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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 379 records · Page 21
All sourcesNASA NTRSDOE OSTI
DOE OSTI2017

Optical Fier Based System for Multiple Thermophysical Properties for Glove Box, Hot Cell and In-Pile Application

Thermal diffusivity of materials is of interest in nuclear applications at temperatures in excess of 2000°C. Commercial laser flash apparatus (LFA) that heats samples with a furnace typically do not reach these elevated temperatures nor are they easily adapted to a glove-box or hot cell environment. In this research, we performed work on an experimental technique using single laser surface heating, i.e. heating the disk sample only at its front surface with the continuous wave (CW) laser, to allow measurement of thermal diffusivity at very high temperatures within a small chamber. Thermal diffusivity is measured using a separate pulsed laser on the front side and IR detector on the rear side. The new way of heating provides easy operation in comparison to other heating methods. The measurement of sample reference temperature is needed for the measured thermal diffusivity. A theoretical model was developed to describe transient heat transfer across the sample due to the laser pulse, starting from the steady state temperature of the sample heated by the CW laser. The experimental setup was established with a 500W CW laser and maximum 50 Joule pulse laser irradiated at the front surface of the sample. The induced temperature rise at the rear surface, along with the steady-state temperature at the front surface, was recorded for the determination of thermal diffusivity and the sample temperature. Three samples were tested in vacuum over a wide temperature range of 500°C to 2100°C, including graphite, Inconel 600 and tungsten. The latter two samples were coated with sprayed graphite on their front surfaces in order to achieve surface absorption/emission needs, i.e. high absorptivity of the front surface against relatively low emissivity of the rear surface. Thermal diffusivity of graphite determined by our system are within a 5% difference of the commercial LFA data at temperatures below 1300°C and agree well with its trend at higher temperatures. Good agreement would also exist for Inconel 600 and tungsten. Despite large uncertainty of measuringthe sample temperature, the uncertainties of thermal diffusivity are less than 6% for all samples at elevated temperatures. The results indicate that single laser surface heating could be convenient and practical for the application of the LFA measurements without extra uncertainty, as temperature dependence of thermal diffusivity is usually negligible in the sample. Moreover, it is concluded that unequal surface treatment, i.e., high absorption on the front side and low emission on the rear side, greatly improves the measurement in serval aspects: less power requirement of the CW laser, less uncertainty of measured thermal diffusivity, and more uniform temperature distribution in the sample. The result of this research can be used as a general guideline for the design of this type of measurement system for nuclear applications. It can also be used directly to design and build a system similar to the one implemented in this project.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Milky Way white dwarfs as sub-GeV to multi-TeV dark matter detectors

Here, we show that Milky Way white dwarfs are excellent targets for dark matter (DM) detection. Using Fermi and H.E.S.S. Galactic center gamma-ray data, we investigate sensitivity to DM annihilating within white dwarfs into long-lived or boosted mediators and producing detectable gamma rays. Depending on the Galactic DM distribution, we set new constraints on the spin-independent scattering cross section down to 10 -45 -10 -41 cm 2 in the sub-GeV DM mass range, which is multiple orders of magnitude stronger than existing limits. For a generalized NFW DM profile, we find that our white dwarf constraints exceed spin-independent direct detection limits across most of the sub-GeV to multi-TeV DM mass range, achieving sensitivities as low as about 10 -46 cm 2 . In addition, we improve earlier versions of the DM capture calculation in white dwarfs, by including the low-temperature distribution of nuclei when the white dwarf approaches crystallization. This yields smaller capture rates than previously calculated by a factor of a few up to two orders of magnitude, depending on white dwarf size and the astrophysical system.

