ??????, when normalized by the albedo difference between cool roofs and regular roofs (????), is in fact more controlled by an energy distribution factor that encodes the efficiencies of surface energy balance components in dissipating heat. Our results suggest that painting the roof white is more effective in reducing the roof surface temperature when the roof has less water holding capacity and smaller thermal admittance and is located in places with more solar radiation, less precipitation, and lower wind speed.

Wang, Linying↗

The CWS Experiments – An Experimental Study of the Effects of Chlorine on Thermal Neutron Absorption

The Chlorine Worth Study (CWS) experiments consist of layers of Zero Power Physics Reactor plates moderated by high density polyethylene, polyvinyl chloride, and chlorinated polyvinyl chloride with the goal to produce a thermal critical experiment. A thick high density polyethylene reflector surrounds the experiments. Aluminum fuel trays and frames were used to conduct the intrinsic heat generation of the plutonium plates away from the core and out to the top plate and the platen, both acting as heat sinks. The goal of the CWS experiments was to provide benchmark critical experiments that were sensitive to chlorine and matched the sensitivity of criticality safety applications for aqueous chloride operations at PF-4 at Los Alamos National Laboratory. The specific aqueous chloride PF-4 applications were solutions of 30 g/L plutonium, 300 g/L plutonium, and 600 g/L plutonium. The CWS experiments were designed using prototype methods developed by the ARCHIMEDES and EUCLID projects at Los Alamos National Laboratory. The CWS experiments were performed in December of 2021 at the National Criticality Experiments Research Center at the Nevada Nuclear Security Site on the Planet critical assembly. It is intended that the CWS experiments will be evaluated and submitted to the ICSBEP in the future as criticality safety benchmarks.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Alpha heating of indirect-drive layered implosions on the National Ignition Facility

We report in order to understand how close current layered implosions in indirect-drive inertial confinement fusion are to ignition, it is necessary to measure the level of alpha heating present. To this end, pairs of experiments were performed that consisted of a low-yield tritium–hydrogen–deuterium (THD) layered implosion and a high-yield deuterium–tritium (DT) layered implosion to validate experimentally current simulation-based methods of determining yield amplification. The THD capsules were designed to reduce simultaneously DT neutron yield (alpha heating) and maintain hydrodynamic similarity with the higher yield DT capsules. The ratio of the yields measured in these experiments then allowed the alpha heating level of the DT layered implosions to be determined. The level of alpha heating inferred is consistent with fits to simulations expressed in terms of experimentally measurable quantities and enables us to infer the level of alpha heating in recent high-performing implosions.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

Interactions Between Clouds and Wind-Driven Surface Heat Exchanges over Land

Earth system model experiments show that increasing horizontal resolution fundamentally alters the simulated soil-moisture-precipitation feedback. Kilometer-scale simulations often produce weaker or even negative feedback compared to coarse-resolution models. A key difference of kilometer-scale models is that they resolve mesoscale secondary circulations, including boundary layer horizontal rolls and cellular structures, in addition to cold pools and downdrafts associated with convective precipitation. However, because the relevant processes occur on yet-smaller scales, these circulations are often poorly resolved. This project demonstrated that boundary layer secondary circulations significantly affect surface heat exchanges and wind gusts, and that current model parameterizations can misrepresent these processes at kilometer-scale resolution. Using DOE Atmospheric Radiation Measurement (ARM) observations and targeted experiments with the DOE Energy Exascale Earth System Model (E3SM), we identified physically unrealistic wind gust and surface flux responses to secondary circulations, diagnosed a systematic overestimation of wind shear in convective cold pools, and uncovered a multivariate relationship between land surface fluxes and the scales of updrafts that form shallow cumulus clouds. These findings provide observation-based recommendations for improving parameterizations of surface fluxes and wind gusts in high-resolution Earth system models, thereby reducing uncertainty in convective storm prediction and land-atmosphere feedbacks.

54 ENVIRONMENTAL SCIENCES↗

Using Hyperoptimized Tensor Networks and First-Principles Electronic Structure to Simulate the Experimental Properties of the Giant {Mn 84 } Torus

The single-molecule magnet {Mn 84 } is a challenge to theory because of its high nuclearity. Here, we directly compute two experimentally accessible observables, the field-dependent magnetization up to 75 T and the temperature-dependent heat capacity, using parameter-free theory. In particular, we use first-principles calculations to derive short- and long-range exchange interactions and compute the exact partition function of the resulting classical Potts and Ising spin models for all 84 Mn S = 2 spins to obtain observables. The latter computation is made possible by using hyperoptimized tensor network contractions, a technique developed to simulate quantum supremacy circuits. We also synthesize the magnet and measure its heat capacity and magnetization, observing qualitative agreement between theory and experiment and identifying an unusual bump in the heat capacity and a plateau in the magnetization. Our work also identifies some limitations of current theoretical modeling in large magnets, such as sensitivity to small, long-range exchange couplings.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

