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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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NASA NTRS2014

The Parallel System for Integrating Impact Models and Sectors (pSIMS)

We present a framework for massively parallel climate impact simulations: the parallel System for Integrating Impact Models and Sectors (pSIMS). This framework comprises a) tools for ingesting and converting large amounts of data to a versatile datatype based on a common geospatial grid; b) tools for translating this datatype into custom formats for site-based models; c) a scalable parallel framework for performing large ensemble simulations, using any one of a number of different impacts models, on clusters, supercomputers, distributed grids, or clouds; d) tools and data standards for reformatting outputs to common datatypes for analysis and visualization; and e) methodologies for aggregating these datatypes to arbitrary spatial scales such as administrative and environmental demarcations. By automating many time-consuming and error-prone aspects of large-scale climate impacts studies, pSIMS accelerates computational research, encourages model intercomparison, and enhances reproducibility of simulation results. We present the pSIMS design and use example assessments to demonstrate its multi-model, multi-scale, and multi-sector versatility.

crop modeling↗
NASA NTRS2017

GEOS Atmospheric Model: Challenges at Exascale

The Goddard Earth Observing System (GEOS) model at NASA's Global Modeling and Assimilation Office (GMAO) is used to simulate the multi-scale variability of the Earth's weather and climate, and is used primarily to assimilate conventional and satellite-based observations for weather forecasting and reanalysis. In addition, assimilations coupled to an ocean model are used for longer-term forecasting (e.g., El Nino) on seasonal to interannual times-scales. The GMAO's research activities, including system development, focus on numerous time and space scales, as detailed on the GMAO website, where they are tabbed under five major themes: Weather Analysis and Prediction; Seasonal-Decadal Analysis and Prediction; Reanalysis; Global Mesoscale Modeling, and Observing System Science. A brief description of the GEOS systems can also be found at the GMAO website. GEOS executes as a collection of earth system components connected through the Earth System Modeling Framework (ESMF). The ESMF layer is supplemented with the MAPL (Modeling, Analysis, and Prediction Layer) software toolkit developed at the GMAO, which facilitates the organization of the computational components into a hierarchical architecture. GEOS systems run in parallel using a horizontal decomposition of the Earth's sphere into processing elements (PEs). Communication between PEs is primarily through a message passing framework, using the message passing interface (MPI), and through explicit use of node-level shared memory access via the SHMEM (Symmetric Hierarchical Memory access) protocol. Production GEOS weather prediction systems currently run at 12.5-kilometer horizontal resolution with 72 vertical levels decomposed into PEs associated with 5,400 MPI processes. Research GEOS systems run at resolutions as fine as 1.5 kilometers globally using as many as 30,000 MPI processes. Looking forward, these systems can be expected to see a 2 times increase in horizontal resolution every two to three years, as well as less frequent increases in vertical resolution. Coupling these resolution changes with increases in complexity, the computational demands on the GEOS production and research systems should easily increase 100-fold over the next five years. Currently, our 12.5 kilometer weather prediction system narrowly meets the time-to-solution demands of a near-real-time production system. Work is now in progress to take advantage of a hybrid MPI-OpenMP parallelism strategy, in an attempt to achieve a modest two-fold speed-up to accommodate an immediate demand due to increased scientific complexity and an increase in vertical resolution. Pursuing demands that require a 10- to 100-fold increases or more, however, would require a detailed exploration of the computational profile of GEOS, as well as targeted solutions using more advanced high-performance computing technologies. Increased computing demands of 100-fold will be required within five years based on anticipated changes in the GEOS production systems, increases of 1000-fold can be anticipated over the next ten years.

