Search NASA⌕ Search

SEARCH · Search NASA

Results for “Volume of fluid method”

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.

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 37 records · Page 2
All sourcesNASA NTRSDOE OSTI
DOE OSTI2019

Simulating bubble dynamics in a buoyant system

Summary Multiphase flows are critical components of many physical systems; however, numerical models of multiphase flows with large parameter gradients can be challenging. Here, two different numerical methods, volume of fluid (VOF) and smoothed particle hydrodynamics (SPH), are used to model the buoyant rise of isolated gas bubbles through quiescent fluids for a range of Bond and Reynolds numbers. The VOF is an Eulerian grid–based method, whereas the SPH is Lagrangian and mesh free. Each method has unique strengths and weaknesses, and a comparison of the two approaches as applied to multiphase phenomena has not previously been performed. The VOF and SPH simulations are compared, verified, and validated. Results using two‐dimensional VOF and SPH simulations are similar to each other and are able to reproduce numerical benchmarks and experimental results for sufficiently large Morton and Reynolds numbers. It is also shown that at low Reynolds numbers, the two methods, SPH and VOF, diverge in the transient regime of the bubble rise. Regimes that require simulations capable of representing three‐dimensional drag are identified as well as regimes in which results from VOF and SPH diverge.

Arai, Erin↗
NASA NTRS1992

A numerical model for atomization-spray coupling in liquid rocket thrust chambers

The physical process of atomization is an important consideration in the stable operation of liquid rocket engines. Many spray combustion computational fluid dynamics (CFD) codes do not include an atomization sub-model but assume arbitrary drop size distributions, drop initial locations, and velocities. A method of coupling an atomization model with the spray model in a REFLEQS CFD code is presented. This method is based on a jet-embedding technique in which the equations governing the liquid jet core are solved separately using the surrounding gas phase conditions. The droplet initial conditions are calculated using a stability analysis appropriate for the atomization regime of liquid jet break-up. This novel coupling model is used to analyze the SSME fuel preburner single injector flow. Results of the diffusion flame characteristics in a single injection element will be presented. The effect of relative velocity, mixture ratio and droplet initial conditions will be shown. The predictions of present atomization model is compared with that of the widely used CICM correlation. The results are also compared with the predictions of volume-of-fluid method.

M. G. Giridharan↗
DOE OSTI2018

A Numerical Study of Two-Phase Flow and Interfacial Mass Transfer in a Wetted Wall Column for Counter-Current Gas Absorption

We present a numerical study to investigate the effects of surface waves of falling films on the mass transfer from flowing gas phase into the liquid film. The model employs the volume of fluid method to explicitly track the gas-liquid phase interface and a one-fluid formulation to model the multiphase flow coupled with mass transfer between the two phases. The surface waves are generated by the time-varying injection rate of the falling film. The effects of surface wave frequencies and amplitudes on the overall mass transfer also are investigated for a counter-current gas-liquid flow of oxygen and water. Because of the solubility difference in the two phases, the model can capture the concentration discontinuity across the liquid-gas interface. Good agreement is obtained between the numerical results and experimental data reported in the literature. By systematically varying the frequencies and amplitudes of flow rate for the falling film, the surface waves generated on the film surface enhance mass transfer in general. Here, the model prediction shows a proportional increase in mass transfer for small frequencies of surface waves, but saturation at higher frequencies.

42 ENGINEERING↗
DOE OSTI2019

Numerical Simulation and Validation of Gas and Molten Metal Flows in Close-Coupled Gas Atomization

Molten metal atomization in close-coupled gas atomization dies can operate between two limiting conditions, jetting and filming, together with several complex mechanisms: liquid-gas drafting, downward/upward shearing, melt bouncing, etc. Liquid jet deformation depends on flow and geometric parameters, such as liquid Reynolds, liquid Weber, and gas Mach numbers, as well as gas jet apex angle and melt tube tip extension and aspect ratio, among others. Understanding their effect is of importance for the metal powder making industry. Numerical gas atomization studies can provide approximated flow information and consider a wide range of conditions, beyond experimental reach. Here, 3D high-resolution simulations employing a 5-equation compressible flow model coupled with the volume-of-fluid method are compared with experiments, for liquid Weber number in the range of 1–30 and liquid Reynolds number below 10,000. This validation explores the predicting capabilities of the numerical model.

