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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
All sourcesNASA NTRSDOE OSTI
DOE OSTI2023

Review—Drag Coefficients of Non-Spherical and Irregularly Shaped Particles

Abstract The knowledge of simple and relatively accurate closure equations for the drag coefficients of nonspherical particles is very important for Eulerian multiphase numerical codes that require such inputs for the solution of the momentum equation. However, the existing correlations for the drag coefficients are laden with high uncertainty, which propagates in the numerical results. This review paper examines critically the state of our knowledge of the drag coefficients of nonspherical particles starting with our understanding of the “size” and “shape” of particles. Lengthscales and other parameters that have been used to characterize sizes of nonspherical particles are presented. Shape factors and shape descriptors that have been used in past correlations are also presented together with an appraisal of their applicability. Several correlations that have been developed for the determination of the drag coefficients of nonspherical particles with regular and irregular shapes are also presented together with available information on their accuracy and applicability. Based on the review of the available correlations general recommendations are offered on the use of the correlations as closure equations and inputs in computatioal fluid dynamics (CFD) codes.

Engineering↗
DOE OSTI2024

Shape effects on the local dynamics of suspensions of spheroidal particles

The effect of shape on the dynamics of suspensions of non-spherical heavy particles is examined by fully resolved numerical simulations of oblate and prolate spheroids, as well as spheres, for a density ratio of ten, volume fractions ranging from 0.5% to 5%, and Reynolds numbers between 20 and 30. The dynamics is determined both by the interactions of the particles with the fluid as well as by collisions, with the number and importance of collisions increasing with volume fractions. A single isolated oblate or prolate spheroid falling under gravity generally falls broadside on, for the governing parameters examined here, and at low-volume fractions, the majority of particles in a suspension fall that way. At higher-volume fractions, the orientation is more random. The slip velocity decreases as the volume fraction increases for all shapes, as expected, but the effect of the shape is much less than seen for a single particle. Furthermore, this seems to be due to two effects. For all volume fractions, the most deformed particles cluster more than spheres and less deformed particles, which increases their slip velocity. As the concentration increases, the increased particle interactions also causes more particles to fall short side-on, which reduces the frontal area and the resulting drag, increasing the slip velocity. This second effect is, of course, absent for spherical particles.

42 ENGINEERING↗
DOE OSTI2021

Coupling particle scale model and SuperDEM–CFD for multiscale simulation of biomass pyrolysis in a packed bed pyrolyzer

An efficient biomass pyrolysis process requires a comprehensive understanding of the chemical and physical phenomena that occur at multi-length and time scales. In this study, a multiscale computational approach was developed and validated for biomass pyrolysis in a packed-bed reactor by integrating pyrolysis kinetics, a particle scale model, and SuperDEM-CFD in open-source code MFiX. A one-dimensional particle-scale model that discretizes the characteristic length of biomass particle into layers was developed to predict the intraparticle phenomena inside a single particle. The 1D model was validated by comparing it with a single biomass particle pyrolysis experiment. Here, a recently developed SuperDEM-CFD model was employed to simulate the non-spherical particle-particle contact and fluid-particle interaction. The coupled model was applied to simulate the pyrolysis of cubic biomass particles in a packed bed and validated by comparing with experimental data. Simulation with and without particle-scale model was compared, and the effect of the gas-solid heat transfer models was also investigated.

09 BIOMASS FUELS↗
DOE OSTI2022

Accurate hydrodynamic force and torque correlations for prolate spheroids from Stokes regime to high Reynolds numbers

Detailed simulations of flow around various prolate spheroids are performed using multi-relaxation time lattice Boltzmann method (LBM). The simulations are performed in the Reynolds numbers range 0.1 ≤ Re ≤ 2000 at different incident angles 0°≤ φ ≤ 90° for various prolate spheroids of aspect ratios 1 ≤ λ ≤ 8. The Re is based on the volume equivalent sphere diameter. From the simulations, accurate correlations for average drag, lift and torque coefficients (C D , C L , and C T respectively) are proposed. The mean deviations between the correlations and the simulation data for C D , C L , and C T are 2%, 6.5%, and 4.7% respectively. Furthermore, the correlations are fitted with the physics in mind such that they can be extrapolated beyond the regimes simulated. The fits are designed such that correlations reduce to analytical (C D and C L ) solutions available for prolate spheroids in the limit Re ≈ 0. At high Re, the correlations mimic the asymptotic flattening of C D as for spheres and therefore, we expect the correlations to be valid until the critical Re (≈ 10 5 ). Furthermore, extensive comparison of our correlations with other high-fidelity simulations from literature demonstrate the accuracy of our work compared to other correlations from literature. This work enables researchers to perform accurate unresolved Euler-Lagrangian simulations for a wide range of elongated particles.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2022

