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At least 451 records · Page 25

Characterizing Pore-Scale Geochemical Alterations in Eagle Ford and Barnett Shale from Exposure to Hydraulic Fracturing Fluid and CO 2 /H 2 O

As demand increases for an affordable energy source that is tied to an environmental obligation to reduce greenhouse gas emissions and water usage, there is a growing consideration in shale production utilizing processes such as 1) enhancing hydrocarbon recovery via carbon dioxide (CO 2 ) flooding, 2) using CO 2 as a fracturing agent to minimize water use, and 3) storing CO 2 in depleted shale formations to mitigate emissions to the atmosphere. Understanding the geochemical reactions and alterations that occur as shale is exposed to fluids and CO 2 is necessary to develop and optimize each of these processes for field applications. While the majority of shale formations are stimulated using traditional fracturing fluid, some may be fractured using CO 2 or other non-traditional means. We examine the effect fracturing fluid has on shale and how it behaves with secondary exposure to dry CO 2 or CO 2 -saturated water using in situ Fourier Transform infrared spectroscopy (FTIR), feature relocation scanning electron microscopy (SEM), and surface area and pore size analysis using volumetric gas sorption. These techniques were performed on Eagle Ford and Barnett shale samples that were exposed to fracturing fluid and unexposed (as received). Shales that have been exposed to traditional fracturing fluid experienced two reaction fronts. The first reaction front was formed during exposure to the fracturing fluid (pH of ~1.4). A secondary reaction front was formed as a result of CO 2 -saturated fluid exposure in the form of carbonic acid (pH ~5.6). These two different reaction mechanisms drove multiple dissolution and precipitation cycles which altered petrophysical properties of the shale and could lead to a significant impact on flow pathways. FTIR showed that equilibration of carbonate dissolution and precipitation cycles could take as long as 35 days. Samples exposed to fracturing fluid showed significantly less carbonate reactivity compared to those exposed to water. Pore size analysis results indicate exposure to fracturing fluid blocked small nanopores (10-15 nm) reducing BET surface area and total pore volume. SEM results show barite precipitated heavily during exposure to fracturing fluid. It appeared that carbonic acid was able to extract sulfur from organic matter to form gypsum evaporites. The mineralogical (barite precipitation and calcite dissolution/precipitation) and pore-scale alterations observed in these samples may lead to enhancement of flow pathways for injected CO 2 or produced hydrocarbons.

04 OIL SHALES AND TAR SANDS↗

Modeling and Experimental Validation of a Direct-Contact Counter-Flow Fluidized Bed Heat Exchanger for Thermal Energy Storage (TES) Applications

Particle-based thermal energy storage (TES) systems are an emerging energy storage technology. The technological advances have reduced costs, making TES more competitive and reliable in the marketplace but an efficient and reliable operation is heavily dependent on coherent heat transfer between air to particles or vice versa. The particle-based TES technologies provide an intermediate system that can store energy for short (0-10 h), long (10-200 h) and seasonal (> 200 h) timescales. The TES systems store energy by converting electricity to thermal energy; electricity can be directly sourced intermittent generation technologies and/or the grid, helping manage peak loads and other mismatches in supply and demand. The overall efficiency of the TES system depends on the performance of system components (particle storage silos and particle transfer mechanism etc.). The particle heat exchanger is one of the key system components that affects the system efficiency. The pressurized fluidized bed heat exchanger (PFB HX) performance is challenging to predict due to the chaotic behavior of particle and fluid interaction. This research presents a computational study of a novel direct-contact, counter-flow and air-to-particles PFB HX, that contributes in advancing the particle-based long-duration TES technologies. For the current analysis an unsteady Eulerian-Eulerian CFD model was developed and validated against experiments performed at the National Laboratory of the Rockies for two particle sizes (600 ..mu..m and 825 ..mu..m ). Following validation, parametric simulations were conducted to evaluate the effects of interphase drag models (Syamlal-O'Brien and Gidaspow), particle size, bed height and the influence of a frictional-viscosity term on hydrodynamics and heat transfer between the air & particles. The key findings from the analysis are: (1) for the studied operating window Syamlal-O'Brien provides superior agreement with measured gas temperatures (errors generally < 10%) while Gidaspow shows large deviations for the coarse particle case; (2) model predictions are most sensitive in the lower 0.2 m above the air distributor where bubble initiation and local mixing dominate interphase heat transfer; (3) representation of the distributor (number of inlet ports) materially affects predicted local mixing and temperature stratification; and (4) the Eulerian-Eulerian framework reproduces bulk thermal trends but shows regime dependent limitations for coarse particles, motivating mesoscale informed closures for scale-up analysis for future studies. These results provide validated guidance for drag selection and distributor design in particle-based thermal energy storage applications. Collectively, the validated model and parametric results quantify key drivers of PHB-HX performance and provide practical guidance for design and optimization. The results provide confidence in the model predictability and provide a step forward to improve on heat exchange performance. The demonstrated performance and modeling approach support the deployment and further development of this novel PHB-HX concept for robust, particle-based long-duration thermal energy storage systems.