Hernandez, F.↗
DOE OSTI2019

Effect of Nozzle Port Angle on Transient Flow and Surface Slag Behavior During Continuous Steel-Slab Casting

Undesirable flow variations can cause severe instabilities at the interface between liquid mold flux and molten steel across the mold top-region during continuous steel casting, resulting in surface defects in the final products. A three-dimensional Large Eddy Simulation (LES) model using the volume of fluid method for the slag and molten steel phases is validated with plant measurements, and applied to gain new insights into the effects of nozzle port angle on transient flow, top slag/steel interface movement, and slag behavior during continuous slab casting under nominally steady conditions. Upward-angled ports produce a single-roll flow pattern with lower surface velocity, due to rapid momentum dissipation of the spreading jet. However, strong jet wobbling from the port leads to greater interface variations. Severe level drops allow easy entrapment of liquid flux by the solidifying steel shell at the meniscus. Sudden level rises may also be detrimental, leading to overflow of the solidified meniscus region. Downward-angled ports produce a classic double-roll pattern with less jet turbulence and a more stable interface everywhere except near the narrow faces. Finally, the flow patterns, surface velocity, and level predicted from the validated LES model are compared with steady-state standard k-ε model predictions.

36 MATERIALS SCIENCE↗
DOE OSTI2021

SOMAFOAM: An OpenFOAM based solver for continuum simulations of low-temperature plasmas

Here, we report the development of SOMAFOAM, a finite volume framework for performing continuum simulations of low-temperature plasmas. The primary goal of this work is to discuss the features of SOMAFOAM along with representative results provided as examples for a range of operating conditions and geometries. This includes plasma and plasma–dielectric systems operating in direct current, radio frequency, and microwave regimes from pressures as low as 100 mTorr to atmospheric pressure. The code has several useful features including the ability to run massively parallel simulations using arbitrary geometries, structured/unstructured meshes, choice of models such as drift–diffusion/full-momentum at runtime, and species-dependent timesteps to name a few. The verification/validation studies presented include comparison with previously published continuum simulations (low-pressure direct current and radio frequency plasma), with experiments (Gaseous Electronics Conference Reference Cell and microwave microplasma ignited in a split ring resonator), and previously published kinetic simulations (low-pressure radio frequency plasma). Other examples provided include a direct current atmospheric pressure microplasma bounded by dielectric sidewalls and a helium–nitrogen plasma ignited using a needle electrode facing a dielectric. The performance of the code is also discussed with serial and distributed memory parallel runs demonstrated up to 512 cores. The design and implementation of the code in a modular object-oriented framework allows for easy extension and seamless coupling with other codes and can be expected to play an important role in both academia and industry.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
DOE OSTI2022

Numerical simulation of evaporating wavy falling liquid films in laminar gas streams

Numerical simulations are performed to investigate the interfacial heat and mass transfer from evaporating wavy falling liquid films in interaction with laminar gas streams. The OpenFOAM solver has been used to conduct the simulations where the liquid-gas interface is resolved using the Volume of Fluid method of solving for three phases, i.e., liquid, vapor, and air. The configuration considered is a falling liquid (water) film on a heated vertical plate with a confined laminar moist air (gas) flow that is either (a) co-current or (b) counter-current to the downward liquid flow. The evaporation at the liquid-gas interface is driven by the interfacial gradient of the vapor mass fraction. Interfacial waves are triggered using a monochromatic forcing disturbance that leads to sinusoidal or solitary waves forming at the liquid-gas interface under respective forcing frequencies. Further, the numerical model is validated with the available experimental data. The results show nearly a 15% enhancement in time-averaged Sherwood number (Sh) due to film waviness (sinusoidal or solitary) at the lower volumetric gas flow rate, Q g = +50 (co-current) and Q g = -50 (counter-current). This enhancement in the Sh for both the waves further increases by 11% with Q g = +800 and 196% with Q g = -800. A closer examination of the mass transfer process over a wave demonstrates that with Q g = +50, the concentration of the gas side streamlines at the trough locations of the wave leads to higher values of Sh at these locations. However, with Q g = +800, although the overall Sh increases, vortices appear at the wave trough locations, leading to a corresponding decrease in the local Sh values. Correlations are proposed for predicting Sh under co-current and counter-current gas flow effects.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Two-phase flow numerical analysis of electrode geometry for alkaline water electrolyzers