Variant selection in laser powder bed fusion of non-spherical Ti-6Al-4V powder

The presence of α/α' on prior β/β grain boundaries directly impacts the final mechanical properties of the titanium alloys. The β/β grain boundary variant selection of titanium alloys has been assumed to be unlikely owing to the high cooling rates in laser powder bed fusion (L-PBF). However, we hypothesize that powder characteristics such as morphology (non-spherical) and particle size (50–120 µm) could affect the initial variant selection in L-PBF processed Ti-6Al-4V alloy by locally altering the cooling rates. Despite the high cooling rate found in L-PBF, the results showed the presence of β/β grain boundary α' lath growth inside two adjacent prior β grains. Electron backscatter diffraction micrographs confirmed the presence of β/β grain boundary variant selection, and synchrotron X-ray high-speed imaging observation revealed the role of the “shadowing effect” on the locally decreased cooling rate because of keyhole depth reduction and the consequent β/β grain boundary α' lath growth. The self-accommodation mechanism was the main variant selection driving force, and the most abundant α/α boundary variant was type 4 (63.26°//[ $\bar{10}$ 5 5 $\bar{3}$ ]). The dominance of Category II α lath clusters associated with the type 4 α/α boundary variant was validated using the phenomenological theory of martensite transformations and analytical calculations, from which the stress needed for the β→α' transformation was calculated.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Tailored particles for powder-based additive manufacturing

The present disclosure relates to a plurality of powder particles configured to be joined in an additive manufacturing process to form a part. Each one of the powder particles has a determined three dimensional, non-spherical shape. The plurality of powder particles are further of dimensions enabling fitting individual ones of the powder particles in abutting relationship with one another. At least a subplurality of the powder particles each have a functionalized surface feature to enhance at least one of clustering or separation of the subplurality of powder particles.

Watts, Seth Evan↗
DOE OSTI2020

Mini Micropulse Lidar measurements in vertical and scanning modes

The Atmospheric Radiation Measurement (ARM) program operates ten Sigma Space (currently Droplet Measurement Technologies/DMT) micropulse lidar systems (MPL-4B-IDS/POL-FS series), which detect the backscattered light in two orthogonal linear polarization channels allowing to distinguish between spherical (e.g. water) and non-spherical (e.g. ice) scattering particles. The ARM MPLs have been providing valuable measurements to the aerosol and cloud research community for well over a decade. DMT’s Mini-Micropulse lidar (MiniMPL) is a compact version of the standard MPL. It reduces the power-aperture product to minimize cost, size, weight, power requirements and has all the electronics integrated with optics in a single box. Although as a result, it has a lower detection range than the MPL, limiting the measurements to the troposphere, its performance is promised to match that of the standard MPL within the troposphere. The MiniMPL weighs 13 kg, and the complete system, consisting of an optical transceiver and a laptop running the data acquisition and post-processing software, fits in a storm case, allowing its transport on domestic or international flights. This can be especially valuable for short field campaigns or Intensive Operational Periods, where time is of the essence when replacing a faulty instrument. In addition, the scanning polarization lidar capability (MiniMPL-SCAN option) could be of great interest for satisfying ARM measurement needs for certain research topics related to clouds and precipitation. To evaluate its full potential in comparison with co-located remote sensing instruments including the ARM MPL-4B-IDS/POL-FS at SGP, a miniMPL was hosted at the ARM Southern Great Plains (SGP) mega-site in 2020 for approximately 3 months. During this time the miniMPL was tested in both vertical sampling and scanning modes.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2021

Undersizing of aged African biomass burning aerosol by an ultra-high-sensitivity aerosol spectrometer