ESMF↗
NASA NTRS2018

Multi-Scale Modeling of Low-Density Carbon-Phenolic Ablators

Protecting a spacecraft during atmospheric entry is one of highest risk factors that needs to be mitigated during design of a space exploration mission. At entry speeds from space, air turns into high-temperature plasma, and spacecraft Thermal Protection Systems (TPS) are needed to protect the vehicle payload. Modern successful material architectures of spacecraft shields use a porous carbon fiber substrate impregnated with phenolic as an ablator material. In the lecture, efforts to build a Predictive Material Modeling framework for porous ablators from micro-scale to macro-scale will be presented. Several numerical methods and techniques will be summarized that use voxelized images to compute geometrical properties of the porous substrate. These computed properties include porosity, specific surface area and tortuosity that are otherwise indirectly measured through experimental techniques. Direct simulation Monte Carlo (DSMC), a particle-based method for approximating the Boltzmann equation, is used to compute the permeability coefficient of the porous substrate based on its digitized representation. The method computes the flow within the microstructure, where the size of the pores may approach the mean-free-path of the flow. Finally, a high-fidelity model implemented in PATO (Porous-material Analysis Toolbox) is discussed, and some examples of ablative material response are presented, including for the first time 3D simulations of the full tiled heat shield for the Mars Science Laboratory (MSL) capsule.

Ablators↗
NASA NTRS2020

AERoBOND Project Summary

Under NASA’s Convergent Aeronautics Solutions (CAS) project, the Adhesive-Free Bonding of Complex Composites (AERoBOND) project investigated off-stoichiometric epoxy polymers for fast, reliable assembly of epoxy matrix composite structures. The project goal was to demonstrate feasibility of the AERoBOND joining method by demonstrating mechanical properties greater than 80% of conventional co-cured materials while reducing structure weight by 1%. The project consisted of three convergent research areas: material and process development, systems analysis, and material and process modeling. Material and process development was the largest component of AERoBOND with approximately 6 FTE and 1WYE of support to formulate and characterize new resins, prepare carbon fiber prepregs, fabricate laminates, measure mechanical properties, analyze failure results, and select material and process improvements. The systems analysis activity estimated the potential reduction in part count and aircraft weight by comparing models of composite wing boxes with no fasteners (co-cured structure), fasteners in major joints (co-cured stringers), and fasteners in all joints. The materials and process modeling activity included a molecular model of the AERoBOND materials system to predict mechanical properties of resins with offset stoichiometry and a process model to predict the effect of resin formulation and processing conditions on the extent of mixing and degree of cure in a finished joint. As the number of airline passenger trips doubles in the next 20 years (IATA/Tourism Economics Air Passenger Forecasts, April 2019), the increased demand for new commercial aircraft is now the single greatest technical challenge to the airframe manufacturing industry. To meet efficiency requirements, new aircraft must be fabricated primarily from high performance structural composites, but manufacturing processes are inherently slow with the largest bottleneck attributed to assembly and installation of fasteners (NASA/TM–2019-220428). Manufactures of commercial transport aircraft are compelled to install more than 100,000 redundant fasteners into bonded joints to prevent failures due to unpredictable weak bonds. In structural adhesive bonds, the interface between adherend and adhesive is nearly two-dimensional making it susceptible to minute quantities of contamination, which can cause weak bonds. Currently, bond strength assessment is only possible through destructive testing (i.e., breaking the joint). For these reasons, regulatory organizations such as the Federal Aviation Administration (FAA) often require redundant load paths in secondary-bonded, primary-structures to alleviate concerns with bond performance. The AERoBOND process enables reflow of matrix resin during assembly to eliminate the material discontinuity at the interface, thereby eliminating the dependence of mechanical performance on interfacial adhesion. The AERoBOND joint is equivalent to the interlaminar region obtained during a co-cure process, so joint performance depends on the cohesive properties of the matrix resin. Conventional co-cured structures, although too costly and complex for large-scale manufacturing, are trusted by manufacturers and regulators, and are certified for flight with few or no redundant fasteners.Systems analysis performed on a composite wing model at the scale of a single-aisle commercial transport aircraft indicated that >20,000 redundant fasteners per wing could be eliminated by implementing the AERoBOND joining method. A total weight reduction of 15% was predicted in a wing box by eliminating fasteners and thinning components that must no longer support localized fastener loads and accommodate fastener dimensions. Interlaminar shear fracture toughness measured by the end-notched flexure test was greater than 1 kJ/m2 (nearly 140% of the co-cured benchmark property), which is greatly in excess of the project goals for mechanical properties. Testing was planned to measure interlaminar tensile fracture toughness as well as interlaminar tensile and shear strengths using the same AERoBOND configuration, but was delayed due to closure of LaRC facilities during the COVID-19 pandemic. The AERoBOND process model is partially validated and available for experimental use. It allows the user to input AERoBOND process parameters such as material composition, laminate configuration, and cure cycle to predict the final cure state of the AERoBOND joint. A preliminary, multi-scale material model was developed to predict AERoBOND joint mechanical properties (stiffness and strength) based on the cure state of the joint provided by the process model. The timing for transition of this technology within NASA is excellent as NASA initiates new enduring projects to address composites manufacturing rate challenges. AERoBOND technology is well suited to AAVP/AATT objectives for rapid manufacturing of a composite wing. A minimal effort (1 FTE/$15k procurement/0 WYE) is proposed in FY21 to continue a minor mechanical testing effort and maintain a SAA with ASX composites to develop commercial quality prepreg material. An RFI with the composites industry is suggested to quantify the technology gap between the current TRL and the TRL needed for transition to industry. A moderate effort [3-4 FTE/$150k/1 WYE (~$115k)] is proposed in FY22 for the “high rate composites manufacturing” project currently in planning. The partnership with ASX Composites will be expanded to produce material for sub-element/element-scale “panel-off” activities. Industry partnerships with airframe manufacturers is an expected component to explore damage tolerance and environmental stability. Further development of multi-scale modeling tools (process model, meso-scale model, and molecular model) is planned to enhance and deliver tools for rapid manufacturing infusion.