25 ENERGY STORAGE↗

Evaluation of flow-induced plate deflection for University of Missouri research reactor low-enriched uranium fuel element

The University of Missouri Research Reactor (MURR), located on the campus of the University of Missouri in Columbia, Missouri, is one of the six United States (U.S.) High Performance Research Reactors (USHPRR), including one critical facility, that are actively collaborating with the U.S. Department of Energy (DOE) National Nuclear Security Administration (NNSA) Office of Material Management and Minimization (M3) Reactor Conversion Program to convert from highly enriched uranium (HEU, ≥20 wt% U-235) fuel to low-enriched uranium (LEU, <20 wt% U-235) fuel. A new type of very high-density LEU fuel based on a monolithic alloy of uranium and 10 wt% molybdenum (U-10Mo) is expected to allow conversion of some USHPRR, including MURR. In the design of its fuel elements, MURR is using thin parallel curved fuel plates separated by coolant channels. In this work, fluid-structure interaction (FSI) analysis of the MURR LEU fuel element is performed at the element level (as compared to the plate level analysis), which models all components of the LEU fuel element, including fuel plates and the supporting structures. Therefore, the effect of supporting structures on the flow distribution within the element and the fuel plate deflection are evaluated. In addition to the element nominal flow rate and dimensions, the tolerances in the geometry of the coolant channel and plate thickness, the effect of a comb on plate deflection, and the uncertainty of the flow rate per element are evaluated. For the LEU fuel plates, which are thinner than the current HEU plates, the predicted plate deflection is found to be small compared to the fabrication and assembly tolerances. Thus, the FSI-induced deflections are not expected to noticeably reduce the coolant flow rate or predicted safety margins in the limiting channels for the MURR LEU fuel element. In addition to the simulation work, a hydraulic performance test of the MURR LEU fuel element is currently being planned to support conversion to the use of LEU fuel.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Enhanced pool boiling heat transfer with metal foam tubes in inline tube bundle configuration

Flooded evaporators, commonly known as shell-and-tube heat exchangers, are widely used in large-scale industrial refrigeration and air-conditioning systems due to their high pool boiling heat transfer efficiency. However, their bulky configuration requires a large refrigerant inventory, which poses safety challenges—particularly when employing next-generation A2L refrigerants that are mildly flammable. Here, to address this issue, the development of compact heat exchangers with enhanced heat transfer performance is essential. In this study, a novel metal foam tube design is proposed to augment pool boiling heat transfer. Experiments were conducted at a saturation temperature of 20 °C and across a heat flux range of 7–60 kW m −2 . The tests were conducted for both smooth and metal foam tubes with an inline tube bundle configuration and for a pitch–to–diameter (P/D) ratios of 1.3 and 1.5. Pool boiling performance was evaluated for next-generation hydrofluoroolefin (HFO) refrigerants, R1234yf and R1234ze(E), with R134a serving as the baseline fluid. The results indicate that the heat transfer coefficient (HTC) of R1234yf is comparable to R134a, while R1234ze(E) shows slightly lower performance. Importantly, the metal foam tubes achieved up to a 217% enhancement in HTC compared to smooth tubes.