79 ASTRONOMY AND ASTROPHYSICS↗
DOE OSTI2023

Surface Merging Technique to Design GA-Optimized Heat Sinks

High-power density inverters require efficient and small heat dissipation systems. For liquid cooling systems, an effective heat sink design is important to enable higher heat transfer and keep the pressure drop within reasonable limits. A heat sink geometry generated from an extruded, 1D fast Fourier transform can achieve more even temperature distribution and improved heat transfer than a conventional heat sink. Building on this concept, this paper proposes a new heat sink geometry creation algorithm. Instead of one plane profile being extruded, multiple plane profiles, each created from the fast Fourier transform method, are subsequently merged by smooth surfaces along the flow direction of the heat sink. Thus, a 3D heat sink geometry is created that enables 3D coolant flow and efficient heat transfer. The volume of this design was reduced by 50% compared with pin fin heat sinks. Compared with extruded 1D fast Fourier transform heat sinks, the proposed design showed an approximately 5% device temperature reduction and a 20% pressure drop reduction.

Barua, Himel↗
DOE OSTI2018

Physics based Reliability Models for Supercritical CO 2 Turbomachinery Components

CSP plants using sCO 2 power cycle can potentially achieve high thermal conversion efficiency at low capital cost due to compact turbo-machinery and other components. An sCO 2 expander and improved heat exchanger is expected to provide a major stepping stone for achieving CSP power at $0.06/kW-hr LCOE, energy conversion efficiency > 50%, and total power block cost < $1,200/kW installed. Hybrid gas bearings (HGB) and Dry gas seals (DGS) are two key components that are critical for robust and efficient operation of future sCO 2 power cycles. From a system perspective, HGBs can provide substantial benefits (~3 to 5%) to the modular CSP operation, while use of DGSs limits the leakage losses as well as the windage losses in the generator and can increase overall generator efficiency by ~ 8%. The life limiting mechanisms of HGBs and DGSs in high pressure, high temperature sCO2 environment were not well understood and hence this program aims at developing physics-based performance prediction and life prediction models for these two components. The output of the performance models serves as input to the life models. The performance models were validated using experimental data and using data from literature. DGS and HGB models have shed light on some risks associated with its operation in sCO2 expander and will guide more robust designs tailored towards sCO 2 cycle applications. A DGS was tested in 1MWe sCO2 turbo expander to study its performance and validate the performance models. To understand the effect of high pressures, high temperatures and sCO 2 environment on crack initiation, crack propagation and LCF/HCF life of these components, a novel experimental setup was developed. The LCF test data was used to calibrate and validate the life prediction models. The effect of sCO 2 corrosion on the life of Ni-based super-alloys is quantified using long duration experiments. Advanced microstructure and spectroscopic analyses conducted shed light on some key differences between IN718 and IN617 in terms of oxidation morphology, chemical species diffusion and trapping, the formation of protective corrosion resistant layers and changes in surface properties. A novel crack initiation model was developed which takes into account strain distribution, temperature, hold times and activation energy at the gas-metal interface and predicts the number of cycles to initiate the crack in the Inconel alloy. An advanced 3D fracture mechanics-based crack propagation model was also developed which takes into account the transient loading mission of the component and predict how fast the crack will grow and what will be its final shape and size. High energy X-Ray tomography measurements were conducted to study and validate 3D morphology of crack growth inside the specimen. These two models along with chemical kinetics models obtained from corrosion tests can be combined to predict the total life of the component under given long term operating conditions. A Bayesian Hybrid Modeling (BHM) probabilistic framework was developed to quantify uncertainty in physics-based performance models and in crack initiation and crack propagation models, to calibrate the models and to validate the models with statistical confidence. Advanced coupled physics multi-phase flow models were developed to study condensation, boiling and phase change behavior of CO 2 under various sCO 2 turbomachinery and heat exchanger conditions. A novel experimental setup was also designed to observe phase change of CO 2 during its transition across liquid-gas-supercritical state lines.