Chemical Recycling of Polycaprolactones via Reactive Melt Processing

Chemical recycling is a promising technology for the deconstruction of waste plastics into monomers or other chemical intermediates, which can be converted into other value-added products or repolymerized into polymers. In this work, polycaprolactone and poly(4-propylcaprolactone) were chemically recycled by exploiting ring-closing depolymerization (RCD). To demonstrate the utility of this approach, reactive distillation experiments were initially conducted in a heated round-bottom flask with a distillation head to explore the effect of temperature and catalyst loading on RCD. Inspired by industrial devolatilization equipment, analogous experiments were conducted using a twin-screw melt compounder that was modified to simultaneously heat and mix polymer in the presence of a catalyst while continuously removing the evolved monomer vapors with a vacuum system and collecting them in a cold trap. Yield and selectivity of the recovered monomer were characterized by 1 H nuclear magnetic resonance spectroscopy and gas chromatography-mass spectrometry. Importantly, the more scalable twin-screw melt compounder approach produced values of monomer selectivity (∼90%) and yield (∼80%) similar to those of the round-bottom flask experiments. The recovered monomers were also successfully repolymerized into the same neat polymer with comparable molar masses without purification steps or adding initiator. Here, the results of this study promote the use of reactive devolatilization extrusion as a scalable approach to polyester depolymerization.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

Achievements and Ongoing Challenges for advanced CFD Boiling Closure Model Development using Physical Insights from Validation-Oriented High-Fidelity Boiling Experiment

The fundamental understanding of the boiling-associated heat transfer, including sliding bubble effect, is still challenging despite the intensive research for decades in both experimental and computational boiling research communities. One of the main difficulties of boiling experiment come from the fact that direct observation of the underlying principle through experiment is very difficult due to the high complexity of the boiling phenomenon. Also, since the heat transfer characteristics associated with boiling is the result of non-linear interaction of various physical parameters coupled to each other, it is challenging to find the relationship between the parameters for modeling. This paper discusses the authors’ past and ongoing boiling research under CASL (Consortium for Advanced Simulation of Light Water Reactors) program, including the efforts to overcome the difficulties of boiling measurement and model development. In particular, we focus on describing the major achievements, lessons learnt, and ongoing challenges for the CFD boiling closure model development based on the high-fidelity subcooled flow boiling experiment at Texas A&M University (TAMU). The major research achievements discussed through this paper include (i) novel boiling measurement strategy and high-fidelity validation data production, (ii) dedicated effort to identify the critical measurement issues in boiling experiment, (iii) new physical insight into sliding bubble heat transfer mechanisms, and (iv) new boiling closure model development. Discussion is also made on the ongoing challenges for the boiling closure model development and the future research plan based on the lessons learnt.

42 ENGINEERING↗

Vertical Structure of Radiative Heating Rates of the MJO during DYNAMO

The vertical structure of radiative heating rates over the region of the tropi-cal Indian Ocean associated with the MJO during the DYNAMO/ARM MJO Investigation Experiment is presented. The mean and variability of heating rates during active, suppressed, and disturbed phases are determined from the Paci?c Northwest National Laboratory combined remote sensing retrieval (CombRet) from Gan Island, Maldives (0.69? S, 73.15? E). TOA and surface ?uxes from the CombRet product are compared with collocated three-hourly CERES SYN1deg Ed4A satellite retrievals. The ?uxes are correlated in time with correlation coef?cients around 0.9, yet CombRet time-mean OLR is 15 W m-2 larger. Previous work has suggested that CombRet under-samples high clouds, due to attenuation by low-level clouds and reduced instrument sensitivity with altitude. However, mean OLR differs between CombRet and CERES for all values of OLR, not just the lowest values corresponding to widespread high clouds. The discrepancy peaks for mid-range OLR, sugges-tive of precipitating, towering cumulus convective clouds, rather than strati-form cirrus clouds. Biases in the cloud-top height of thick clouds substantially contribute to the overestimate of OLR by CombRet. CombRet data is used to generate composite shortwave and longwave atmospheric heating rate pro-?les as a function of the local OLR. Though there is considerable variability in CombRet not directly related to OLR, the time-height structure of mean heating rate composites generated using OLR as the interpolant is broadly representative of tropical convective variability on intraseasonal time scales.

