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DOE OSTI2025

Preliminary modeling of triply periodic minimal surface (TPMS) structures using RELAP5-3D

With the United States Department of Energy (DOE)’s goal of quadrupling the nation’s nuclear energy supply by 2050, and with the Advanced Fuels Campaign pushing for new types of advanced reactor fuels and geometries, the need has arisen for new nuclear fuel designs. One such design is to swap out current nuclear fuel geometries in exchange for another type of geometry, called a Triply Periodic Minimal Surface (TPMS). TPMSs are self-supporting, infinitely repeating lattices—attributes that lend themselves well to additive manufacturing. These surfaces also possess enhanced heat transfer properties thanks to their internal area changes and large surface-area-to-volume ratios. Their drawback, however, is an increased pressure drop. Given the small amount of correlations and data (Reynolds numbers in the 2,000–8,000 range), and the minimal amount of experience so far obtained by modeling TPMS structures using 1D systems codes such as the Reactor Excursion and Leak Analysis Program (RELAP5-3D), further research into this topic was needed. Using data from the University of Wisconsin - Madison (UW), curve fits were created for both a Heat Transfer Coefficient (HTC) correlation and a Darcy friction factor empirical coefficient correlation. The curves’ coefficients and multipliers were then output and utilized in RELAP5-3D models of two upcoming experiments—Flow Loop for INFLUX Pressure drop (FLIP) and Microreactor Agile Non-nuclear Experimental Test (MAGNET)—aimed at increasing the available data for Reynolds numbers to the 16,000–36,000 range for TPMS structures. The models were run under the conditions utilized by a Computational Fluid Dynamics (CFD) analysis performed by another group at Idaho National Laboratory. Only CFD pressure drop values were obtained from the FLIP test, and those values showed that the RELAP5-3D models had a lower rate of pressure increase in comparison to the CFD values. In addition, there seemed to be a vertical shift upward in the pressure drop for both models whenever the TPMS porosity decreased, and the RELAP5-3D models showed a higher vertical shift in comparison to the CFD values. The MAGNET results did not correspond to any CFD or experimental results against which they could be compared, so they were instead compared against the proposed CFD input conditions. These values were then compared with each other to make sure the model seemed to be performing as expected, paving the way for future tests that can be run for the purpose of further analyses and comparisons. The pressure drop increased with temperature and mass flow rate independently. The temperature change would decrease with increasing mass flow rate and temperature, which was just as we expected based on the fact that the lower viscosity and decreased density would result in higher friction and churning losses. The last metric that was assessed was the enthalpy flow change, which increased with increasing mass flow rate and decreasing temperature.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

NASA NTRS2009

Multimodal Friction Ignition Tester

The multimodal friction ignition tester (MFIT) is a testbed for experiments on the thermal and mechanical effects of friction on material specimens in pressurized, oxygen-rich atmospheres. In simplest terms, a test involves recording sensory data while rubbing two specimens against each other at a controlled normal force, with either a random stroke or a sinusoidal stroke having controlled amplitude and frequency. The term multimodal in the full name of the apparatus refers to a capability for imposing any combination of widely ranging values of the atmospheric pressure, atmospheric oxygen content, stroke length, stroke frequency, and normal force. The MFIT was designed especially for studying the tendency toward heating and combustion of nonmetallic composite materials and the fretting of metals subjected to dynamic (vibrational) friction forces in the presence of liquid oxygen or pressurized gaseous oxygen test conditions approximating conditions expected to be encountered in proposed composite material oxygen tanks aboard aircraft and spacecraft in flight. The MFIT includes a stainless-steel pressure vessel capable of retaining the required test atmosphere. Mounted atop the vessel is a pneumatic cylinder containing a piston for exerting the specified normal force between the two specimens. Through a shaft seal, the piston shaft extends downward into the vessel. One of the specimens is mounted on a block, denoted the pressure block, at the lower end of the piston shaft. This specimen is pressed down against the other specimen, which is mounted in a recess in another block, denoted the slip block, that can be moved horizontally but not vertically. The slip block is driven in reciprocating horizontal motion by an electrodynamic vibration exciter outside the pressure vessel. The armature of the electrodynamic exciter is connected to the slip block via a horizontal shaft that extends into the pressure vessel via a second shaft seal. The reciprocating horizontal motion can be chosen to be random with a flat spectrum over the frequency range of 10 Hz to 1 kHz, or to be sinusoidal at any peak-to-peak amplitude up to 0.8 in. (.2 cm) and fixed or varying frequency up to 1 kHz. The temperatures of the specimen and of the vessel are measured by thermocouples. A digital video camera mounted outside the pressure vessel is aimed into the vessel through a sapphire window, with its focus fixed on the interface between the two specimens. A position transducer monitors the displacement of the pneumatic-cylinder shaft. The pressure in the vessel is also monitored. During a test, the output of the video camera, the temperatures, and the pneumatic-shaft displacement are monitored and recorded. The test is continued for a predetermined amount of time (typically, 10 minutes) or until either (1) the output of the position transducer shows a sudden change indicative of degradation of either or both specimens, (2) ignition or another significant reaction is observed, or (3) pressure in the vessel increases beyond a pre-set level that triggers an automatic shutdown.