14 SOLAR ENERGY↗
DOE OSTI2019

Physics based Reliability Models for Supercritical CO 2 Turbomachinery Components

CSP plants using sCO 2 power cycle can potentially achieve high thermal conversion efficiency at low capital cost due to compact turbo-machinery and other components. An sCO 2 expander and improved heat exchanger is expected to provide a major stepping stone for achieving CSP power at 0.06/kW-hr LCOE, energy conversion efficiency > 50 % ,and total power block cost< $1,200/kW installed. Hybrid gas bearings (HGB) and Dry gas seals (DGS) are two key components that are critical for robust and efficient operation of future sCO 2 power cycles. From a system perspective, HGBs can provide substantial benefits (~3 to 5%) to the modular CSP operation, while use of DGSs limits the leakage losses as well as the windage losses in the generator and can increase overall generator efficiency by ~ 8%. The life limiting mechanisms of HGBs and DGSs in high pressure, high temperature sCO 2 environment were not well understood and hence this program aims at developing physics-based performance prediction and life prediction models for these two components. The output of the performance models serves as input to the life models. The performance models were validated using experimental data and using data from literature. DGS and HGB models have shed light on some risks associated with its operation in sCO 2 expander and will guide more robust designs tailored towards sCO 2 cycle applications. A DGS was tested in 1MWe sCO 2 turbo expander to study its performance and validate the performance models. To understand the effect of high pressures, high temperatures and sCO 2 environment on crack initiation, crack propagation and LCF/HCF life of these components, a novel experimental setup was developed. The LCF test data was used to calibrate and validate the life prediction models. The effect of sCO 2 corrosion on the life of Ni-based super-alloys is quantified using long duration experiments. Advanced microstructure and spectroscopic analyses conducted shed light on some key differences between IN718 and IN617 in terms of oxidation morphology, chemical species diffusion and trapping, the formation of protective corrosion resistant layers and changes in surface properties. A novel crack initiation model was developed which takes into account strain distribution, temperature, hold times and activation energy at the gas-metal interface and predicts the number of cycles to initiate the crack in the Inconel alloy. An advanced 3D fracture mechanics-based crack propagation model was also developed which takes into account the transient loading mission of the component and predict how fast the crack will grow and what will be its final shape and size. High energy X-Ray tomography measurements were conducted to study and validate 3D morphology of crack growth inside the specimen. These two models along with chemical kinetics models obtained from corrosion tests can be combined to predict the total life of the component under given long term operating conditions. A Bayesian Hybrid Modeling (BHM) probabilistic framework was developed to quantify uncertainty in physics-based performance models and in crack initiation and crack propagation models, to calibrate the models and to validate the models with statistical confidence. Advanced coupled physics multi-phase flow models were developed to study condensation, boiling and phase change behavior of CO 2 under various sCO 2 turbomachinery and heat exchanger conditions. A novel experimental setup was also designed to observe phase change of CO 2 during its transition across liquid-gas-supercritical state lines.

14 SOLAR ENERGY↗
DOE OSTI2020

A Code-Agnostic Driver Application for Coupled Neutronics and Thermal-Hydraulic Simulations

While the literature has numerous examples of Monte Carlo and computational fluid dynamics (CFD) coupling, most are hard-wired codes intended primarily for research rather than as standalone, general-purpose applications. In this work, we describe an open source application, ENRICO, that enables coupled neutronic and thermal-hydraulic simulations between multiple codes that can be chosen at runtime (as opposed to a coupling between two specific codes). The application has been designed such that the control flow logic, domain mapping, nonlinear fixed-point iteration, solution transfers, and convergence checks are all agnostic to the underlying physics solvers used. Special emphasis has also been placed on enabling efficient execution on distributed-memory computing environments. The transfer of solution fields between solvers is performed in memory rather than through filesystem I/O. Additionally, solvers can be configured to run on overlapping or disjoint sets of processes. To date, coupling with the OpenMC and Shift Monte Carlo codes, the Nek5000 CFD code, and a simplified heat diffusion and subchannel solver has been implemented in ENRICO. We present results for coupled simulations of a single light-water reactor fuel assembly based on the NuScale reactor using various combinations of the physics solvers. For this problem, the coupled simulations are shown to converge in about four Picard iterations. A comparison of the heat source and temperature distributions computed by ENRICO using OpenMC coupled with Nek5000 and Shift coupled with Nek5000 illustrates remarkable agreement between the codes.

