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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 37 records · Page 2

Fourier-like Thermal Relaxation of Nanoscale Explosive Hot Spots

Hot spots are local regions of high temperature that are widely considered to govern explosive initiation. Hot spot dynamics rests on a delicate balance between heat generation due to chemical reactions and heat loss through thermal conduction, making accurate determinations of the conductivity under extreme conditions a key component of predictive explosive models. We develop here an approach to directly determine the thermal transport properties of explosive hot spots with realistic initial structures through a combination of molecular dynamics (MD) and diffusive heat equation (HEq) modeling. Effective thermal conductivity values are determined by fitting HEq models to MD predictions of long timescale hot spot relaxation. The approach is applied to model hot spots in the molecular crystalline explosive 1,3,5-triamino-2,4,6-trinitrobenzene (TATB) for a range of shock strengths and two limiting cases for impact orientation. Isotropic and anisotropic HEq models yield similar results, despite TATB exhibiting some of the largest and most anisotropic thermal conductivity values for explosive near normal conditions. The conductivity is found to be a strong function of density, which parametrically captures dependence on temperature, pressure, and material state. The associated root-mean-square errors of the fitted HEq models are approximately 5% of MD predicted final equilibrium temperatures. Here, the conductivity values determined here for TATB hot spots are considerably larger than those used in a prior hot spot criticality study, which may significantly impact predictions for critical hot spot sizes. The approach provides a convenient foundation for determining the effective thermal conductivity for hot spot problems in other explosives and directly yields information on reasonable approximations that might be taken in higher-level models for those materials.

36 MATERIALS SCIENCE↗

Atomistic simulations of the thermal conductivity of liquids

We present a method based on sinusoidal approach to equilibrium molecular dynamics (SAEMD) to compute the thermal conductivity of liquids Similar to nonequilibrium molecular dynamics, and unlike equilibrium simulations based on the Green-Kubo formalism, the method only requires the calculation of forces and total energies. The evaluation of heat fluxes and energy densities is not necessary, thus offering the promise of efficiently implementing first principles simulations based on density functional theory or deep molecular dynamics. Our approach is a generalization of SAEMD for solids, where the thermal conductivity is computed in the steady state, instead of a transient regime, thus properly taking into account diffusive terms in the heat equation. We present results for liquid water at ambient conditions and under pressure and discuss simulation requirements to obtain converged values of the thermal conductivity as a function of size and simulation time.

36 MATERIALS SCIENCE↗

Error Estimates for the Optimal Control of a Parabolic Fractional PDE

In this work, we consider the integral definition of the fractional Laplacian and analyze a linear-quadratic optimal control problem for the so-called fractional heat equation; control constraints are also considered. We derive existence and uniqueness results, first order optimality conditions, and regularity estimates for the optimal variables. To discretize the state equation we propose a fully discrete scheme that relies on an implicit finite difference discretization in time combined with a piecewise linear finite element discretization in space. We derive stability results and a novel $L^2(0,T;L^2(\Omega))$ a priori error estimate. On the basis of the aforementioned solution technique, we propose a fully discrete scheme for our optimal control problem that discretizes the control variable with piecewise constant functions, and we derive a priori error estimates for it. We illustrate the theory with one- and two-dimensional numerical experiments.

97 MATHEMATICS AND COMPUTING↗

Adamantine 1.0: A Thermomechanical Simulator for Additive Manufacturing

Adamantine is a thermomechanical simulation code that is written in C++ and built on top of deal.II (Arndt et al., 2023), p4est (Burstedde et al., 2011), ArborX (Lebrun-Grandié et al., 2020), Trilinos (The Trilinos Project Team, 2020), and Kokkos (Trott et al., 2022). Adamantine was developed with additive manufacturing in mind and it is particularly well adapted to simulate fused filament fabrication, directed energy deposition, and powder bed fusion. Adamantine employs the finite element method with adaptive mesh refinement to solve a nonlinear anisotropic heat equation, enabling support for various additive manufacturing processes. It can also perform elastoplastic and thermoelastoplastic simulations. It can handle materials in three distinct phases (solid, liquid, and powder) to accurately reflect the physical state during different stages of the manufacturing process. To enhance simulation accuracy, adamantine incorporates data assimilation techniques (Asch et al., 2016). This allows it to integrate experimental data from sensors like thermocouples and infrared (IR) cameras. This combined approach helps account for errors arising from input parameters, material properties, models, and numerical calculations, leading to more realistic simulations that reflect what occurs in a particular print.