Davis, Eddie↗

DOE OSTI2023

Large-Eddy Simulation of Flow Over Boeing Gaussian Bump Using Multiagent Reinforcement Learning Wall Model: Preprint

We develop a wall model for large-eddy simulation (LES) that takes into account various pressure-gradient effects using multi-agent reinforcement learning. The model is trained using low-Reynolds-number flow over periodic hills with agents distributed on the wall at various computational grid points. It utilizes a wall eddy-viscosity formulation as the boundary condition to apply the modeled wall shear stress. Each agent receives states based on local instantaneous flow quantities at an off-wall location, computes a reward based on the estimated wall-shear stress, and provides an action to update the wall eddy viscosity at each time step. The trained wall model is validated in wall-modeled LES of flow over periodic hills at higher Reynolds numbers, and the results show the effectiveness of the model on flow with pressure gradients. The analysis of the trained model indicates that the model is capable of distinguishing between the various pressure gradient regimes present in the flow. To further assess the robustness of the developed wall model, simulations of flow over the Boeing Gaussian bump are conducted at a Reynolds number of 2 x 10^6, based on the free-stream velocity and the bump width. The results of mean skin friction and pressure on the bump surface, as well as the velocity statistics of the flow field, are compared to those obtained from equilibrium wall model (EQWM) simulations and published experimental data sets. The developed wall model is found to successfully capture the acceleration and deceleration of the turbulent boundary layer on the bump surface, providing better predictions of skin friction near the bump peak and exhibiting comparable performance to the EQWM with respect to the wall pressure and velocity field. We also conclude that the subgrid-scale model is crucial to the accurate prediction of the flow field, in particular the prediction of separation.

boundary layer↗

NASA NTRS1973

Evaluation of compressible-flow Preston tube calibrations

An experimental and analytical study has been made of the accuracy of various Preston tube calibration equations to determine local skin friction in two-dimensional supersonic and low-hypersonic flows. Experimental Preston tube calibration data from the present and previous studies were used to evaluate the calibration equations. The maximum value of the calibration parameters of the present data is more than an order of magnitude larger than that previously obtained; thereby, the evaluation of the various calibration equations is facilitated. The Preston tube technique was found to be very inaccurate in the low range of the calibration parameters. Above this range, there was a steady increase in accuracy with increasing values of the calibration parameters. No critical maximum tube diameter was found even with tubes about twice as large as the theoretical maximum allowable diameter. Of the two forms of the calibration equation previously existing, the logarithmic laws gave more accurate results than the power laws over an extended range of the calibration parameters in supersonic adiabatic flow.

Allen, J. M.↗

NASA NTRS1979

Preliminary results in the NASA Lewis H2-O2 combustion MHD experiment

MHD (magnetohydrodynamic) power generation experiments were carried out in the NASA Lewis Research Center cesium-seeded H2-O2 combustion facility. This facility uses a neon-cooled cryomagnet capable of producing magnetic fields in excess of 5 tesla. The effects of power takeoff location, generator loading, B-field strength, and electrode breakdown on generator performance are discussed. The experimental data is compared to a theory based on one-dimensional flow with heat transfer, friction, and voltage drops.

Smith, J. M.↗

NASA NTRS1979

Preliminary results in the NASA Lewis H2-O2 combustion MHD experiment

MHD power generation experiments have been carried out in the NASA Lewis Research Center cesium-seeded H2-O2 combustion facility. This facility uses a neon-cooled cryomagnet capable of producing magnetic fields in excess of 5 tesla. The effects of power takeoff location, generator loading, B-field strength, and electrode breakdown on generator performance are discussed. The experimental data is compared to a theory based on one-dimensional flow with heat transfer, friction, and voltage drops.