42 ENGINEERING↗
DOE OSTI2023

Final Technical Report Wireless Microsensors System for Monitoring Deep Subsurface Operations

This final technical report describes the main findings of the project Wireless Microsensors System for Monitoring Deep Subsurface Operations (FE0031850). The project was part of the U.S. Department of Energy National Energy Technology Laboratory FOA 1998 program to develop new sensor systems for direct observation of parameters associated with CO2 injection and to provide data collection without being disruptive to operations. The overall DOE program was aimed at developing and validating innovative transformational sensor systems, amenable for integration with autonomous intelligent monitoring systems, that are capable of being deployed within the casing annulus and do not have casing perforation or wires/cables in the annulus for installation, power supply, or data transmission needs. Project accomplishments included 1) design and fabrication of a wireless downhole sensor system to monitor parameters for CO2 storage, 2) field testing of the sensor system in two legacy oil & gas wells, and 3) development of an analysis approach that validates the measurements and demonstrates the application of the technology to depict CO2 movement in the subsurface. The project leveraged new sensor technologies along with specialized wellbore telemetry, deployment, and analysis methods designed to address the challenges and risks related to CO2 storage in the subsurface. Results from field testing were a mixture of successes and challenges. The temperature sensor rings, installation procedures in legacy oil & gas wells, wireless powering demonstration, automated data collection, and material compatibility were successful. The wireless data transfer through cement to the wellhead via the sensor relays was not functional beyond the first relay. Consequently, work in the last year of the project included some additional testing of data transmission through different materials along with modeling and analysis of field data for CO2 monitoring applications. This work suggested there are options like polymer cements and open hole annuli that may allow point-to-point transmission along the borehole. The techno-economic analysis suggests that the sensor system is ~40% less expensive than fiber optic distributed temperature system. Modeling of CO2 storage applications suggests temperature can provide an indicator of CO2 saturation but would be best combined with pressure sensors.

47 OTHER INSTRUMENTATION↗
DOE OSTI2023

Toward local core outlet temperature monitoring in gas-cooled nuclear reactors using distributed fiber-optic temperature sensors

Gas-cooled nuclear reactors operate at temperatures up to 950 °C with significant spatial variations in power generation and coolant flow through hundreds of parallel flow channels, resulting in complex mixing at the core outlet. The high temperatures and complex mixing can damage downstream components, challenge reactor calorimetry for power determination, and result in significant conservatism in calculated peak fuel temperatures, which ultimately limits the total power output. Directly measuring each gas stream individually is unrealistic using single point thermocouples, requiring more robust sensing techniques. Fiber-optic sensors are resilient to high temperatures (up to 1,000 °C) and radiation damage. Moreover, distributed measurements can be made along the length of one fiber, making them potential candidates for monitoring local core outlet temperatures to improve core calorimetry and identify hot channels. Here, to the authors’ knowledge, this manuscript is the first to report spatially distributed fiber optic temperature measurements to quantify mixing at the outlet of a relevant orifice plate under prototypic temperature and flow regimes to assess the feasibility of using fiber-optic sensors for distributed measurements of coolant temperature in gas-cooled reactors. A single optical fiber captured dynamic changes in local temperatures, whereas the mixed outlet temperature exhibited a muted response and could not identify which channels were responsible for the change in the mixed outlet temperature. The discussion focuses on potential challenges for deploying distributed optical fibers in gas-cooled reactors, including the effects of vibrations, radiation-induced signal attenuation and drift, and routing of the fiber while minimizing flow obstructions.