The ultra-high-sensitivity aerosol spectrometer (UHSAS) differs from most other optical particle spectrometers by using a high-power infrared (IR) laser to detect small particles and reduce the sizing ambiguity due to the non-monotonicity of scattering with particle size. During the NASA ORACLES project (ObseRvations of Aerosols above CLouds and their intEractionS) over the southeast Atlantic Ocean, the UHSAS clearly undersized particles in the biomass burning plume extending from southern Africa. Since the horizontal and vertical extent of the plume was vast, the NASA P-3B research aircraft often flew through a fairly uniform biomass burning plume for periods exceeding 30 min, sufficient time to explore the details of the UHSAS response by selecting single particle sizes with a differential mobility analyzer (DMA) and passing them to the UHSAS. This was essentially an in-flight calibration of the UHSAS using the particles of interest. Two modes of responses appeared. Most particles were undersized by moderate amounts, ranging from not at all for 70 nm aerosols to 15 % for 280 nm particles. Mie scattering calculations show that composition-dependent refractive index of the particles cannot explain the pattern. Heating of brown carbon or tarballs in the beam causing evaporation and shrinking of the particles is the most plausible explanation, though mis-sizing due to non-sphericity cannot be ruled out. A small fraction (10 %–30 %) of the particles were undersized by 25 % to 35 %. Those were apparently the particles containing refractory black carbon. Laboratory calibrations confirm that black carbon is drastically undersized by the UHSAS, because particles heat to their vaporization point and shrink. A simple empirical correction equation was implemented that dramatically improves agreement with DMA distributions between 100 and 500 nm. It raised the median particle diameter by 18 nm, from 163 to 181 nm, during the August 2017 deployment and by smaller amounts during deployments with less intense pollution. Calculated scattering from UHSAS size distributions increased by about 130 %, dramatically improving agreement with scattering measured by nephelometers. The correction is only valid in polluted instances; clean marine boundary layer and free troposphere aerosols behaved more like the calibration spheres. We were unable to directly test the correction between 500 and 1000 nm, though aerodynamic particle sizer (APS) data appear to show that the correction is poor at the largest diameters, which is no surprise as the composition of those particles is likely to be quite different than that of the accumulation mode. This adds to the evidence that UHSAS data must be treated cautiously whenever the aerosol may absorb infrared light. Similar corrections may be required whenever brown carbon aerosol is present.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2022

Fast estimation of reaction rates in spherical and non-spherical porous catalysts

Here we present a methodology for modeling multi-step reaction rates in porous catalyst particles for use in CFD-DEM and two fluid models. Single-step effectiveness factors based on a Thiele modulus, while useful, cannot accurately capture the cascading reaction systems common in high temperature vapor-phase chemical reactors like fluidized catalytic cracking units and catalytic biomass fast pyrolysis systems. Instead, multi-step effectiveness vectors derived from steady-state solutions to the governing reaction-diffusion equations are needed. Solutions for various catalyst shapes are presented, including spheres, cylinders, and prisms. Computational challenges inherent in repeated evaluation of reaction rates with diffusion limitations are discussed, and an efficient implementation based on pre-computed lookup tables is proposed and demonstrated on a simulation of a fluidized bed reactor. Open-source code is provided for the compilation of reaction rate tables for use in ODE, DEM, and two-fluid models.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2025

Fatigue behavior of low-cost, non-spherical Ti-6Al-4V powder processed via laser powder bed fusion

Hydride-dehydride Ti-6Al-4V powder with particle size distribution of 75–175 μm were used to manufacture fatigue samples. Optimized processing parameters were used to maintain a relative density of >99.5% in the samples. Fatigue tests were carried out in R = σ min /σ max = -1 condition under stresses ranging from 150 to 500 MPa and the results were compared to samples that were additively manufactured using spherical powders. The fatigue lives were similar between the two types of powder; i.e., powder morphology has no effect on fatigue performance. However, the high surface roughness and martensitic microstructure resulting from the laser powder bed fusion process result in poor performance compared to samples machined from conventionally produced materials. In conclusion, crack initiation occurred consistently from surface defects because of high surface roughness of the additively manufactured parts.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Investigating the Evolution of Ice Particle Distributions in Mixed-Phase Clouds