Frank Louis Palmieri↗
NASA NTRSDate not supplied

The Additive Manufacturing Moment Measure - A Parallel Computation Technique for Determining Build Variance in the Laser Powder Bed Fusion Process

Additive manufacturing (AM) has unique process attributes that facilitate the creation of optimized, complex, and unique parts for aerospace applications. However, the multi-scale and complicated building process for AM parts can cause unexpected build conditions that result in microstructural variability within the deposited material. The need for richer datasets and computational modeling capabilities to improve AM process reliability is a consequence of this microstructural variability. A computational approach, referred to as the Additive Manufacturing Moment Measure (AM3), addresses this need by leveraging the way AM processes fuse material in precise, incremental steps. During the layering sequence, each previous step contributes to the condition of the current step at the center of the heat source. The precise steps can be selected to systematically create a time-space point field with co-located machine input and in-situ sensor data. The sequential nature of the AM process, coupled with nearest neighbor calculations, allows for a fully parallel computation for part-scale build profile analysis. The AM3 concept introduced here enables part-scale assessment directly from build files and in-situ process monitoring sensors alike. The AM moment measures were calculated for build point fields and compared with co-located in-situ and ex-situ nondestructive evaluation and optical microscopy observations. These comparisons permit a better understanding of how the sequential process actions can affect the quality of a laser powder bed fusion (LPBF) build. Details of the AM3technique will be discussed and compared to measured LPBF part characteristics. The AM3 results indicate a strong potential to advance the qualification process for aerospace applications.