42 ENGINEERING↗
DOE OSTI2018

Modeling The Effects of Shock Pressure and Pore Morphology on Hot Spot Mechanisms in HMX

Here, we investigate the effects of shock pressure and pore morphology on the formation and growth of hot spots in HMX (octahydro-1,3,5,7-tetranitro-1,3,5,7-tetrazocine). Both non-reactive and reactive ALE3D simulations are used in these studies. Our non-reactive simulations show a viscous-dominated pore collapse mode at lower shock pressures (2–10 GPa) with shear band formation and a hydrodynamic-dominated mode at higher shock pressures (20-40 GPa) due to bulk melting. When normalized by bulk shock heating, viscous-dominated pore collapse modes are more efficient at generating hot spots. Pore morphology influences the post-collapse temperature distributions and reaction rate for a fixed pore area and shock pressure. We find that multiple surface pores at the binder-grain interface tend to react the fastest. Due to their upstream location in the HMX grain, the surface pores collapse sooner than interior pores; thus, the extent of reaction will generally favor these morphologies because they have more time to grow. In general, multiple smaller hot spots tend to react faster than a single larger hot spot because they accelerate one another's burning. The rank order of morphology effects, however, is not the same for non-reactive and reactive simulations. For example, while multiple surface pores produce the highest reaction rates they do not produce the highest (non-reactive) hot spot temperatures. In conclusion, our numerical studies provide insights on hot spot mechanisms in lieu of direct measurements and can be used to develop advanced shock initiation models.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2023

A framework to measure the properties of intergalactic metal systems with two-point flux statistics

ABSTRACT The abundance, temperature, and clustering of metals in the intergalactic medium are important parameters for understanding their cosmic evolution and quantifying their impact on cosmological analysis with the Ly α forest. The properties of these systems are typically measured from individual quasar spectra redward of the quasar’s Ly α emission line, yet that approach may provide biased results due to selection effects. We present an alternative approach to measure these properties in an unbiased manner with the two-point statistics commonly employed to quantify large-scale structure. Our model treats the observed flux of a large sample of quasar spectra as a continuous field and describes the one-dimensional, two-point statistics of this field with three parameters per ion: the abundance (column density distribution), temperature (Doppler parameter), and clustering (cloud–cloud correlation function). We demonstrate this approach on multiple ions (e.g. ${\rm C\, \small {\rm IV}}$ , ${\rm Si\, \small {\rm IV}}$ , and ${\rm Mg\, \small {\rm II}}$ ) with early data from the Dark Energy Spectroscopic Instrument (DESI) and high-resolution spectra from the literature. Our initial results show some evidence that the ${\rm C\, \small {\rm IV}}$ abundance is higher than previous measurements and evidence for abundance evolution over time. The first full year of DESI observations will have over an order of magnitude more quasar spectra than this study. In a future paper, we will use those data to measure the growth of clustering and its impact on the Ly α forest, as well as test other DESI analysis infrastructure such as the pipeline noise estimates and the resolution matrix.

79 ASTRONOMY AND ASTROPHYSICS↗
DOE OSTI2021

Transition to Online Cable Insulation Condition Monitoring

Nuclear power plant cables were originally qualified for 40 year life and generally have not required specific test verification to assure service availability through the initial plant qualification period. However, license renewals to 60 and 80 years of operation require a cable aging management program that depends on some form of test and verification to assure fitness for service. Environmental stress (temperature, radiation, chemicals, water, and mechanical) varies dramatically within a nuclear power plant and, in some cases, cables have degraded and required repair or replacement before their qualified end-of-life period. In other cases, cable conditions have been mild and dependable cable performance confirmed to extend well beyond the initial qualified life. Most offline performance-based testing requires cables to be de-coupled and de-energized for specially trained technicians to perform testing. These offline tests constitute an expensive operational burden that limits the economic viability of nuclear power plants. Although initial investment may be higher, new online test practices are emerging as options or complements to offline testing that avoid or minimize the regularly scheduled offline test burden. These online methods include electrical and fiber-optic partial discharge measurement, spread spectrum time or frequency domain reflectometry, distributed temperature profile measurements, and local interdigital capacitance measurement of insulation characteristics. Introduction of these methods must be supported by research to confirm efficacy plus either publicly financed or market driven investment to support the start-up expense of cost-effective instrumentation to monitor cable condition and assure reliable operation. This work summarizes various online cable assessment technologies plus introduces a new cable motor test bed to assess some of these technologies in a controlled test environment.