Metal foam tubes↗

Initial study on cross-section generation requirements for a PBR equilibrium core

A Serpent model of the equilibrium core HTR-PM small modular nuclear reactor in China, was developed for use in cross-section preparation studies in order to guide methods development for the Griffin reactor multiphysics application. The model includes detailed isotopics for 10 distinct pebble burnup groups in 126 core zones with unique fuel and moderator temperatures obtained from a coupled neutronics-thermal-fluids equilibrium core calculation using Griffin-Pronghorn. A sensitivity study of the fuel and moderator temperatures for various core regions was performed with the MOOSE stochastic tools. The results show that the uncertainties are, not unexpectedly, dominated by the value of the fluid temperature and that the power level, heat transfer coefficient and effective conduction to neighboring pebbles and fluid constitute, at best, second order effects. The temperature uncertainty range varies from 28 K to 57 K between the core entry and exit planes, respectively, but these values are probably higher. We still have to quantify the significance of these uncertainties in the preparation of cross-sections in future work. In addition, we verified that the effective pebble approximation used in the PEBBED and V.S.O.P. computer codes works well for the preparation of region averaged cross-sections. Nevertheless, there are some discrepancies in the cross-sections when compared to the multi-pebble model, which could affect the prediction of peak values and the depletion calculation. We conclude that is highly desirable for future studies with Griffin to be able to handle both the 'effective' pebble approximation and the multi-pebble approach for various pebble burnup groups. This enables Griffin users with the flexibility to perform higher-fidelity studies. Finally, we initiated the preparation of cross-sections for various core regions from the full core Serpent reference model. We quantified the differences in 26 group cross-sections from infinite domain models versus the full core approach. These reference cross-sections will serve to verify the double heterogeneity, self-shielding, and spectrum-correction methods in Griffin. (authors)

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

Film Cooling Performance Predictions For Air And Supercritical CO 2

The current study explores the possibility of cooling the vanes and blades of a direct-fired sCO 2 turbine using film cooling geometries. The operating conditions of a direct-fired sCO 2 cycle and thermophysical properties of the fluid at those conditions can alter the flow field characteristics of the coolant jet and its mixing with the mainstream. Very little information is present in the literature regarding the performance of film cooling geometries employing a supercritical fluid. The objective of this study is to estimate the resulting film cooling effectiveness while also capturing the effects of the crossflow-to-mainstream velocity ratio on the coolant jet. A computational fluid dynamic model is used to study the coolant jet exiting a cylindrical hole located on a flat plate, with the coolant fed by an internal channel. Steady-state RANS equations were solved along with the SST kω model to provide the turbulence closure. The operating conditions for the direct-fired sCO 2 turbine are obtained using an in-house Cooled Turbine Model. Numerical predictions revealed that the crossflow effects and jet lift-off were more pronounced in the case of sCO 2 when compared to air. Spatial distribution of flow field and cooling effectiveness will be presented at different operating conditions. Recommendations for future studies will be given wherever applicable.

42 ENGINEERING↗

Influence of extreme fracture flow channels on the thermal performance of open-loop geothermal systems at commercial scale

Abstract Adequate stewardship of geothermal resources requires accurate forecasting of long-term thermal performance. In enhanced geothermal systems and other fracture-dominated reservoirs, predictive models commonly assume constant-aperture fractures, although spatial variations in aperture can greatly affect reservoir permeability, fluid flow distribution, and heat transport. Whereas previous authors have investigated the effects of theoretical random aperture distributions on thermal performance, here we further explore the influence of permeability heterogeneity considering field-constrained aperture distributions from a meso-scale field site in northern New York, USA. Using numerical models of coupled fluid flow and heat transport, we conduct thermal–hydraulic simulations for a hypothetical reservoir consisting of a relatively impervious porous matrix and a single, horizontal fracture. Our results indicate that in highly channelized fields, most well design configurations and operating conditions result in extreme rates of thermal drawdown (e.g., 50% drop in production well temperatures in under 2 years). However, some other scenarios that account for the risks of short-circuiting can potentially enhance heat extraction when mass flow rate is not excessively high, and the direction of geothermal extraction is not aligned with the most permeable features in the reservoir. Through a parametric approach, we illustrate that well separation distance and relative positioning play a major role in the long-term performance of highly channelized fields, and both can be used to help mitigate premature thermal breakthrough.