Additive Manufacturing↗
NASA NTRSDate not supplied

The Additive Manufacturing Moment Measure (AM3) Approach to Predictions of Solid Cooling Rate and Time Above Melt

Qualification of a laser powder bed fusion additive manufacturing (LPBF-AM) process requires knowledge of the multi-scale material physics during the process, per part. As the LPBF-AM build occurs, each moment is influenced by the process history. Knowledge of the build sequence can be used to generate a discretized time-space-condition point field that when coupled with a nearest neighbors’ calculation results in a generalized and fully parallel process model computation. This GPU accelerated approach was developed for part-scale analysis of build files along with in-situ process monitoring sensor data and is termed the “Additive Manufacturing Moment Measure” (AM3). The AM3 approach will be presented and then used to evaluate an AM Bench relevant geometry with synchronized in-situ process data, ex-situ nondestructive evaluation, and optical microscopy observations. These comparisons permit a better understanding of how the process actions can affect the LPBF-AM build quality and the signals generated during in-situ process monitoring.

Additive Manufacturing↗
NASA NTRSDate not supplied

Leveraging the Multiplatform Precipitation Feature Database of Combined Ground Radar and Satellite Lightning Observations for Convective Studies

The Multiplatform Precipitation Feature (MPF) database combines coincident observations of lightning from space with satellite- and ground-based radar data in a storm-based, feature-defined framework. The concept for the MPF database stems from the motivation to extend the scale and scope of investigations into the complex connections between ice precipitation, updrafts, and lightning in thunderstorms. The earliest iteration of the MPF database incorporates NASA International Space Station Lightning Imaging Sensor (ISS LIS) observations alongside the NASA Global Precipitation Measurement (GPM) Mission Dual-frequency Precipitation Radar (DPR) and Validation Network (VN). Because of the specific role of the GPM VN in forming the first MPFs, this subset is referred to as the VNMPF database. The synthesis of these multi-scale and multi-resolution observations leveraged each platform’s unique insights into convective properties and processes, offering a more complete view of deep convection over the large viewing area afforded by satellite coverage. The VNMPF database established the feasibility and infrastructure to combine microphysical, kinematic, and lightning observations from multiple satellite- and ground-based platforms. Following this successful proof-of-concept, recent progress has expanded the MPF database to make use of coincident ISS LIS lightning observations and data from the operational Weather Surveillance Radar - 1988 Doppler (WSR-88D) network, where individual WSR-88D proximity facilitates vertical wind retrievals via dual-Doppler analysis. These database changes have expanded the scope of the dataset by removing the requirement for coincident GPM and ISS LIS overpasses. This increases the sample size dramatically and facilitates analysis of higher-resolution radar-derived properties. These advancements allow both storm-scale and unprecedented broad statistical analyses of deep convection from electrical, kinematic, and microphysical perspectives over the contiguous United States. This presentation outlines the construction of the new MPF database and introduces some preliminary analyses of the convection captured within it. Early results summarize relationships based on updraft characteristics ascertained from WSR-88D dual-Doppler three-dimensional wind retrievals, properties of ice microphysics gleaned from dual-polarization analyses, and electrical characteristics observed by the ISS LIS. The expanded scale and scope offered by more than five years of ISS LIS observations enable new insights into regional and seasonal variations in the microphysical, kinematic, and electrical relationships of convection. Analysis of the database highlights the potential for advancements in lightning meteorology made possible by combining large-scale spaceborne lightning detection and proven storm interrogation tools such as operational polarimetric Doppler radar.

Lightning↗
DOE OSTI2014

MULTI-SCALE COHERENT TURBULENCE AT TIDAL ENERGY SITES

Turbulence is known to affect the performance and survivability of tidal turbines, yet characterization of turbulence in the field remains limited. Here, we refine and demonstrate a new approach to turbulence measurements, in which an array of multiple Acoustic Doppler Velocimeters (ADV) is suspended above the seabed at the hub height of a tidal turbine. These measurements provide information on the intensity, structure, and coherence of turbulence across the scale of a turbine rotor (< 10 m). Deployment of multiple moorings expands the analysis to array scales (> 10 m). Motion correction of the moored ADV data is essential to this approach and is verified using the turbulent kinetic energy spectra. Additional measurements include a bottommounted 5-beam Acoustic Doppler Current Profiler, from which scales can be assessed using the velocities a separation distances along a given beam. These methods are demonstrated with data collected at the site of the Snohomish PUD pilot project in Admiralty Inlet, Puget Sound, WA (USA). Coherent motion is found to be largely isotropic, such that coherence is high only at scales less than the advective length scale or the water depth, whichever is less.