Glass, Samuel W.↗
DOE OSTI2025

Heat load measurements for the PIP-II pHB650 cryomodule

This study presents a brief overview of the 1st and 2nd phases and an in-depth analysis of the 3rd phase heat load testing performed on the pHB650 (prototype High Beta 650 MHz) cryomodule at PIP2IT (PIP-II Injector Test Facility), with a focus on both the results and the methodological advancements that have improved testing efficiency and accuracy. A key challenge identified in the testing campaign is the higher-than-expected heat loads observed in the first PIP-II (Proton Improvement Plan II) prototype cryomodules (pSSR1 and pHB650) tested at PIP2IT. Elevated heat loads are concerning given the fixed capacity of the PIP-II cryoplant that is currently being installed at Fermilab. However, understanding the sources of these elevated heat loads offers a critical opportunity to implement effective heat load mitigations on upcoming PIP-II cryomodules to stay within the available capacity of the PIP-II cryoplant. The study includes a summary of test results, descriptions of measurement procedures, and key observations on parameters directly and indirectly related to heat load measurements. Direct observations include measured heat loads and the effectiveness of JT heat exchanger under varying conditions, while indirect observation analyze factors such as the temperature distribution on the two-phase pipe and relief piping under varying conditions. Thermal acoustic oscillations (TAO) were identified during testing, which was mitigated by replacing the original G10 stem with a stainless steel stem equipped with wipers for the cryomodule cooldown valve. A major innovation during pHB650 Phase 3 testing was the development of an automated Python script to streamline data acquisition, analysis, and reporting of heat load results. This script automatically retrieved data from ACNET (Accelerator Control Network), performed heat load calculations, and generated detailed reports featuring plots and tables. This advancement significantly reduced manual labor and enhanced the thoroughness of data analysis compared to earlier campaigns. The heat load test reports were promptly uploaded to the electronic logbook shortly after each test, enabling rapid feedback and collaboration between the SRF and cryogenic teams. The heat load measurements included various components: HTTS (high-temperature thermal shield), LTTS (low-temperature thermal shield), 2K isothermal and non-isothermal heat loads. Results were recorded both within the cryomodule and between the bayonet can supply and return. Measurements were conducted under different operating conditions such as "standard", "linac", and "simulated dynamic". Additionally, HTTS and LTTS heat loads were calculated in real time, allowing for the tracking of thermal stability and identification of changes during testing, both in steady-state and transient conditions. The results of this testing campaign not only provide valuable insights into the performance of the pHB650 cryomodule but also highlight best practices and lessons learned that will inform future cryomodule testing at PIP2IT. These include adopting automated tools for data analysis, refining real-time measurement capabilities, and emphasizing detailed pre-test planning. The framework established in this campaign aims to set an improved standard for cryomodule testing and heat load reporting in future cryomodule test campaigns.

Porwisiak, D. [Fermilab; Wroclaw Tech. U.]↗
DOE OSTI2023

High-Resolution Thermal Profiling of a High-Power Diode Laser Facet During Aging

Here, we study the facet temperature distribution of a high-power diode laser over its lifetime using a noncontact, high spatial resolution CCD-based thermoreflectance technique. Based on the known correlation between non-radiative defects and heating, thermal maps can provide valuable information regarding the formation and evolution of small point defects that are at or near the facet during aging. In the laser under study in this work we measure the appearance of local hot spots on the facet, including concentrated hot spots that appear just before or just after COD and are correlated with loss of local light emission. The locations of these hot spots do not exhibit morphology changes in high-resolution SEM imaging of the facet, indicating that the related defects are too small to be observable in SEM or are located at some depth under the facet. Prior to COD, we measure a gradual facet temperature increase accompanied by a gradual optical power decrease and gradual facet optical absorption increase, indicating gradual degradation of the laser.