Smith, J. M.↗

NASA NTRS1984

An analytical method to predict efficiency of aircraft gearboxes

A spur gear efficiency prediction method previously developed by the authors was extended to include power loss of planetary gearsets. A friction coefficient model was developed for MIL-L-7808 oil based on disc machine data. This combined with the recent capability of predicting losses in spur gears of nonstandard proportions allows the calculation of power loss for complete aircraft gearboxes that utilize spur gears. The method was applied to the T56/501 turboprop gearbox and compared with measured test data. Bearing losses were calculated with large scale computer programs. Breakdowns of the gearbox losses point out areas for possible improvement.

Anderson, N. E.↗

NASA NTRS1984

An analytical method to predict efficiency of aircraft gearboxes

Anderson, N. E.↗

NASA NTRS1987

Analysis of viscous transonic flow over airfoil sections

A full Navier-Stokes solver has been used to model transonic flow over three airfoil sections. The method uses a two-dimensional, implicit, conservative finite difference scheme for solving the compressible Navier-Stokes equations. Results are presented as prescribed for the Viscous Transonic Airfoil Workshop to be held at the AIAA 25th Aerospace Sciences Meeting. The NACA 0012, RAE 2822 and Jones airfoils have been investigated for both attached and separated transonic flows. Predictions for pressure distributions, loads, skin friction coefficients, boundary layer displacement thickness and velocity profiles are included and compared with experimental data when possible. Overall, the results are in good agreement with experimental data.

Huff, Dennis L.↗

NASA NTRS1987

Analysis of viscous transonic flow over airfoil sections

Huff, Dennis L.↗

NASA NTRS1988

Compressibility effects on flow friction in a fully developed pipe flow

A method was evolved to account for the effects of compressibility in flows through long circular pipes of uniform diameter. Velocity and density variations across the flow cross section were approximated by profile shapes recommended for a flow past flat plates. The wall of the pipe was assumed to have attained an adiabatic condition. An integral method was used to obtain solutions for the governing equations of flow. The method was then used to analyze the detailed pressure measurements made in a long pipe for flow of air at different flow rate settings. Flow friction values derived from these pressure measurements were compared with the standard incompressible pipe flow data available in existing literature.

Murthy, Sreedhara V.↗

NASA NTRS1991

Three-dimensional viscous flow computations of high area ratio nozzles for hypersonic propulsion

The PARC3D code was selected by the authors to analyze a variety of complex and high-speed flow configurations. Geometries considered for code validation include ramps and corner flows, which are characteristic of inlets and nozzles. Flows with Mach numbers of 3-14 were studied. Both two- and three-dimensional experimental data for shock-boundary-layer interaction were considered to validate the code. A detailed comparison of various flow parameters with available experimental data is presented; agreement between the solutions and the experimental data in terms of pitot pressure profiles, yaw-angle distributions, static pressures, and skin friction is found to be very good. In addition, two- and three-dimensional flow calculations were performed for a hypersonic nozzle. Comparison of the wall pressure results with the published solutions is made for the two-dimensional case.

Reddy, D. R.↗

NASA NTRS1993

A Reynolds stress model for near-wall turbulence

The paper formulates a tensorially consistent near-wall second-order closure model. Redistributive terms in the Reynolds stress equations are modeled by an elliptic relaxation equation in order to represent strongly nonhomogeneous effects produced by the presence of walls; this replaces the quasi-homogeneous algebraic models that are usually employed, and avoids the need for ad hoc damping functions. The model is solved for channel flow and boundary layers with zero and adverse pressure gradients. Good predictions of Reynolds stress components, mean flow, skin friction, and displacement thickness are obtained in various comparisons to experimental and direct numerical simulation data. The model is also applied to a boundary layer flowing along a wall with a 90-deg, constant-radius, convex bend.

Durbin, P. A.↗

NASA NTRS1959

Analysis of Turbulent Flow and Heat Transfer on a Flat Plate at High Mach Numbers with Variable Fluid Properties

A previous analysis of turbulent heat transfer and flow with variable fluid properties in smooth passages is extended to flow over a flat plate at high Mach numbers, and the results are compared with experimental data. Velocity and temperature distributions are calculated for a boundary layer with appreciative effects of frictional heating and external heat transfer. Viscosity and thermal conductivity are assumed to vary as a power or the temperature, while Prandtl number and specific heat are taken as constant. Skin-friction and heat-transfer coefficients are calculated and compared with the incompressible values. The rate of boundary-layer growth is obtained for various Mach numbers.