ADV↗
DOE OSTI2016

A Demonstration of Advanced Safety Analysis Tools and Methods Applied to Large Break LOCA and Fuel Analysis for PWRs

The U.S. Nuclear Regulatory Commission (NRC) is currently proposing a rulemaking designated as 10 CFR 50.46c to revise the loss-of-coolant accident (LOCA)/emergency core cooling system acceptance criteria to include the effects of higher burnup on fuel/cladding performance. We propose a demonstration problem of a representative four-loop PWR plant to study the impact of this new rule in the US nuclear fleet. Within the scope of evaluation for the 10 CFR 50.46c rule, aspects of safety, operations, and economics are considered in the industry application demonstration presented in this paper. An advanced safety analysis approach is used, by integrating the probabilistic element with deterministic methods for LOCA analysis, a novel approach to solving these types of multi-physics, multi-scale problems.

LOCA RIMM RISMC RELAP-7↗
DOE OSTI2019

Multi-scale processes driving tropical convection and influence of the aerosol (Final Technical Report)

This DOE GoAmazon collaborative project between scientists in the US and Brazil addresses fundamental processes that drive tropical deep convection including aerosol effects. The results provide guidance for improving the parameterizations of cloud and aerosol effects by increasing the knowledge of processes at work in tropical convection, especially over tropical land. Highlights include: • GoAmazon2014/5 observations permitted, for the first time, a comprehensive evaluation of the strong relationship between lower free tropospheric moisture and deep convective onset over the Amazon (Schiro et al. 2016, JAS; Schiro et al. 2018b, PNAS; Chakraborty et al. 2018, ACP; Schiro and Neelin 2018c). A set of diagnostics for deep convective onset has been established using data from the GoAmazon2014/5 campaign (Schiro et al. 2016, JAS), highlighting similarities and differences between the convective transition statistics over tropical land versus corresponding statistics from ARM campaigns in the tropical Western Pacific. The initial set of diagnostics has been provided as a module to be incorporated into the ARM Diagnostics Package of Shaocheng Xie and coworkers, which is being integrated into the PCMDI and E3SM diagnostics packages. Additionally, a set of downdraft diagnostics to inform model parameterizations has been developed (Schiro and Neelin 2018a, ACP). • These diagnostics have been used in constraining the behavior of modeled convective parameterizations. This includes using them with parameter perturbation experiments in the Community Earth System Model to show which parameter ranges are consistent with observed onset statistics, and to show that the primary causal direction of the water vapor-precipitation relationship is via the impact of mixing processes and free tropospheric moisture on convection (Kuo et al. 2017, JAS). Lintner et al. (2017, GRL) used this impact of free tropospheric moisture to systematically analyze issues in the simulation of Amazon rainfall in the CMIP5 model ensemble. • Leveraging the multi-instrument GoAmazon observations, Schiro et al. (2018, PNAS) are able to provide for the first time an empirical mixing using radar wind profiler data that provides a good predictor of precipitation for both mesoscale convective systems and smaller-scale convection. In addition, buoyancy estimated from these results is a good predictor of precipitation across the seasonal and diurnal cycles (Schiro and Neelin 2018c, JAS) and permits the effects of aerosols to be distinguished from those of the thermodynamic environment in the transition to deep convection (Chakraborty et al. 2018, ACP). • Placing the GoAmazon campaign in a larger context, in collaboration with U. São Paulo investigators, Rehbein et al. (2018) analyzed the characteristics of the mesoscale convective systems (MCS) that affect Amazon rainfall, including origins, lifetimes, propagation speed and displacement. de Barros Soares et al. (2017) establish statistically significant observed warming trends over much of South America and are able to attribute the origin of this to anthropogenic forcing based on the agreement of climate model simulations with and without anthropogenic forcings. This analysis left open the attribution of precipitation trends due to large natural variability. Barkhardorian et al. (2018) provide evidence indicating that the observed regional precipitation decrease and drying during recent over northern South America during recent austral springs will continue and intensify in the course of unfolding anthropogenic climate change.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2016