47 OTHER INSTRUMENTATION↗
DOE OSTI2023

Computational fluid dynamics investigations of flow, heat transfer, and oxidation in heat recovery steam generator

Modern heat recovery steam generators (HRSGs) operate at elevated temperatures, leading to the formation of oxides inside the tubes of heat exchangers (HXs). This oxide growth reduces the heat recovery efficiency. Moreover, after reaching a certain critical thickness, some oxide scales detach from the tube surface (exfoliation), causing erosion damage to the components downstream. Predicting the metal temperature distribution and associated oxide thickness in the HXs of an HRSG can aid in mitigating these problems. Here, a computational fluid dynamics (CFD) model was developed within the commercial code STAR-CCM+ for the prediction of fluid flow, conjugate heat transfer, and associated oxidation in HRSGs. Moreover, a new Porous Media Model (PMM) method was developed to model the fin effect on the heat transfer in HX, which can substantially reduce the prohibitive computational costs of fin meshes. The developed CFD model was used to conduct a high-fidelity simulation of a real-scale HRSG to investigate flow, heat transfer, and oxide growth. The calculated oxide thickness on different tubes can be used to identify HX regions that require oxide-resistant coatings to prevent exfoliation and ensuing damages. Furthermore, this CFD framework can serve as a reference for future studies that intend to model and investigate high-temperature oxidation in HXs used for any applications.

42 ENGINEERING↗
DOE OSTI2018

Experimental Study on Portable Air-Conditioning System with Enhanced PCM Condenser

A portable personal air-conditioning system with a vapor compression cycle (VCC), electrical battery, and thermal battery is an attractive option for localized cooling as compared with stationary air-conditioning systems. A phase change material (PCM) can be used for storing waste heat from the VCC condenser, thereby acting as a thermal battery. In the PCM condenser, copper tubes are submerged in the PCM container. Due to the low thermal conductivity of pure PCM, the overall heat transfer coefficient of the PCM condenser is limited resulting in high VCC condensing pressure and thus, low VCC coefficient of performance (COP). Therefore, it is necessary to improve VCC system performances by applying heat transfer augmentation in PCM. In this work, a portable air-conditioning system with heat transfer enhanced PCM that stores heat from condenser during VCC operation and is regenerated by a thermosyphon operation is proposed. The system also includes a receiver to address the charge difference between the thermosyphon and the VCC operation. The paper experimentally studies the effects of the following three types of enhanced PCM condensers on the system performance: (1) copper mesh enhanced PCM with helically coiled copper tube branches and large refrigerant distribution headers (CMPHX), (2) graphite matrix enhanced PCM with straight copper tube branches and small headers (GMPHX1), and (3) graphite matrix enhanced PCM with straight copper tube branches and large headers (GMPHX2). Results show that this system operates properly and effectively during both VCC and PCM regeneration operations. The system can provide four hours of continuous cooling, and the PCM can be fully regenerated after 7.4 hours by thermosyphon operation. The comparisons of three PCM condensers indicate that the system with GMPHX2 performs the best with the average VCC COP of 4.7. The VCC system with CMPHX has an average COP of 4.2, and GMPHX1 has an average COP of 3.1. GMPHX2 has the best heat transfer enhancement with an overall heat transfer coefficient of 632.1 W∙m-2∙K-1, which is more than twice of GMPHX1 and five times of CMPHX. Moreover, GMPHX2 can achieve more uniform refrigerant flows and PCM temperature distributions than GMPHX1. This leads to the higher utilization ratio of PCM latent heat. CMPHX is the second best but needs larger heat transfer surface area and inner volume as well as more refrigerant charge. In conclusion, the system design with GMPHX2 is recommended due to its small refrigerant charge, high VCC COP, and the use of good heat transfer enhancement material.