Hydrogen is a promising component of a future energy-secure and efficient economy, but its competitiveness depends on reducing production costs. One strategy is to operate alkaline water electrolyzers at higher current densities to increase output. However, this intensifies performance losses due to gas bubble accumulation, which blocks transport pathways and deactivates electrochemically active surfaces. Enhancing bubble evacuation through electrode design is therefore essential. Previous studies have explored various approaches — such as modifying surface morphology, applying sonication or pressure modulation, and introducing surfactants — but these efforts have addressed a limited range of conditions due to the complexity of two-phase flow and electrode geometries. Experiments have also largely been focused on either cell level improvements, which lack the information necessary to isolate each contributing factor, or on modified geometries that are not relevant to practical cell operation. From a modeling perspective, conventional Eulerian multiphase models do not track the complex gas–liquid interfacial dynamics and often neglect surface tension and contact angle effects, reducing their predictive accuracy. To provide insights on the effects of different electrode geometries on the performance of alklaine water electrolyzers this work employs an immersed boundary volume-of-fluid method to simulate bubble behavior in 3D porous electrodes. Multiple base electrode geometries, typically used in practice, with varying porosity are evaluated under a constant surface gas generation rate. Simulation data is analyzed to quantify electrode gas coverage, bubble size dynamics and other relevant metrics. Results show that porosity strongly influences bubble accumulation on electrode surfaces, with higher porosity reducing gas coverage, and its not strictly dependent on the electrode geometry. However, the electrode’s base geometry significantly affects gas accumulation at the separator gap, independent of porosity. A foam electrode geometry resulted in the lowest gas coverage of all electrodes with a median volumetric gas coverage of 11%, but at the cost of a 70% reduction in active area compared with the largest surface area electrode, while gyroid electrodes showed the best trade-off between gas coverage, particularly at the separator surface, and electrochemically active area. In conclusion, the results highlight the need for holistic electrode design strategies.

Alkaline↗
DOE OSTI2019

Direct Effect of Solvent Viscosity on the Physical Mass Transfer for Wavy Film Flow in a Packed Column

ABSTRACT Post-combustion carbon capture via solvent absorption in a packed column can be a promising technology for mitigating greenhouse gas emissions. The mass transfer between gas and liquid solvent phases plays a critical role in determining the packing height of the packed column. Recent experiments [1] involving physical mass transfer for aqueous amine in a packed column have distinguished the direct and indirect impacts of viscosity (µ_L) on the mass transfer coefficient ?( k?_L). The direct impact of viscosity on the mass transfer coefficient has been found to be significantly higher for a packed column ?(k?_L~µ_L^(-0.38)) than a wetted wall column (WWC) ?(k?_L~µ_L^(-0.17)). To explain the deviation from the well-controlled uniform film flow in a WWC, we propose a mechanism involving the unavoidable wavy film flow and eddy-enhanced mass transfer in a packed column. A mathematical analysis based on fundamental flow and mass transfer equations is presented to quantify this deviation. The correlation for mass transfer coefficient derived from the mathematical analysis is found to match the corresponding one derived from the experiments for a packed column. Multiphase flow simulations using the Volume of Fluid method also are conducted to verify the direct impact of viscosity on the mass transfer coefficient for both uniform and wavy film flows. The mass transfer coefficient calculated from simulations shows steeper variation with viscosity for wavy film compared to the uniform film, further confirming our proposed theory. A similar relation ?(k?_L~µ^(-0.38)) for wavy film flow in a packed column is observed for aqueous solvent from both theory, experiment, and computer simulations.