Grizzly: A Multi-scale and Multi-Physics Tool to Model Aging of Nuclear Power Plant Components

Grizzly is a multi-scale multi-physics tool being developed at Idaho National Laboratory (INL) as part of the US Department of Energy's Light Water Reactor Sustainability program to provide improved safety assessments of systems, components, and structures in nuclear power plants subjected to age-related degradation. Its goal is to provide an improved scientific basis for decisions surrounding license renewal, which would permit operation of commercial nuclear power plants beyond 60 years. Grizzly is based on INL's MOOSE framework, which enables multi-physics simulations in a massively parallel computing environment. The reactor pressure vessel (RPV) has been chosen as the initial application for Grizzly. The primary concern for the RPV is that it becomes increasingly susceptible to fracture initiation at the sites of pre-existing flaws over time. This is because exposure to irradiation and high temperatures embrittles the steel. Assessing the safety of an RPV under transient conditions involves simulations at multiple scales. At the engineering scale, strongly coupled equations of heat conduction and solid mechanics are solved to simulate the global response of the RPV to accident conditions. Sub-models are used to represent regions with pre-existing flaws and the stress intensity factors are evaluated from the domain integrals. Crack propagation is then determined using a model that provides the temperature and neutron fluence dependent fracture toughness of the RPV steel. The ability of Grizzly to provide accurate engineering scale estimates of RPV safety beyond 60 years of operation strongly relies on the predictability of the embrittlement model. Multiple models for embrittlement have been proposed, and the physically based empirical model is implemented in Grizzly. However, the formation of late blooming phases greatly reduces the confidence on the extrapolated values obtained from embrittlement model, which is further exacerbated by the absence of real field data for validation. Experimentally validated lower length scale models can significantly improve the predictability of the embrittlement model beyond the calibrated range and the development of such models is another ongoing effort in Grizzly. The modeling activity in Grizzly spans across different length scales, and can be divided into: (i) Irradiation induced microstructure evolution at the atomistic and single crystal length scale using molecular dynamics, atomistic kinetic Monte-Carlo, phase-field and rate theory; (ii) Effect of the irradiation induced defects on the flow stress and fracture processes at the polycrystalline scale using crystal plasticity. Subsequently, the prediction from these models can be used to obtain irradiation induced ductile-to-brittle transition temperature (DBTT) shifts from specimen-scale simulations; (iii) Global thermo-mechanical response of the RPV under normal and accident scenarios, and probabilistic risk analyses at the engineering scale using the DBTT shifts obtained from the lower length scale models. The item (i) has been discussed in a previous report. In this extended abstract an overview of items (ii) and (iii) is provided. The extended abstract summarizes the current status of the modeling effort under Grizzly. At the engineering scale, reduced order model development is underway using the statistical tool RAVEN. This will allow probabilistic analysis considering a wide range of flaw topologies in a computationally efficient manner. Coupling the irradiation induced defect growth predictions to crystal plasticity is also in progress. (authors)