The goal of this project is to conduct modeling studies that focus on the processes that control the macrophysical and microphysical properties of mixed phase clouds, such as the partitioning of water phase and the processes that promote precipitation and govern cloud evolution. The process specific to this project is the collection of vapor-grown non-spherical ice crystals and snow hydrometeors through aggregation, as uncertainty remains in the evolution of particle properties as they aggregate. To aid in the understanding of ice particle evolution from pristine monomers to aggregates, the aggregation process is depicted using an offline simulator for ice crystal collection, namely the Ice Particle and Aggregate Simulator (IPAS). Of particular interest in the context of this work is the influence of monomer habit on aggregation and subsequently on cloud microphysical structure. This overarching goal has been completed by conducting modeling studies using the Adaptive Habit Model (AHM) in mixed-phase cloud systems, which predicts and evolves ice shape. While the AHM is designed with physical detail in mind, those details may be lost on larger spatial or temporal scales. Hence, how the contributions of particle growth and collection control the evolution of ice particle size distributions (PSDs) and redistribute mass within the cloud and at the surface has been investigated. Analyses include microphysical sensitivity investigations that inform on future improvement capabilities of microphysical parameterizations in larger scale models. Further, improvements of processes within ice clouds have resulted from this work as the environmental processes controlling ice crystal growth, microphysical processes, and precipitation are inherently integrated within this investigation.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2024

On the force exerted on a non-spherical asymmetric dust grain from homogeneous, stationary, isotropic, non-magnetized plasma

Whereas the conventional wisdom suggests that the force between non-magnetized homogeneous, stationary, isotropic plasma, and the dust grain is only possible for the case of relative plasma–grain velocity, it is shown that stationary non-spherical asymmetric dust grain immersed in stationary, non-magnetized, isotropic plasma can experience a force caused by the grain–plasma interactions. The component of the force due to scattering of plasma particles in the limit of infinite Debye length is considered analytically. Both the particle scattering and absorption force components are modeled numerically in the limits of infinite and finite Debye length using a newly developed 2D3V Aspherical Particle-in-Cell code. The code simulates interactions of dust grain of selected non-spherical asymmetric shape with plasmas using dust shape conforming coordinates. Here, the simulations confirm the existence of the force on non-spherical asymmetric grain in stationary non-magnetized plasma and show that the plasma screening effects can lead to reversal of the force direction.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2025

Development and Evaluation of a General Drag Model for Gas-Solid Flows via Deep Learning

This project presents the development and evaluation of a general drag model for gas–solid multiphase flows using deep learning techniques. A comprehensive database of more than 4,000 experimental and numerical data points for spherical and non spherical particles was compiled, incorporating geometric features such as sphericity, aspect ratio, and orientation. Several predictive approaches—including traditional em pirical correlations, machine learning, and deep neural networks—were benchmarked, with the proposed Drag Coefficient Correlation-aided Deep Neural Network (DCC DNN) demonstrating superior accuracy. To account for particle–particle interactions, additional drag data were generated using CFD-based simulations of packed and flu idized beds, leading to the development of a retrained model capable of incorporat ing volume fraction effects. Integration of the trained model with the MFiX CFD solver was achieved using FTorch, enabling drag predictions during discrete element method (DEM) simulations. Validation against experimental data for single particles and fluidized beds confirmed the model’s improved predictive ability, particularly for non-spherical geometries. While the model performed strongly under fluidized con ditions, limitations remained in unfluidized regimes, suggesting a need for expanded datasets. Overall, this study demonstrates the feasibility of combining deep learning with physics-informed CFD to improve drag modeling for gas–solid flows, with promis ing implications for scaling multiphase simulations in industrial applications.

42 ENGINEERING↗
DOE OSTI2022

Industrial scale mesofluidic particle separation

Here we explore the potential of a mesofluidic separator that fits within industrial piping and is designed to remove large aspherical particles out of an abrasive slurry at fast flow rates. Mesofluidic separators have recently demonstrated separation of spherical particles at flow rates of ~1 gallon/min (gpm) (6.3.10 -5 m 3 /s). Yet, the performance of these separators at flow rates achievable within industrial piping have not been explored. Here we evaluate the permeate flowrate fraction, large particle mass fraction, and pressure drop from approximately 35-100 gpm (2.2.10-3-6.3.10-3 m 3 /s) in a three inch tube using an abrasive and modestly non-spherical slurry. Faster flow rates may be achieved with larger pumps and larger diameters. We find the permeate fraction and pressure drop both increase with flow rate, though the pressure drop remains modest. Only two feet of inserts removed 97.6±2.1% of large particles for conditions tested. Separation was demonstrated in both vertical and horizontal orientations with the horizontal orientation benefiting marginally from gravitational settling.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2021