Mass transfer, viscosity, eddy diffusion↗
DOE OSTI2022

Vorticity-induced flow-focusing leads to bubble entrainment in an inkjet printhead: Synchrotron x-ray and volume-of-fluid visualizations

The oscillatory flows present in an inkjet printhead can lead to strong deformations of the air-liquid interface at the nozzle exit. Such deformations may lead to an inward directed air jet with bubble pinch-off and the subsequent entrainment of an air bubble, which is highly detrimental to the stability of inkjet printing. Understanding the mechanisms of bubble entrainment is therefore crucial to improving print stability. Here, in the present work, we use ultrafast x-ray phase-contrast imaging and direct numerical simulations based on the volume-of-fluid method to study the mechanisms underlying the bubble entrainment in a piezoacoustic printhead. We first demonstrate good agreement between experiments and numerics. We then show the different classes of bubble pinch-off obtained in experiments, and that those were also captured numerically. The numerical results are then used to show that the baroclinic torque, which is generated at the gas-liquid interface due to the misalignment of density and pressure gradients, results in a flow-focusing effect that drives the formation of the air jet from which a bubble can pinch off.

42 ENGINEERING↗
DOE OSTI2018

Modeling physical vapor deposition of energetic materials

Morphology and microstructure of organic explosive films formed using physical vapor deposition (PVD) processes strongly depends on local surface temperature during deposition. Currently, there is no accurate means of quantifying the local surface temperature during PVD processes in the deposition chambers. This study focuses on using a multiphysics computational fluid dynamics tool, STARCCM+, to simulate pentaerythritol tetranitrate (PETN) deposition. The PETN vapor and solid phase were simulated using the volume of fluid method and its deposition in the vacuum chamber on spinning silicon wafers was modeled. The model also included the spinning copper cooling block where the wafers are placed along with the chiller operating with forced convection refrigerant. Implicit time-dependent simulations in two- and three-dimensional were performed to derive insights in the governing physics for PETN thin film formation. PETN is deposited at the rate of 14 nm/s at 142.9 °C on a wafer with an initial temperature of 22 °C. The deposition of PETN on the wafers was calculated at an assumed heat transfer coefficient (HTC) of 400 W/m 2 K. This HTC proved to be the most sensitive parameter in determining the local surface temperature during deposition. Previous experimental work found noticeable microstructural changes with 0.5 mm fused silica wafers in place of silicon during the PETN deposition. This work showed that fused silica slows initial wafer cool down and results in ~10 °C difference for the surface temperature at 500 μm PETN film thickness. It was also found that the deposition surface temperature is insensitive to the cooling power of the copper block due to the copper block's very large heat capacity and thermal conductivity relative to the heat input from the PVD process. Future work should incorporate the addition of local stress during PETN deposition. Lastly, based on simulation results, it is also recommended to investigate the impact of wafer surface energy on the PETN microstructure and morphology formation.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Device-scale CFD study for mass transfer coefficient and effective mass transfer area in packed column

Carbon dioxide (CO 2 ) is a significant contributor of greenhouse gases emissions responsible for global warming. The fossil-fueled power plant is one of the major sources of CO 2 emission worldwide and needs to be mitigated. Post-combustion carbon capture by chemical absorption can be a promising technology to reduce CO 2 emission from power plants. The absorption is carried out via countercurrent flow in the packed columns. Although monoethanolamine (MEA) is a popular solvent, it has also limitations such as high volatility of solvent, corrosivity that leads to product degradation and damage to apparatuses, low CO 2 loading capacity, etc. Therefore, alternate solvents are being explored as prospective materials for carbon capture. A water-lean solvent, CO 2 binding organic liquids (CO2BOL), is currently being developed as a prospective material in carbon capture at the Pacific Northwest National Laboratory. Since the development of the material is at the primitive stage, it needs extensive investigation before industrial deployments. Hydrodynamics and mass transfer phenomena in the packed column using CO 2 BOL is unknown. Computational fluid dynamics (CFD) can be a useful tool to understand these phenomena in the packed column. Before employing the extensive CFD investigations, one needs to carefully validate CFD predictions for accurate flow predictions. This report demonstrates the validation of multiphase flow simulations against the experimental results for both structured and random packed columns. The reactive multiphase flow simulations using volume of fluid method were conducted at a wide range of liquid loads and contacts angles. The effective area is one of the critical factors dictating interphase mass transfer due to chemical reactions. Accordingly, CFD-predicted effective areas were compared with the experimental results of Tsai et al. [1] for Mellapak 250.Y structured packing. Both results matched well at different liquid loads in the presence of fast chemical kinetics using caustic solvents. Further, reactive multiphase flow simulations were also conducted in pall ring random packing to compute effective areas in the presence of fast chemical reactions. The CFD-predicted effective area compared well with correlation developed by Song et al. [2]. With successful validations, the current simulation framework can be further used for prediction of hydrodynamics and mass transfer phenomena using CO 2 BOL solvents in the packed column. Subsequently, it would be helpful in design optimization of a packed column. In addition to validation of the CFD model, this report also explains the mechanism for enhanced liquid side mass transfer for a structured packed column as compared to the wetted wall column.