36 MATERIALS SCIENCE↗

Multiscale Approach to Fast ModSim for Laser Processing of Metals for Future Nuclear Deterrence Environments

Predicting performance of parts produced using laser-metal processing remains an out- standing challenge. While many computational models exist, they are generally too computationally expensive to simulate the build of an engineering-scale part. This work develops a reduced order thermal model of a laser-metal system using analytical Green's function solutions to the linear heat equation, representing a step towards achieving a full part performance prediction in an "overnight" time frame. The developed model is able to calculate a thermal history for an example problem 72 times faster than a traditional FEM method. The model parameters are calibrated using a non-linear solution and microstructures and residual stresses calculated and compared to a non-linear case. The calibrated model shows promising agreement with a non-linear solution.

36 MATERIALS SCIENCE↗

Enhancement of PyARC for Westinghouse Electric Company’s Lead Fast Reactor Design and Modeling (Final TCF Report)

Westinghouse Electric Company is a nuclear reactor vendor headquartered in the U.S. that is developing advanced reactor technology for the U.S. and global markets. Westinghouse has been relying on the neutronics Argonne Reactor Codes (ARC) executed through the NEAMS Workbench and its PyARC module that are developed under the DOE-NE Nuclear Energy Advanced Modeling and Simulation (NEAMS) and Advanced Reactor Technology (ART) – Fast Reactor programs. Through this user experience, Westinghouse identified several enhancements that would benefit the ARC codes’ usability by the US industry and therefore its commercialization potential. The enhancements were proposed to deliver both improvements in workflow and analysis capabilities to better support effective fast reactor core design and analysis to the nuclear industry. The PyARC workflow was extended in this project by integrating non-neutronic ARC codes DASSH and NUBOW-3D. The Ducted Assembly Steady-State Heat equation (DASSH) code is developed at ANL to perform steady-state thermal hydraulic sub-channel analysis in liquid metal fast reactor assemblies to determine optimized coolant flow and temperature distributions, which in this project was updated and validated for lead fast reactor (LFR) applications. The interface between REBUS and NUBOW-3D were improved in this project to assess the impact of the core restraint design and thermal induced expansion effects on the reactivity of the core, and to model the deformations of the fuel assemblies induced by temperature and irradiation. Finally, the ARC models that were extensively verified and validated through various SFR-based modeling benchmarks are extended in this project through code-to-code comparison on relevant LFR-specific neutronics benchmarks against Monte-Carlo neutronic solutions. Overall, this work enables verification of the capability of the ARC codes for a wide range of Generation-IV reactor designs. The outcome of this project is the release of a comprehensive modeling toolkit of validated, robust and efficient codes, as well as their user interface, that enables industry to perform a wide range of fast reactor analyses for design and licensing of their concepts.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

Multiphase representation of hotspot formation and growth

Multiphase reacting flow approach has been adopted for modeling of hotspot formation and growth on sub-zonal scale. Mechanical response of the high explosive (HE) is modeled by the Visco-Plastic SCRAM model which includes plastic work, crack growth, and frictional heating along the cracks. In this work a sub-zonal regions with high temperature, hotspots, are modeled as a new phase. Formation and growth of the hotspot phase from the cold phase is modeled as a phase change. Each phase has its own temperature and pressure. Chemical reactions also progress in both phases. The growth of hotspots are determined by the solution of the heat conduction equation with appropriate heat sources due to friction and plastic heating. Sample calculations using the BABBO code show successful detonation calculations with hotspot formation and growth.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗

Hardness Prediction by Incorporating Heat Transfer and Molten Pool Fluid Flow in a Multi-pass, Multi-layer Weld for Onsite Repair of Grade 91 steel