Qiao, Yiyuan↗
DOE OSTI2021

MHD simulations of cold bubble formation from 2/1 tearing mode during massive gas injection in a tokamak

Massive gas injection (MGI) experiments have been carried out in many tokamaks to study disruption dynamics and mitigation schemes. Two events often observed in those experiments are the excitation of the m = 2, n = 1 magnetohydrodynamic mode, and the formation of cold bubble structure in the temperature distribution before the thermal quench (TQ). Here m is the poloidal mode number, n the toroidal mode number. The physics mechanisms underlying those phenomena, however, have not been entirely clear. In this work, our recent NIMROD simulations of the MGI process in a tokamak have reproduced the main features of both events, which has allowed us to examine and establish the causal relation between them. In these simulations, the 3/1 and 2/1 islands are found to form successively after the arrival of impurity ion cold front at the corresponding q = 3 and q = 2 rational surfaces. At the interface between impurity and plasma, a local thin current sheet forms due to an enhanced local pressure gradient and moves inward following the gas cold front, this may contribute to the formation of a dominant 2/1 mode. Following the growth of the 2/1 tearing mode, the impurity penetration into the core region inside the q = 2 surface gives rise to the formation of the cold bubble temperature structure and initiates the final TQ. Here, a subdominant 1/1 mode developed earlier near the q = 1 surface alone does not cause such a cold bubble formation, however, the exact manner of the preceding impurity penetration depends on the nature of the 1/1 mode: kink-tearing or quasi-interchange.

2/1 tearing mode↗
DOE OSTI2019

A Forward Time Stepping Heat Conduction Model for Spot Melt Additive Manufacturing

Solidification dynamics are crucial for determining microstructure development in additively manufactured parts. Multiphysics models based on finite element or finite volume methods may help gain insight for complicated phenomena such as fluid flow, keyholing, and porosity but are too computationally expensive to use for simulating actual builds. Recent analytic and semi-analytic solutions for moving heat sources in a semi-infinite three-dimensional space provide a way to accurately estimate the solidification conditions for entire builds. The downside to these methods is that, unlike finite element or finite volume methods, they cannot use the temperature distribution of the previous timesteps to march the solution forward in time. This paper provides the mathematical formulation and implementation of a forward time stepping (FTS) approach to an existing semi-analytic solution. The speed and accuracy of the two methods are then compared for various scan patterns. The result is that, for spot melts, the forward time-stepping model provides improvements in both speed and accuracy. This is especially true for longer simulations, where the simulation can be orders of magnitude faster. Finally, the longest simulation analyzed in this paper was roughly 30× faster when using the forward time-stepping model versus the straightforward implementation of the semi-analytic solution.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Numerical simulation of falling film sensible heat transfer over round horizontal tubes

Numerical simulations are performed to explore the heat transfer characteristics of falling films over horizontal round tubes with uniform heat flux imposed for a range of Reynolds numbers spanning the droplet, jet, and sheet regimes. Simulations results agree well with available experimental measurements. The study analyzes the local as well as average heat transfer behavior under the different flow modes. The numerical results show that the local Nusselt number (Nu) distribution depends on the flow features in each mode and varies substantially in all directions for the respective mode. In the droplet mode, the Nu value varies significantly as the droplet impinges and the remnant liquid-bridge retracts (peak instantaneous Nu near 6), followed by wave propagation over the tube surface with peak Nu around 0.25. For the jet modes, the local maximum in the heat transfer occurs off-center to the impingement location with magnitudes of peak Nu = 3.1 for the inline jet mode and Nu = 2.7 for the staggered jet mode, while on the rest of the tube surface, it has an inverse relation with the liquid film thickness. Substantial variations in the heat transfer value are also recorded in the middle of the two impinging jets with Nu = 0.95 in the inline jet mode where the neighboring jets do not interact, and Nu = 0.60 in the crest region of the staggered jet mode where the neighboring jets interact with each other. In the sheet mode, the Nu was seen to depend on the thickness of the liquid waves traversing over the tube surface. Lower Nu values were recorded beneath the crest location of the liquid waves, which increases (1.4–11.6% depending on circumferential location) abruptly in magnitude at the advancing fronts of the waves. The temperature distribution in the liquid film in each of the modes was examined to evaluate the mechanism of heat transfer process. This study also compares the local heat transfer coefficient distribution with the analytical heat transfer models derived to predict heat transfer performance over horizontal tube surfaces.

42 ENGINEERING↗