Rangel-Jurado, Nicolás↗

Coupled Monte Carlo and thermal-hydraulics modeling of a prismatic gas reactor fuel assembly using Cardinal

Cardinal is a MOOSE application that couples OpenMC Monte Carlo transport and NekRS computational fluid dynamics to the MOOSE framework, closing the neutronics and thermal-fluid gaps in conducting tightly-coupled, high-resolution multiscale and multiphysics analyses. By leveraging MOOSE's interfaces for wrapping external codes, Cardinal overcomes many challenges encountered in earlier multiphysics coupling works, such as file-based I/O or overly-restrictive geometry mapping requirements. In this work, we leverage a subset of the multiphysics interfaces in Cardinal to perform coupling of OpenMC neutron transport, MOOSE heat conduction, and THM thermal-fluids for steady-state modeling of a prismatic gas reactor fuel assembly.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

Organic Rankine Cycle Integration and Optimization for High Efficiency CHP Genset Systems (Final Technical Report)

This project successfully advanced the integration of Organic Rankine Cycle (ORC) technology with reciprocating engine–based combined heat and power (CHP) systems to improve electrical efficiency, total CHP efficiency, and grid-responsive operation. Over three budget periods, the work progressed from high-temperature ORC component development and thermodynamic model validation to next-generation system design, working fluid transition, and techno-economic analysis. Key technical accomplishments include development and validation of a thermodynamic model capable of accurately predicting ORC performance across an expanded temperature and pressure envelope; successful identification and validation of low-global-warming-potential (GWP) working fluids—most notably R1233zd(E)—as viable replacements for R245fa; and demonstration of scalable ORC architectures suitable for integration with 1–20 MW class reciprocating engines. These advances enable flexible CHP configurations that can increase electrical output while maintaining high overall utilization of available thermal energy. The project also produced a clean-sheet design for a next-generation ORC system targeting substantially higher power output per unit, supported by detailed component selection, heat exchanger evaluation, and system-level modeling. Techno-economic analyses indicate that ORC-enabled flexible CHP systems can meet or exceed Department of Energy (DOE) efficiency targets while providing value to both facility operators and the electric grid.. Late-stage testing of the largest next-generation ORC prototype identified limitations related to pump net positive suction head (NPSH) requirements and condenser flooding under certain operating conditions. Although these issues constrained full validation of that configuration within the project timeframe, they provided clear and actionable design guidance for future system refinements. Importantly, validated modeling, smaller-scale testing, and working fluid evaluations confirmed the technical viability of the overall approach. In aggregate, this project met its core objectives by establishing validated design tools, de-risking key ORC technologies for CHP applications, and defining a credible pathway toward commercialization of flexible, high-efficiency CHP systems. The results form a strong foundation for continued development and deployment beyond the conclusion of the DOE-funded effort.

20 FOSSIL-FUELED POWER PLANTS↗

Avoiding pitfalls in molecular simulation of vapor sorption: Example of propane and isobutane in metal–organic frameworks for adsorption cooling applications

This study introduces recommendations for conducting molecular simulations of vapor adsorption, with an emphasis on enhancing the accuracy, reproducibility, and comparability of results. The first aspect we address is consistency in the implementation of some details of typical molecular models, including tail corrections and cutoff distances, due to their significant influence on generated data. We highlight the importance of explicitly calculating the saturation pressures at relevant temperatures using methods such as Gibbs ensemble Monte Carlo simulations and illustrate some pitfalls in extrapolating saturation pressures using this method. For grand canonical Monte Carlo (GCMC) simulations, the input fugacity is usually calculated using an equation of state, which often requires the critical parameters of the fluid. We show the importance of using critical parameters derived from the simulation with the same model to ensure internal consistency between the simulated explicit adsorbate phase and the implicit bulk phase in GCMC. We show the advantages of presenting isotherms on a relative pressure scale to facilitate easier comparison among models and with experiment. Extending these guidelines to a practical case study, we evaluate the performance of various isoreticular metal–organic frameworks (MOFs) in adsorption cooling applications. This includes examining the advantages of using propane and isobutane as working fluids and identifying MOFs with a superior performance.