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2016

Multiscale Modeling of Accident Tolerant Fuels under the NEAMS ATF Program

The U.S. Department of Energy's Nuclear Energy Advanced Modeling and Simulation (NEAMS) program has been developing computational analysis tools for nuclear fuel simulation. These codes include BISON and Marmot for investigation of fuel behavior at the continuum and microstructural scales, respectively. In 2014, NEAMS introduced what it calls High Impact Problems (HIPs) into its development plan. These HIPs are intended to make significant advancements in a particular area of nuclear power research in a short period of time (3 years or less). NEAMS has chosen an accident tolerant fuel (ATF) project, which emphasizes utilizing BISON and Marmot to model proposed materials, as its first HIP. Since the events that occurred at the Fukushima-Daiichi nuclear power plant in 2011, the U.S. Department of Energy's Office of Nuclear Energy accelerated research in nuclear fuel concepts with enhanced accident tolerance as part of its Fuel Cycle Research and Development (FCRD) Advanced Fuels Campaign (AFC). Accident tolerant fuels are expected to perform at least as well as conventional fuel during normal conditions and provide significantly increased response time in the event of an accident. Given the many unknowns associated with proposed ATF concepts, the research and development being undertaken by AFC in this area is a challenge, particularly considering the desire to have a lead test rod or assembly in a commercial plant by 2022. With the AFC as its primary stakeholder, the NEAMS ATF HIP is developing material models (using a multi-scale approach) for multiple candidate materials. Through a variety of analyses employing these models, the ATF HIP is providing insight and support to the AFC as it strives to understand these materials and prioritize further development. Use of computational tools such as BISON and Marmot are a vital component of the AFC's strategy since experimental data will not be available broadly and quickly enough to understand the proposed materials fully by the time the AFC must make further development decisions. This summary reviews the overall approach of the NEAMS ATF HIP. First, we give an overview of the current materials chosen for investigation. We also review the overall multi-scale approach to model development. We briefly review the work underway at multiple national laboratories to develop mechanistic engineering scale models based on lower length scale insight. Note that coordinated work is also underway at multiple universities, but those efforts are not detailed here. The NEAMS ATF HIP is assisting the AFC in assessing two accident tolerant materials, uranium silicide fuel and FeCrAl cladding. A multi-scale material model development approach is being undertaken to formulate the models necessary to investigate the materials over a range of normal and off-normal scenarios. This approach includes molecular dynamics, density functional theory, mesoscale modeling, and engineering scale modeling. Sensitivity studies are underway to understand the most critical scenarios and material model input parameters. The information generated is being given to the AFC for their use in selecting promising ATF concepts. (authors)

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2017

Fragmentation Prediction for a Brittle Ceramic: An Integrated Two-Scale Model Approach

A new implementation of a multi-scale fragmentation model is introduced that combines existing independent macro and micro-scale models into a single material model within the Library of Advanced Materials for Engineering (LAME) that can be used directly by the finite element structural mechanics code SIERRA/SM, developed at Sandia National Laboratories. The implementation not only joins existing independent fragmentation models into a single framework, but also enables further development by virtue of being integrated into SIERRA/SM. Integration with a finite element structural mechanics code for a true two-way coupling of the fragmentation models that were previously independent. Hereafter, the prior implementation will be referred to as the sequentially applied fragmentation model. In contrast, the newly developed model will be called the integrated two-scale model. The sequentially applied fragmentation model consists of two independent models applied sequentially to account for the macro-scale and microscale fragmentation. The macro-scale fragmentation behavior is calculated using an elastic gradient damage explicit material model developed to model fracture in brittle materials. The micro-scale fragmentation model is an implementation of the 1D cohesive-zone model developed by Zhou, et al. The micro-scale model is implemented by post-processing the macro-scale data that provides initial conditions for the 1D analysis. The micro-scale model is necessary to predict the resulting fragment size distribution at length scales inaccessible to the finite element based macro-scale model. The full range of fragmentation behavior is then predicted by combining the results from the two independent models. The sequentially applied fragmentation model was used to predict the fragments that result from impact loading of a brittle material, which in that case was a ceramic cylinder of commercial UO{sub 2} nuclear fuel. Understanding the fragmentation behavior of such materials is important for evaluating the risk of airborne particulate release under impact loading scenarios. This work will verify the implementation of the integrated two-scale model using the same experiment modeled by the existing sequentially applied model. The purpose of this manuscript is to introduce the new integrated two-scale fragmentation model and validate the implementation against the existing sequentially applied model for a specific case of impact loading of a brittle material. This validation case will not fully utilize the benefits of having the model integrated into the finite element code as a material model. Rather, this study will demonstrate consistency between the two fragmentation models to ensure that the success of the sequentially applied model will be duplicated by the integrated two-scale approach. Once validated, further development of the model can be made by utilizing the integration into the finite element code to create a fully two-way coupled fragmentation model that will be extended to include higher fidelity models.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2024