Introduction: In the current fleet of fossil-fired power plants, creep strength enhanced ferritic steels (CSEF) are used to sustain the harsh service conditions. Enhanced properties of Grade 91 steel result from tempered martensite with a fine distribution of MX and M23C6 carbides. Grade 91 steel is subjected to onsite welding repair to remedy their degradation due to extreme service condition. Knowledge of weld repairability of these steels, such as as-welded hardness distribution, is essential to establishing sound repair procedures. Experimental trial and error tests can consume a lot of time as many welding variables need to be studied. For numerical modelling, most of the multi-pass multi-layer models are based on finite element method, which are limited to solve the heat conduction equation and ignore convective heat transfer due to melt flow. Moreover, the mesh has to be pre-built based on a known or assumed weld cross-section geometry. These finite element based models thus have limited predictive capability as defects are not considered and nugget size are pre-assumed. This research aims at developing a thermal and microstructure evolution model incorporating molten pool dynamics in a multi-pass multi-layer material deposition to predict the as-welded hardness distribution. Technical Approach: All the thermal, physical, and metallurgical properties of Grade 91 as a function of temperature are collected from the literature and inputted into the thermo-fluid model based on Flow-3D, a computational fluid dynamics software. A multi-pass, multi-layer material deposition is simulated where the melting of filler wire into the molten pool is directly considered based on the volume of fluid (VOF) method. The flow behaviour of the molten pool is used to understand the formation of deposition geometry and defects. The temperature profiles during the multi-pass, multi-layer welding are calculated. The results computed using the new model are compared against the experimental data of fusion zone geometry and thermal cycles. Hardness prediction in the heat-affected zone (HAZ) are made using Johnson-Mehl-Avrami (JMA) equation for solid-state phase transformation kinetics. The JMA parameters are extracted from the experimental data available in the literature. For comparison, a standard finite element heat conduction model is also developed to predict the thermal cycles and hardness distribution in the multi-pass, multi-layer weld. Expected Result: Results obtained using the molten pool dynamic simulation versus the finite element heat conduction model are compared. Specifically, the effects of convective heat transfer on the accuracy of the calculated thermal history, bead shape and size, and HAZ hardness distribution are examined.

Modeling, Grade 91 steel, Multi-pass multi-layer d↗

Internal energy balance and aerodynamic heating predictions for hypersonic turbulent boundary layers

The elemental equation governing heat transfer in aerodynamic flows is the internal energy equation. For a boundary layer flow, a double integration of the Reynolds-averaged form of this equation provides an expression of the wall heat flux in terms of the integrated effects, over the boundary layer, of various physical processes: turbulent dissipation, mean dissipation, turbulent heat flux, etc. Recently available direct numerical simulation data for a Mach 11 cold-wall turbulent boundary layer allows a comparison of the exact contributions of these terms in the energy equation to the wall heat flux with their counterparts modeled in the Reynolds-averaged Navier-Stokes (RANS) framework. Various approximations involved in RANS, both closure models as well as approximations involved in adapting incompressible RANS models to a compressible form, are assessed through examination of the internal energy balance. There are a number of potentially problematic assumptions and terms identified through this analysis. Here, the effect of compressibility corrections of the dilatational dissipation type is explored, as is the role of the modeled turbulent dissipation, in the context of wall heat flux predictions. The results indicate several potential avenues for RANS model improvement for hypersonic cold-wall boundary-layer flows.

42 ENGINEERING↗

High-Speed and High-Quality Field Welding Repair Based on Advanced Non-Destructive Evaluation and Numerical Modeling