36 MATERIALS SCIENCE↗

Probing interfacial momentum closures in two-phase bubbly flow with machine learning-aided methods

Computational fluid dynamics (CFD) approach has already reached a high level of maturity for single-phase flows, however the development of closure models for two-phase flow requires additional attention. Multiphase CFD (M-CFD) methods resolve the conservation equations for mass, momentum and energy while differing in the approaches and strategies adopted in the physical closure models. The most widely adopted framework for M-CFD is the Eulerian-Eulerian two-fluid approach which assumes that all phases are co-existing inside each computational cell. For each fluid, the full set of conservation equations is solved; therefore, each fluid has a different velocity field. For adiabatic two-phase flow, the mechanisms of the interfacial momentum transfer are modeled by the interfacial forces representing different physical mechanisms. One of the crucial issues in the development and application of two-fluid model is the understanding of the interfacial momentum closures which determines the bubble distribution and migration behaviors. Dedicated experiments are performed to support the physical understanding and drive the closures’ development. However, limitations exist due to the uncertainties in the experimental measurement and the simplified analytical assumptions which have difficulties on representing the complex non-linear flow fields. In this paper, a data-driven approach, Feature Similarity Measurement (FSM), is developed and proposed to resolve the challenges of modeling the interfacial forces closures. Case study is performed with two-phase flow scenarios where the high-fidelity experimental data is available. Within the Eulerian-Eulerian two-fluid framework, only momentum equations for gas and liquid phases are solved and reduced-order interfacial momentum closures are aided with FSM. Predictions of void fraction and velocity fields are analyzed and demonstrate the potential of machine learning-driven interfacial forces closures.

97 MATHEMATICS AND COMPUTING↗

Liquid Piston with Spray Cooling Near-Isothermal Compressor

The goal of this project was to prototype and characterize the performance of a liquid-piston spray-cooled gas compressor. The working principle of the compressor enables optimized high-efficiency operation over a very wide range of operating conditions, unlike conventional compressors that are optimized for a narrow range of operating conditions. The compressor technology is suitable for many applications, such as gas pipeline transport, gas storage, and commercial and residential heat pumps. Both physical testing and computational fluid dynamics (CFD) modeling of the processes using the Oak Ridge National Laboratory high-performance computing center were completed. The experimental and CFD studies focused on a near-isothermal liquid-piston compressor (LPC) that uses propylene glycol to compress CO 2 . The first prototype demonstrated isothermal operation during several sequentially executed cycles of CO 2 compression and raised the temperature of the compressed CO 2 by only 2 K, compared with approximately 6 K when the gas was compressed non-isothermally. Isothermal operation was demonstrated at CO 2 flow rates of up to 2 L/min. The second prototype was designed with two compression chambers to allow continuous flow of high-pressure CO 2 . However, the design of the valve train to direct flow between the compression chambers was not sufficient to allow demonstration of CO 2 compression. Numerical simulations of the LPC in which the compression chamber was filled with propylene glycol injected from the bottom inlet were performed using large eddy simulation (LES) with the wall-adapting local eddy-viscosity subgrid-scale model coupled with the multiphase volume of fluid (VOF) model to simulate the transient interface between gas and liquid and to capture the heat and mass transfers within the compression chamber. In this effort, the effects of boundary conditions applied to the LES-VOF calculations (i.e., no wall, an adiabatic wall, and a wall with a heat flux subscribed) on the overall pressure and temperature of the CO 2 gas as well as the transient evolution of flow and heat transfer within the compression chamber were investigated and are discussed in this report. The LES calculation with no wall showed no dynamical flow patterns, and the volume-averaged temperature of CO 2 increased from 305 to 392.7 K, whereas LES calculations with a constant wall temperature or a wall heat flux had similar increases of CO 2 temperatures. The results of the LES simulation using a wall heat flux showed different stages in the compression process and revealed dynamical formation and interaction of CO 2 gas layers and circulation flow patterns within the chamber that contributed to the overall heat transfer between the solid wall, gas, and liquid surface in the compressor. Though an industrial partnership for commercializing the compressor was not secured, the technology was attractive for an industrial partner to use in two research proposals in response to US Department of Energy funding opportunity announcements.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