Systems Level Fuel Cycle Modeling in TMAP8 - A Demonstration

The tritium migration analysis program (TMAP) has been used for tritium inventory tracking and analysis for several years, and the Multiphysics Object Oriented Simulation Environment (MOOSE)-based TMAP8 has several improvements over TMAP4 and TMAP7, such as support for multiple dimensions and non-cartesian coordinate systems, as well as interoperability with sub-apps at higher and lower length scales. We demonstrate that TMAP8 has the additional capacity to solve systems-level problems using zero-dimensional ordinary differential equations by reproducing a literature model which describes a systems-level fuel-cycle of tritium inventory in a hypothetical fusion power plant. The capacity to run several coupled multi-scale physics calculations as part of a single package will be necessary for accurate blanket and fuel-cycle design.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2026

Surface heterogeneity propagation and homogenization for pouch cell-scale Li metal anodes

Li metal anode is a promising candidate for next-generation energy storage systems and is widely explored in Li-ion and solid-state batteries. Despite its potential, Li metal anodes face instabilities during long-term cycling, especially when paired with NMC or sulfur-based cathodes, where Li is cycled at high capacities of 6-8 mAh/cm2, equivalent to a thickness of 30-40 µm. During such extensive utilization, degradation mechanisms such as excessive solid electrolyte interphase (SEI), dendrites, and dead Li emerge, and ultimately lead to sudden failure and reduced cycle life. The origin of the degradation mechanisms stem from surface heterogeneities introduced during Li foil manufacturing and storage [1, 2]. As cycling progresses, the local heterogeneities propagate, resulting in uneven Li utilization and degradation-prone regions across the electrode [3], which consequently induce performance variations at the cell level. This heterogeneity propagation is particularly pronounced in large-format pouch cells in practical applications, where the surface effects are magnified. Without a clear understanding of the multi-scale heterogeneities and the development of surface homogenization methods, the performance consistency will be compromised, hindering the commercialization of Li metal batteries. In this presentation, we investigate the evolution of surface heterogeneity propagation on commercially available Li foils. We discover that inhomogeneous Li utilization appears as early as the first half-cycle of formation, manifesting as localized clusters and pits. In pouch cell configurations, these features exhibit areal density variations across the electrode on a scale of millimeters. To improve Li utilization homogeneity, a scalable mechanical brushing method is introduced to remove the chemically heterogeneous surface passivation layer. Furtherore, the influence of utilization homogeneity on cell-to-cell consistency is evaluated using 32 Li-NMC811 pouch cells divided into as-received and brushed Li groups. On the brushed Li, clusters and pits are no longer observable, and the cells exhibit significantly improved consistency in discharge capacity trajectories and cycle lifetime. Overall, this study highlights the role of Li surface utilization homogeneity on long-term cycling performance. Our research provides a pathway for improving large-area electrode uniformity and establishing evaluation methods for cell-to-cell consistency, both are key steps toward the commercialization of Li metal batteries and beyond. [1] Otto, Svenja-K., et al. "In-depth characterization of lithium-metal surfaces with XPS and ToF-SIMS: toward better understanding of the passivation layer." Chemistry of Materials 33.3 (2021): 859-867. [2] Hatzell, Kelsey, et al. "Aligning lithium metal battery research and development across academia and industry." Joule (2024). [3] Kim, Sangwook, et al. "Calendar life of lithium metal batteries: Accelerated aging and failure analysis." Energy Storage Materials 65 (2024): 103147.

25 - ENERGY STORAGE↗