Creep strength-enhanced ferritic (CSEF) steels such as Grade 91 (9Cr-1Mo-V) and Grade 92 (Fe-9Cr-2W-0.5Mo) steels are widely used in the fossil-fuel-fired and nuclear power plants. The weld integrity of these steels is crucial for power plants' safe and reliable operations. Due to harsh service conditions, the steel weld can become susceptible to environmental degradation. Field welding repair is used to restore the degraded weld’s performance where a controlled temper-bead welding technique is commonly used to temper the freshly formed martensite during welding. However, knowledge of weld repairability is limited and experimental trial and error optimization to achieve desired microstructure and joint properties is expensive and time-consuming. Many existing computational models, e.g., finite element models, are limited to solving heat conduction equation and ignoring convective heat transfer due to molten metal flow. These models can result in over-prediction of peak temperatures of weld pool and heat-affected zone (HAZ), which in turn can affect the accuracy of tempering prediction. Moreover, these finite element models require an input of the deposit profiles in advance and thus limits the usability of these models. Here, a molten pool-based, multi-pass multi-layer model has been developed based on computational fluid dynamics (CFD) approach with the Volume of Fluid (VOF) method. The model calculates the bead formation, thereby eliminating the need for pre-determined bead profiles required by finite element models. For computational efficiency, a coordinate system attached to the moving heat source is utilized. A subroutine is developed to convert the temperature profiles in the reference frame stationary to the heat source to that stationary to the workpiece. The converted thermal cycles are then imported into a microstructure model to compute the tempering kinetics and resultant hardness using a Johnson-Mehl-Avrami-Kolmogorov (JMAK), and modified Grange-Baughman parameter. The modeling approach is first developed and validated on single- and multi-pass deposition of stainless steel filler metal onto a SA-533 high strength steel substrate. The models are then applied to a multi-pass V-groove repair weld of Grade 91 steel plate as well as directed energy deposition of Grade 92 steel. Non-destructive characterization of microstructures was performed on Grade 91 and 92 steel welds. Two welding processes, cold metal transfer (CMT) and flux-cored arc welding (FCAW), were investigated for the Grade 91 steel weld samples. For the Grade 92 weld samples, three different heat inputs (low, medium, and high) of gas tungsten arc welding (GTAW) were utilized to replicate traditional field welding processes. The non-destructive evaluation (NDE) method used for this research was immersion ultrasonic testing (UT) using a micro-resolution ultrasonic imaging methodology specifically designed to operate in the through-transmission configuration operating at 20 MHz of frequency. The system used a focused ultrasonic beam spot size diameter between 250-300 μm, and a 6 μm laser vibrometer spot size for detection, to produce highly defined images with longitudinal and mode-converted shear waves. From the micro-resolution ultrasonic C-scan images, three microstructural regions, i.e., weld metal (WM), HAZ, and base metal (BM), were clearly identifiable. Various levels of ultrasonic amplitudes distributed over the three regions were correlated with electron beam backscattered diffraction (EBSD) images using grain size, grain boundaries, and dislocation densities. The results showed that areas with relatively higher ultrasonic amplitude levels were associated with smaller grains and higher dislocation densities, while areas with lower amplitude levels were associated with larger grains and lower dislocation densities. In addition, ultrasonic velocity data obtained across the three different weld microstructural regions of Grade 91 test samples were correlated with optical metallographic images and hardness measurements. The results showed distinctive decreases in ultrasonic velocity and hardness over the HAZ region, where weld failures often occur during service.

36 MATERIALS SCIENCE↗

Stability margin analysis of the Holos-quad microreactor design

A simplified point model of the Holos-Quad microreactor is introduced. The model is based on the point kinetics equations coupled to three heat balance equations, representing the mean temperatures of the fuel particles, the graphite moderator and the helium coolant. The differential equations are converted to the frequency domain, enabling the construction of the closed-loop reactor transfer function. Using this function the stability margins of the core design is analyzed for various power levels. It is shown that the gain margins approaches infinity, demonstrating the stability of the reactor for all power levels. The phase margin at nominal power is about 60 degrees, however it shows a non-monotonous dependence on power, with minimal value obtained for about 10% of nominal power. As power level is further increased, the phase margin also increases, demonstrating the reactor becomes more stable. This behavior may be of high importance in load-follow scenarios, where the power level of the reactor changes with time. (authors)

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

A reduced-order modeling of a tubular solar reactor for long duration thermochemical energy storage