20 FOSSIL-FUELED POWER PLANTS↗
NASA NTRS1995

Advanced Multi-phase Flow CFD Model Development for Solid Rocket Motor Flowfield Analysis

A Navier-Stokes code, finite difference Navier-Stokes (FDNS), is used to analyze the complicated internal flowfield of the SRM (solid rocket motor) to explore the impacts due to the effects of chemical reaction, particle dynamics, and slag accumulation on the solid rocket motor (SRM). The particulate multi-phase flowfield with chemical reaction, particle evaporation, combustion, breakup, and agglomeration models are included in present study to obtain a better understanding of the SRM design. Finite rate chemistry model is applied to simulate the chemical reaction effects. Hermsen correlation model is used for the combustion simulation. The evaporation model introduced by Spalding is utilized to include the heat transfer from the particulate phase to the gase phase due to the evaporation of the particles. A correlation of the minimum particle size for breakup expressed in terms of the Al/Al2O3 surface tension and shear force was employed to simulate the breakup of particles. It is assumed that the breakup occurs when the Weber number exceeds 6. A simple L agglomeration model is used to investigate the particle agglomeration. However, due to the large computer memory requirements for the agglomeration model, only 2D cases are tested with the agglomeration model. The VOF (Volume of Fluid) method is employed to simulate the slag buildup in the aft-end cavity of the redesigned solid rocket motor (RSRM). Monte Carlo method is employed to calculate the turbulent dispersion effect of the particles. The flowfield analysis obtained using the FDNS code in the present research with finite rate chemical reaction, particle evaporation, combustion, breakup, agglomeration, and VOG models will provide a design guide for the potential improvement of the SRM including the use of materials and the shape of nozzle geometry such that a better performance of the SRM can be achieved. The simulation of the slag buildup in the aft-end cavity can assist the designer to improve the design of the RSRM geometry.

Liaw, Paul↗
NASA NTRS1996

The study of flow pattern and phase-change problem in die casting process

The flow pattern and solidification phenomena in die casting process have been investigated in the first phase study. The flow pattern in filling process is predicted by using a VOF (volume of fluid) method. A good agreement with experimental observation is obtained for filling the water into a die cavity with different gate geometry and with an obstacle in the cavity. An enthalpy method has been applied to solve the solidification problem. By treating the latent heat implicitly into the enthalpy instead of explicitly into the source term, the CPU time can be reduced at least 20 times. The effect of material properties on solidification fronts is tested. It concludes that the dependence of properties on temperature is significant. The influence of the natural convection over the diffusion has also been studied. The result shows that the liquid metal solidification phenomena is diffusion dominant, and the natural convection can affect the shape of the interface. In the second phase study, the filling and solidification processes will be considered simultaneously.