Scale-up of microwave-assisted, continuous flow, liquid phase reactors: Application to 5-Hydroxymethylfurfural production

Microwave (MW) technology can be powerful for the electrification and intensification of chemical manufacturing. However, very few examples of scaled MW processes exist. In this work, we build a scaled, MW-assisted, continuous flow reactor for the processing of liquid phase chemistries with specific application to 5-hydroxymethylfurfural (HMF) production. Here, we demonstrate a corresponding computational fluid dynamics model to simulate the reactor’s temperature profile and performance, both of which are in good agreement with experiments. We construct a surrogate model to relate operating parameters to performance for guiding experiments, without demanding simulations, via active learning. Heat recirculation is demonstrated in this scaled reactor, further extending its scale and reducing the energy demand. An HMF yield of ~55 % and a productivity of 0.1 kg/hr, 8x higher than any other reactor, at a flowrate >20x than prior work, are demonstrated while maintaining energy efficiency of >98 %. A basic economic analysis estimates a $1.85/kg cost of HMF from fructose and >60 % reduction in CO 2 emissions than a conventional system without considering the impact of green electricity. We demonstrate that MW technology is well-applied to systems larger than the laboratory scale, and strategies to further reduction in cost and CO 2 are discussed.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

Oxygen enrichment combustion to reduce fossil energy consumption and emissions in hot rolling steel production

The reheating furnace operation in the hot mill is natural gas- and electricity-intensive. Oxygen enrichment combustion for reheating furnaces has been proposed to curb and replace natural gas use. In this study, heat transfer in steel slabs in the combustion environment of a push-type reheating furnace was simulated using a computational fluid dynamics (CFD) model. Two oxygen enrichment methods that optimized for performance were selected— a medium oxygen enrichment (MOE) case and an oxy-fuel (OF) case. A life cycle analysis (LCA) characterized the energy and emission profiles of an integrated iron and steel manufacturing process using the two oxygen enrichment cases for the hot mill. These conditions were evaluated for energy use and carbon intensity and compared with a baseline case. Results show that with oxygen enrichment, natural gas consumption can decrease by 19.6%–26.8%, total energy consumption (natural gas and electricity) can decrease by 15.1%–20.7% in the hot mill. Emissions of greenhouse gases can decrease by 11.1%–15.2% in the two optimized cases with 14%–27% reductions in regulated criteria pollutants (nitrogen oxides, carbon monoxide, particulate matter, volatile organic compounds, black carbon, organic carbon, and volatile organic carbons). There is a tradeoff between reducing natural gas consumption and increasing electricity demand from a life cycle perspective. Although the OF case resulted in higher energy- and emissions-related benefits, the MOE case showed the more desirable heat flux uniformity, which is key to maintaining product quality. The analysis suggests that oxygen enrichment in the reheating furnace process can have a significant impact on hot mill environmental performance and become a contributing factor in transitioning to low-carbon steel manufacturing.

36 MATERIALS SCIENCE↗

Investigation of species-mass diffusion in binary-species boundary layers at high pressure using direct numerical simulations

Here, direct numerical simulations of single-species and binary-species temporal boundary layers at high pressure are performed with special attention to species-mass diffusion. The working fluids are nitrogen or a mixture of nitrogen and methane. Mean profiles and turbulent fluctuations of mass fraction show that their qualitative characteristics are different from those of streamwise velocity and temperature, due to the different boundary conditions. In a wall-parallel plane near the wall, the streamwise velocity and temperature have streaky patterns and the fields are similar. However, the mass fraction field at the same location is different from the streamwise velocity and temperature fields indicating that species-mass diffusion is not similar to the momentum and thermal diffusion. In contrast, at the centre and near the edge of the boundary layer, the mass fraction and temperature fields have almost the same pattern, indicating that the similarity between thermal and species-mass diffusion holds away from the wall. The lack of similarity near the wall is traced to the Soret effect that induces a temperature-gradient-dependent species-mass flux. As a result, a new phenomenon has been identified for a non-isothermal binary-species system – uphill diffusion, which in its classical isothermal definition can only occur for three or more species. A quadrant analysis for the turbulent mass flux reveals that near the wall the Soret effect enhances the negative contributions of the quadrants. Due to the enhancement of the negative contributions, small species-concentration fluid tends to be trapped near the wall.