The storage of solar energy in a solid form, referred to as a “solar fuel”, can be achieved through a process known as endothermic solar thermochemistry. This process transforms the absorbed solar energy into a stable and retrievable form that can be stored for extended periods of time. This paper presents a low–order heat transfer model of a counter–current tubular falling bed reactor designed to produce thermally reduced magnesium manganese oxide pellets for long duration thermochemical energy storage. The energy required for the endothermic reduction was supplied by concentrated solar energy or renewable electricity via indirect heating of the gas and solid reactants flowing in a ceramic tube. The counter-current gas flow enhances the mixing of the solid particles with the heat recuperation zone, allowing the gas and particles to enter and exit the tubular reactor close to room temperature. Further, the reactor was vertically oriented and was heated circumferentially by an adjustable level heat flux along a finite segment of its length. The temperature distribution of the reactor in response to transient changes along the tube was modeled by considering conduction, convection, and radiation heat transfer. Governing equations for the heat transfer model were solved by discretizing the reactor tube into a finite number of control volumes and using an energy balance for the heat exchange between the reactor wall, gas, and particles within the control volume. The energy absorbed during this endothermic reaction was modeled numerically by fitting the data of the chemical conversion rate with the corresponding temperature of particles in the heating zone. The numerical model has been experimentally validated using a reactor prototype made of a 121.92 cm alumina tube heated by a 7kW electric tube–furnace. The alumina tube receives magnesium manganese oxide pellets of 3.66±0.516 mm in diameter from the top, and a counter–current gas flow from the bottom. The reactor wall temperature was monitored by six thermocouples installed along the reactor tube length. The experimental procedure was numerically simulated, and the temperature variation along the reactor tube was compared with a matrix of experimental runs for a range of particles mass flowrates (0.75–1.25g/s) and corresponding gas flowrates (36–65 SLPM). The reactor system was heated gradually from room temperature to a steady state temperature of 1673K, and then cooled down to room temperature. The heating and cooling processes were simulated, and the numerical and experimental results were compared throughout processes. The numerical model showed similar trends to the experimental results, with an error of 0.69 to 7.9% for the particle inlet and 0.7 to 7.9% for the gas inlet during steady-state operation. The proposed numerical model can be implemented as a simplified physical model to design a feedback control system to regulate reactor temperature.

14 SOLAR ENERGY↗

Real-time estimation of the electron temperature profile in DIII-D by leveraging neural-network surrogate models

Control of both the magnitude and the shape of tokamak profiles will be necessary to achieve stable, high-performance plasmas. In order to reject disturbances in real time, feedback-control algorithms rely on accurate real-time knowledge of the plasma state. When diagnostics alone are insufficient, either because they are limited in number or their measurements are too noisy, observers can be used to combine diagnostic data with a response model to provide a better estimation of different plasma properties. An observer has been developed to estimate the electron temperature profile in real time using both diagnostic data from the Thomson scattering system and a model based on the electron heat transport equation describing the evolution of the electron temperature profile. Here, neural network surrogate models are leveraged to help improve the overall model prediction while staying within computation time constraints for real-time use. The observer algorithm is shown in offline tests to produce smooth profiles that are consistent with both the diagnostic data and the electron heat transport equation. When implemented into the real-time plasma control system, this observer will provide valuable information on the electron temperature profile to many potential feedback-control applications.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

Embedding condition describing shearing, dissipative collapse

Highlights: • Perturbative approach to the time-dependent Karmarkar condition in shearing collapse. • Analysis of the (in)stability of the collapsing fluid using the TOV equation. • Study of the temperature profiles using a causal heat transport equation. In this work we employ the time-dependent Karmarkar condition to model dissipative gravitational collapse in the presence of shear which leads to a final static configuration. We believe that this is a first attempt at using the time-dependent Karmarkar condition describing a radiating star with shear in which the collapsing core dissipates energy in the form of a radial heat flux. The final static configuration which is described by an embedding class I spacetime was obtained by Hansraj and Moodly who showed that this solution satisfies all the physical requirements for a static compact object. As the collapse proceeds and the heat flux tends to zero the dynamical core evolves into a static compact core with the exterior spacetime being described by the vacuum Schwarzschild solution.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗

Modeling Heat Transfer and Reaction Kinetics of Biomass in Pyrolysis Feeding Systems