Experiment and computational fluid dynamics investigation of biochar elutriation in fluidized bed

Here, in fluidized bed biomass fast pyrolysis, the biomass is converted to biochar and elutriated. The elutriation rate is a key parameter in reactor designs and operations. This research presents a video-based continuous measurement of biochar elutriation rate in a fluidized bed with sands and biomass as bed materials. The fluidized bed is simulated with the Computational Fluid Dynamics - Coarse-Grained Discrete Element Method (CFD-CGDEM) in MFiX. The fluidization behavior of non-spherical sands can be more accurately captured when a rolling friction model is used. The predicted elutriation rate is close to the experimental measurement when the particle size distributions are considered and the filtered drag with a shape correction is used. These results validated the accuracy of the MFiX based CFD framework for the prediction of biochar elutriations in the fluidized bed biomass fast pyrolysis reactor.

09 BIOMASS FUELS↗
DOE OSTI2025

Basic Physical Processes Involving Dust in Fusion Plasmas

This report presents the main outcomes of our research focused on understanding the behavior and effects of dust particles in fusion plasmas, particularly in the edge regions of tokamaks and stellarators. We conducted computer modeling studies of burst injections of carbon and tungsten dust particles in DIII-D like divertor plasmas. The studies investigated effects of transient influx of the low- and high-Z material plasma contaminants in form of dust on the edge plasma dynamics in a modern mid-size tokamak. We also performed theoretical and computational studies of the forces acting on non-spherical dust grains in magnetized and nonmagnetized plasmas. In addition, we cooperated with General Atomics slag management group on development of DIII-D dust injection experiments to measure trajectories of dust grains in the divertor plasma and compare them with DUSTT code predictions for validation of the dust modeling capabilities. We collaborated with JET experimentalists on evaluation of radiative losses induced by injection of mixed neon-deuterium ice pellets for disruption and run-away electron generation mitigation during thermal and current quench phases. We also cooperated with experimentalists at LHD fusion device (Japan) on modeling support of experiments on injection of boron granules in fusion plasma discharges to assess their dynamics and effectiveness for in situ dynamic wall conditioning.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2022

Fatigue performance of laser powder bed fusion hydride-dehydride Ti-6Al-4V powder

We report hydride-dehydride (HDH) Ti-6Al-4V alloy with particle size distribution of 50–120 µm is laser powder bed fusion (L-PBF) processed using optimum processing parameters and a near-fully dense structure with a density of 99.9 % is achieved. Microstructural observations and phase analyses indicate formation of columnar β grains with acicular α/α' phases in as-built condition. The roughness of the as-fabricated samples is significant with an average roughness of R a = 15.71 ± 3.96 µm and a root mean square roughness of R rms = 108.4 ± 24.9 µm, however, both values are reduced to R a = 0.19 ± 0.04 µm and R rms = 4.9 ± 0.6 µm after mechanical grinding. Mechanical tests are carried out on as-fabricated specimens followed by stress relief treatment. All samples are tested to failure in fatigue, under fully-reversed tension-compression conditions of R = –1. The as-built samples failed from the surface with crack initiation mainly at micro-notches, whereas after mechanically grinding, crack initiation changed to subsurface defects such as pores. Minimizing surface roughness by mechanically grinding eliminates surface micro-notches which improves fatigue strength in the high cycle fatigue region. Fatigue notch factor calculations showed that the effect of surface roughness was significantly lower when HDH powder is used compared to standard spherical powder. X-ray diffraction analysis revealed an in-plane compressive stress, micro-strain and grain refinement on the surface of the mechanically ground samples. Fractography observations (macroscale) revealed a fully brittle fracture in the first stage of crack growth with a transition to a dominantly ductile fracture in the third stage of crack growth. On the other hand, at the micro scale, even the brittle fracture regions showed evidence of ductile fracture within the α' martensite laths.

36 MATERIALS SCIENCE↗