42 ENGINEERING↗

Understanding the depletion of electrons in dusty plasmas at atmospheric pressure

The nucleation and growth of NPs in the gas phase using atmospheric-pressure plasma systems is an important approach to synthesizing novel dimensionally-controlled materials. In this paper, we investigated the effect of the NPs on a typical type of continuous-flow, substrate-free plasma at atmospheric pressure to understand their potential contribution to electron density changes. A tandem plasma system was set up consisting of one plasma reactor that produced carbonaceous NPs from mixtures of argon and hexane, and another identical plasma reactor where the as-grown particles were injected and non-intrusive electrical and optical measurements were performed. The electron densities obtained from conductivity measurements and a plasma fluid model were found to decrease in the presence of NPs. However, control experiments revealed that the main source of the electron depletion was residual vapor or reaction byproducts in the form of molecular species or nanoclusters and not the particles themselves. These results were validated by constant number Monte Carlo simulations which showed that at the experimentally-measured conditions, the NPs were not of sufficiently high enough concentration to reduce the electron density; however, if molecules or clusters are ionizable, they remain in sufficient concentration to deplete electron densities. Our study shows that at atmospheric pressure, because of their typically larger electron density values, particle-producing plasmas are distinct from those at low pressure, and nanoparticle formation does not have the same impact while molecular-scale species may be a more important consideration.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

Modeling the hydrodynamic impact on the tool influence function during hemispherical subaperture optical polishing

To fabricate high-precision and accurate optics relative to the optical design surface, a high level of deterministic control of material removal (i.e., the tool influence function, TIF) during subaperture tool polishing is required. In this study, a detailed analysis of the pressure distribution, which is a key component of the TIF, has been performed using finite element analysis to couple together solid mechanics and fluid dynamics. Modeling experimental parameters of recently published work reveals that, when considering tool deformation, which in turn influences the fluid film thickness between the tool and workpiece, the effective pressure profile has a flat-top distribution. This flat-top pressure profile differs from the parabolic pressure distributions predicted by Hertzian mechanics. Furthermore, the shear contribution is shown here to be a key contributor to material removal, inducing the removal at the periphery of the contact edge and even outside the generally accepted contact area. Finally, the simulated fluid velocities provide evidence of mixed-mode contact polishing, supporting recent experimental findings that also suggest that onset of hydroplaning contributions lead to material removal drop-off.

36 MATERIALS SCIENCE↗

An Experimental Investigation of Multilayer Flow in a Slide Die Coating Process

Roll-to-roll coating technology has been actively applied not only for conventional film production but also for emerging energy devices such as organic solar cells, organic light emitting diodes, batteries, smart windows, and fuel cells. The devices are multilayer structures requiring several coating and drying steps when implemented in a serial fashion, which increases capital costs and energy consumption. Simultaneous multilayer (ML) coating technologies present an opportunity for cost reductions and improved process efficiency by reducing equipment footprint and the number of process steps. In this talk, we experimentally investigate ML slide die coating flow for the manufacturing of fuel cell membrane electrode assemblies (MEAs). For ML slide coating, understanding fluid properties such as density, surface tension, and viscosity are necessary for stable flows and limiting intermixing of the miscible layers. Here, we utilize a design-of-experiment methodology - Box-Behnken design (BBD) - to correlate ink formulation parameters to fluid properties. Using the ink properties obtained from the BBD, we performed numerical flow simulations to obtain a proper process conditions to guide experimental coating trials. Finally, experimental verification is performed on a ML slide die and a degree of miscibility was observed for various ink formulation conditions.

28 EE - Advanced Manufacturing Office (EE-5A)↗