Biomass feedstocks can be used to produce low carbon-intensity chemicals and liquid fuels by displacing fossil-fuel sources. Pyrolysis is the thermal decomposition of biomass in the absence of oxygen and can be used to produce crude biofuels. A typical feeding mechanism for pyrolysis reactors is by lock hopper followed by a horizontal auger feeder. Particle agglomeration and plugging of the auger screw are regularly occurring phenomena that is detrimental to the process since it results in the need for periodic inspection and cleaning. The underlying mechanisms leading to agglomeration and plugging are unclear, but a working hypothesis is that heat from the reactor raises the temperature of the biomass in the feeder to the point at which preliminary decomposition reactions occur and produce "sticky" products. Using principles of heat and mass transfer, we derived one-dimensional differential equations for heat flow from the pyrolysis reactor through the auger feeder. Temperature profiles were solved from the system of one-dimensional differential equations using the shooting method. Subsequently, we used the temperature profiles as a one-way coupling to a reaction model for the biomass in the feeder. Kinetic models were adopted from the literature and used to predict the formation of intermediates, products, char, extractives, and metaplastics as well as phase changes along the auger feeder. Species were identified that correlated with softening of the biomass, causing it to become sticky and plug the feeder. We will discuss the details of this work, our findings, and the direction of future work that includes fully coupled transport and reaction-kinetics simulations.

BIOMASS FUELS↗

Thermal model for time-domain thermoreflectance experiments in a laser-flash geometry

Time-domain thermoreflectance (TDTR) is a well-established pump–probe method for measuring thermal conductivity and interface conductance of multilayers. Interpreting signals in a TDTR experiment requires a thermal model. In standard front/front TDTR experiments, both pump and probe beams typically irradiate the surface of a multilayer. As a result, existing thermal models for interpreting thermoreflectance experiments assume that the pump and probe beams both interact with the surface layer. Here, we present a frequency-domain solution to the heat-diffusion equation of a multilayer in response to nonhomogeneous laser heating. This model allows analysis of experiments where the pump and probe beams irradiate opposite sides of a multilayer. We call such a geometry a front/back experiment to differentiate such experiments from standard TDTR experiments. As an example, we consider a 60nm amorphous Si film. We consider how signals differ in a front/front vs front/back geometry and compare thermal model predictions to experimental data.

Peng, Wanyue↗

HePHAESTUS: Heat Pipe Heterogeneous Approximation of Energy and Navier-Stokes Equations, Transience, and Non-Uniform Surface Heating [Slides]

A heat pipe is a liquid/vapor filled metal pipe capable of transporting large amounts of heat through evaporation of a liquid at one end and condensation of vapor at the other end creating a closed fluid loop. Heat pipes are widely used in the cooling of electronics and in space applications. Heat pipes are typically composed of a pipe wall, a wick material, a working fluid, and a central vapor channel. Heat is transferred into the working fluid at the “evaporator” end, through an adiabatic section, and heat is removed at the opposite end at the “condenser.” If no wick is used, gravitational acceleration can circulate the fluid due to the buoyancy of the vapor in the central core and a falling film of liquid at the pipe wall forming a “thermosyphon."

42 ENGINEERING↗

A robust fourth-order finite-difference discretization for the strongly anisotropic transport equation in magnetized plasmas

We propose a second-order temporally implicit, fourth-order-accurate spatial discretization scheme for the strongly anisotropic heat transport equation characteristic of hot, fusion-grade plasmas. Following Du Toit et al. (2018), the scheme transforms mixed-derivative diffusion fluxes (which are responsible for the lack of a discrete maximum principle) into nonlinear advective fluxes, amenable to nonlinear-solver-friendly monotonicity-preserving limiters. The scheme enables accurate multi-dimensional heat transport simulations with up to seven orders of magnitude of heat-transport-coefficient anisotropies with low cross-field numerical error pollution and excellent algorithmic performance, with the number of linear iterations scaling very weakly with grid resolution and grid anisotropy, and scaling with the square-root of the implicit timestep. We propose a multigrid preconditioning strategy based on a lower-order approximation that renders the scheme efficient and scalable under grid refinement. Several numerical tests are presented that display the expected spatial convergence rates and strong algorithmic performance, including fully nonlinear magnetohydrodynamics simulations of kink instabilities in a Bennett pinch in 2D helical geometry and of ITER in 3D toroidal geometry.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