Shell, Karen M.↗

Supporting data for "Frozen flume experiments indicate rapid permafrost riverbank erosion depends on bank roughness"

This dataset contains supporting files detailing five frozen flume experiments conducted at the Caltech Earth Surface Dynamics Laboratory to investigate rates of ablation-limited permafrost riverbank erosion under controlled conditions. Water flowed past a bank of saturated, frozen sand and ice and gradually eroded the bank by thawing pore ice and immediately entraining sand and washing it downstream. Experiments were scaled for flow hydraulics and heat transfer allowing comparisons between our results and natural permafrost riverbanks. For each experiment, we measured the initial and final sand bank topography using a Keyence laser scanner, water surface slope at 3-min intervals throughout the experiment using a Massa sonar scanner, bank erosion using 10-sec overhead timelapse imagery taken by an overhead camera, water and bank temperature using thermistors frozen into the sand bank and sampling at 2 Hz, and water discharge using an in-line flow meter. We include calibration data for the carriage (engineered by the Saint Anthony Falls Laboratory) used to make sonar and laser topography measurements. We also include calibration data for temperature sensors, water discharge measurements, and images of a regular grid placed in the flume to align overhead camera images with the carriage datum. Grain size analysis for the channel bed (gravel) was produced using a pebble count and bank sand was measured using a Camsizer X2. In addition to the five frozen experiments, we include sonar scans of water surface slope and Keyence scans of bed and bank topography for calibration experiments ran with an immobile gravel bank and bed.

54 ENVIRONMENTAL SCIENCES↗

Time-domain theory of transient heat conduction in the local limit

Ultrafast and nanoscale heat conduction demands a unified theoretical framework that rigorously bridges macroscopic transport equations with microscopic material properties derived from statistical physics. Existing empirical generalizations of Fourier's law often lack a solid microscopic foundation, failing to connect observed non-Fourier behavior with underlying atomic-scale mechanisms. In this work, we present a time-domain theory of transient heat conduction rooted in Zwanzig's statistical theory of irreversible processes. Central to this framework is the time-domain transport function $\overleftrightarrow{𝑍}$⁡(𝑡) defined through equilibrium time-correlation functions of heat fluxes. This function generalizes the conventional concept of steady-state thermal conductivity, governing the transition of conduction dynamics from onset second sound type wave propagation at finite speeds to diffusion-dominated behavior across broad temporal and spatial scales. Unlike phonon hydrodynamic models that rely on mesoscopic constructs such as phonon drift velocity, our approach provides a quantitative and microscopic description of intrinsic memory effects in transient heat fluxes and applies universally to bulk materials at any temperature or length scale. By integrating atomistic-scale first-principles calculations with continuum-level macroscopic equations, this framework offers a robust foundation for numerical simulations of transient temperature fields. Furthermore, it facilitates the interpretation and design of transient thermal grating experiments using nanometer-scale heat sources and ultrafast laser systems in the extreme ultraviolet and x-ray wavelength ranges, advancing our understanding of heat dissipation dynamics.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

Development of pebble-based extruded carbon rods for extreme plasma heat flux environments

This work presents first experiments toward the development of continuously renewable (extrudable) pebble-based carbon rods for use as plasma-facing components in extreme steady-state plasma flux environments. The primary envisioned application of this work is a first wall that can survive long-term in future magnetic fusion power reactors while also improving recovery of the reactor fuel (tritium and deuterium atoms). Bench tests applying extreme steady-state front-surface heat loads of up to 50 MW/m 2 are presented. Continuous pebble rod front-surface recession and intact pebble recovery are successfully demonstrated, at a rate of order 0.2 cm/s. Numerical simulations of the pebble rod front-surface recession are able to match observations reasonably well, indicating that the recession mechanism can be understood as occurring due to pebble thermal expansion and resulting shock and cracking of the inter-pebble binder. Tests of the pebble rod extrusion demonstrate that friction between the rods and the stainless-steel extrusion channel is tolerably low (<50 N for the expected channel length) over a wide range of temperatures. Front-surface outgassing rates below 1000 Torr L/s/m 2 are achieved, believed to be sufficiently low for use in magnetic fusion reactors. In conclusion, initial parametric scans over pebble rod size and binder fraction to vary front-surface recession rates are presented.