Wang, T. S.↗
NASA NTRS1998

Computational Study of Surface Tension and Wall Adhesion Effects on an Oil Film Flow Underneath an Air Boundary Layer

The fringe-imaging skin friction (FISF) technique, which was originally developed by D. J. Monson and G. G. Mateer at Ames Research Center and recently extended to 3-D flows, is the most accurate skin friction measurement technique currently available. The principle of this technique is that the skin friction at a point on an aerodynamic surface can be determined by measuring the time-rate-of-change of the thickness of an oil drop placed on the surface under the influence of the external air boundary layer. Lubrication theory is used to relate the oil-patch thickness variation to shear stress. The uncertainty of FISF measurements is estimated to be as low as 4 percent, yet little is known about the effects of surface tension and wall adhesion forces on the measured results. A modified version of the free-surface Navier-Stokes solver RIPPLE, developed at Los Alamos National Laboratories, was used to compute the time development of an oil drop on a surface under a simulated air boundary layer. RIPPLE uses the volume of fluid method to track the surface and the continuum surface force approach to model surface tension and wall adhesion effects. The development of an oil drop, over a time period of approximately 4 seconds, was studied. Under the influence of shear imposed by an air boundary layer, the computed profile of the drop rapidly changes from its initial circular-arc shape to a wedge-like shape. Comparison of the time-varying oil-thickness distributions computed using RIPPLE and also computed using a greatly simplified numerical model of an oil drop equation which does not include surface tension and wall adhesion effects) was used to evaluate the effects of surface tension on FISF measurement results. The effects of surface tension were found to be small but not necessarily negligible in some cases.

Celic, Alan↗
NASA NTRS2005

Analysis of a Free Surface Film from a Controlled Liquid Impinging Jet over a Rotating Disk Including Conjugate Effects, with and without Evaporation

A detailed analysis of the liquid film characteristics and the accompanying heat transfer of a free surface controlled liquid impinging jet onto a rotating disk are presented. The computations were run on a two-dimensional axi-symmetric Eulerian mesh while the free surface was calculated with the volume of fluid method. Flow rates between 3 and 15 1pm with rotational speeds between 50 and 200 rpm are analyzed. The effects of inlet temperature on the film thickness and heat transfer are characterized as well as evaporative effects. The conjugate heating effect is modeled, and was found to effect the heat transfer results the most at both the inner and outer edges of the heated surface. The heat transfer was enhanced with both increasing flow rate and increasing rotational speeds. When evaporative effects were modeled, the evaporation was found to increase the heat transfer at the lower flow rates the most because of a fully developed thermal field that was achieved. The evaporative effects did not significantly enhance the heat transfer at the higher flow rates.

Sankaran, Subramanian↗
NASA NTRSDate not supplied

Characterization of Slosh Damping for Ortho-Grid and Iso-Grid Internal Tank Structures

Grid stiffened tank structures such as Ortho-Grid and Iso-Grid are widely used in cryogenic tanks for providing stiffening to the tank while reducing mass, compared to tank walls of constant cross-section. If the structure is internal to the tank, it will positively affect the fluid dynamic behavior of the liquid propellant, in regard to fluid slosh damping. As NASA and commercial companies endeavor to explore the solar system, vehicles will by necessity become more mass efficient, and design margin will be reduced where possible. Therefore, if the damping characteristics of the Ortho-Grid and Iso-Grid structure is understood, their positive damping effect can be taken into account in the systems design process. Historically, damping by internal structures has been characterized by rules of thumb and for Ortho-Grid, empirical design tools intended for slosh baffles of much larger cross-section have been used. There is little or no information available to characterize the slosh behavior of Iso-Grid internal structure. Therefore, to take advantage of these structures for their positive damping effects, there is much need for obtaining additional data and tools to characterize them. Recently, the NASA Marshall Space Flight Center conducted both sub-scale testing and computational fluid dynamics (CFD) simulations of slosh damping for Ortho-Grid and Iso-Grid tanks for cylindrical tanks containing water. Enhanced grid meshing techniques were applied to the geometrically detailed and complex Ortho-Grid and Iso-Grid structures. The Loci-STREAM CFD program with the Volume of Fluid Method module for tracking and locating the water-air fluid interface was used to conduct the simulations. The CFD simulations were validated with the test data and new empirical models for predicting damping and frequency of Ortho-Grid and Iso-Grid structures were generated.

Douglas G. Westra↗