36 MATERIALS SCIENCE↗

Development and evaluation of a skeletal mechanism for EHN additized gasoline mixtures in large Eddy simulations of HCCI combustion

Advanced Low Temperature Combustion modes, such as the Sandia proposed Additive-Mixing Fuel Injection (AMFI), can unlock significant potential to boost fuel conversion efficiency and ultimately improve the energy conversion of internal combustion engines. This is a novel improved combustion process that is enabled by supplying small (<5%) variable amounts of autoignition improver to the fuel to enhance the engine operation and control. Common, diesel-fuel ignition-quality enhancing additive, 2-ethylexyl nitrate (EHN), is doped into gasoline to enable Sandia LTGC + AMFI combustion. This manuscript focuses on the development of a reduced sub-mechanism for EHN chemical kinetics at engine relevant conditions that is implemented into a skeletal mechanism for chemical kinetic studies of gasoline surrogate fuels. The mechanism validation utilized zero-dimensional numerical simulations and comparison to shock tube ignition-delay data of pure and EHN-doped n-heptane. Additional validation is presented with Homogeneous Charge Compression-Ignition (HCCI) engine data of pure and EHN-doped research-grade E10 gasoline. Then, the mechanism was deployed in a 3-D computational fluid dynamics (CFD) using Large Eddy Simulations (LES) to model the HCCI engine experiments of 0.4% vol EHN additized E10 gasoline at several equivalence ratios. Simulations showed a very good performance of the mechanism, and the model accurately reproduced (a) the ignition point, (b) combustion phasing, (c) combustion duration, and (d) the peak of the heat release rates of the engine experiments. The results show that EHN promotes Low-Temperature Heat Release, ultimately driving the gasoline to autoignite at thermodynamic conditions where the fuel would not otherwise ignite. Overall, this work demonstrates a viable reduced chemical-kinetic mechanism for EHN and shows that it can be combined with a skeletal gasoline mechanism for CFD-LES analysis of well-mixed LTGC that matches well with experimental results. The CFD-LES analysis also shows the spatial distribution of EHN-fuel interactions that control the autoignition throughout the combustion chamber.

Guleria, Gaurav↗

A dynamic volumetric heat source model for laser additive manufacturing

Melt pool scale models of laser powder bed fusion (LPBF) offer insights into the process-structure-property relationships in additive manufacturing (AM). These models often neglect physical phenomena such as vapor cavity formation and fluid mechanics to reduce computational demands. Instead, volumetric heat source models are used to represent the effects that these phenomena have on the predicted melt pool dimensions. Generally, the dimensions and effective absorption of the volumetric heat source are calibrated to reproduce melt pool dimensions observed in metallographic cross sections taken from single-track experiments on bare plate. However, the transient nature of LPBF often deviates the melt pool dimensions from the assumed steady-state conditions of single-track experiments, motivating the need for a volumetric heat source model that more generally considers the dynamic relationship between melt pool shape and laser-material interactions. Here, we introduce a two-parameter volumetric heat source model that integrates several existing models into a generalized mathematical expression, providing independent control over the radial heat distribution via the parameter k and the volumetric shape of the heat source via the parameter m. This parameterization enables the calibration of melt pool shape predictions through simultaneous adjustment of these parameters, while keeping the radial heat source dimensions consistent with the experimental spot size (D4σ) and constraining the heat source depth and absorption to physically derived expressions for cavities. Consequently, the proposed volumetric heat source model adapts to changes in the local melt pool conditions due to scanning strategy and part geometry by dynamically adjusting the heat source depth and absorption. We demonstrate the capabilities of the proposed model through comparisons with a collection of experiments from the Additive Manufacturing Benchmark (AMBench).

36 MATERIALS SCIENCE↗

Dynamic response of 17-4 stainless steel as a function of manufacturing method and heat treatment

We present a series of plate-impact experiments on 17-4 stainless steel to study the effect of manufacturing method and heat treatment on the Hugoniot elastic limit (HEL), Hugoniot, phase transformation stress, and spallation strength. Two traditional manufacturing methods were considered, wrought processing and casting, as well as two additive manufacturing methods, laser powder-bed fusion (LPBF) and wire-fed electron beam (EBAM). For both LPBF and EBAM 17-4 stainless steel variants, two billets were printed, enabling the application of two unique heat treatments. The HEL stress depended heavily on the thermal history, with the HEL increasing after the formation of Cu-rich precipitates via heat treatment. The Hugoniot response both below and above the phase transition was unaffected by the manufacturing method or heat treatment. The phase transition stress depended heavily on the thermal history, with its variation being attributed to the presence of various microstructural features. This is supported by a marked increase in the phase transition stress after precipitation hardening. These results suggest that the notion of the phase transition stress being dictated by bulk composition is an oversimplification and the stress fields generated by the meso-scale structure are a dominant force. The spallation strength was lower in the cast material compared to all other 17-4 stainless steel variants due to the presence of brittle δ-ferrite inclusions. Additionally, a drop in the tensile strain-rate was observed in the spallation response above the phase transition stress, which was hypothesized to stem from the kinetics of the reversion to the low-pressure phase during spall.

Compressive stress↗