Deissler, R. G.↗

NASA NTRS1958

Turbulent Skin Friction at High Mach Numbers and Reynolds Numbers

For a number of years now, experimenters have been making measurements of skin friction. Formerly, the main interest was at low Mach numbers; later, measurements were made at supersonic Mach numbers. However, almost all of these measurements were over a limited range of Reynolds numbers. On the other hand, these measurements fairly well determined the effects of Mach number and heat transfer on skin friction. The purpose of this paper is to give the results of skin-friction measurements in turbulent boundary layers at high Mach numbers and high Reynolds numbers where data have not previously existed. The equipment used was expressly designed to provide these conditions. As is well known, it is difficult to obtain high Mach numbers and high Reynolds numbers simultaneously with air in a wind tunnel. In order to avoid condensation, it is necessary to heat the air, with a resulting loss in density and Reynolds number. It is desirable, then, to use a gas that does not condense at high Mach numbers. This suggested helium, which was used as a working fluid in some of the tests. At high Mach numbers in a given wind tunnel, higher Reynolds numbers can be obtained with helium than with air, principally because no heating of the helium is required. The different ratios of specific heats also contribute to the increase. In using helium as a working fluid, it is, of course, necessary to determine the equivalence of air and helium in the turbulent boundary layer.

Matting, Fred W.↗

NASA NTRS2012

Surface and Flow Field Measurements on the FAITH Hill Model

A series of experimental tests, using both qualitative and quantitative techniques, were conducted to characterize both surface and off-surface flow characteristics of an axisymmetric, modified-cosine-shaped, wall-mounted hill named "FAITH" (Fundamental Aero Investigates The Hill). Two separate models were employed: a 6" high, 18" base diameter machined aluminum model that was used for wind tunnel tests and a smaller scale (2" high, 6" base diameter) sintered nylon version that was used in the water channel facility. Wind tunnel and water channel tests were conducted at mean test section speeds of 165 fps (Reynolds Number based on height = 500,000) and 0.1 fps (Reynolds Number of 1000), respectively. The ratio of model height to boundary later height was approximately 3 for both tests. Qualitative techniques that were employed to characterize the complex flow included surface oil flow visualization for the wind tunnel tests, and dye injection for the water channel tests. Quantitative techniques that were employed to characterize the flow included Cobra Probe to determine point-wise steady and unsteady 3D velocities, Particle Image Velocimetry (PIV) to determine 3D velocities and turbulence statistics along specified planes, Pressure Sensitive Paint (PSP) to determine mean surface pressures, and Fringe Imaging Skin Friction (FISF) to determine surface skin friction (magnitude and direction). This initial report summarizes the experimental set-up, techniques used, data acquired and describes some details of the dataset that is being constructed for use by other researchers, especially the CFD community. Subsequent reports will discuss the data and their interpretation in more detail

Bell, James H.↗

NASA NTRS2013

Net Shape Spin Formed Cryogenic Aluminum Lithium Cryogenic Tank Domes for Lower Cost Higher Performance Launch Vehicles

With the goal of lower cost (simplified manufacturing and lower part count) and higher performance (higher strength to weight alloys) the NASA Technical Maturation Program in 2006 funded a proposal to investigate spin forming of space launch vehicle cryogenic tank domes. The project funding continued under the NASA Exploration Technology Development Program through completion in FY12. The first phase of the project involved spin forming of eight, 1 meter diameter "path finder" domes. Half of these were processed using a concave spin form process (MT Aerospace, Augsburg Germany) and the other half using a convex process (Spincraft, Boston MA). The convex process has been used to produce the Ares Common Bulkhead and the concave process has been used to produce dome caps for the Space Shuttle light weight external tank and domes for the NASDA H2. Aluminum Lithium material was chosen because of its higher strength to weight ratio than the Aluminum 2219 baseline. Aluminum lithium, in order to obtain the desired temper (T8), requires a cold stretch after the solution heat treatment and quench. This requirement favors the concave spin form process which was selected for scale up. This paper describes the results of processing four, 5.5 meter diameter (upper stage scale) net shaped spin formed Aluminum Lithium domes. In order to allow scalability beyond the limits of foundry and rolling mills (about 12 foot width) the circular blank contained one friction stir weld (heavy lifter scales require a flat blank containing two welds). Mechanical properties data (tensile, fracture toughness, stress corrosion, and simulated service testing) for the parent metal and weld will also be discussed.

Curreri, Peter A.↗

NASA NTRS1976

Lunar sample analysis

Room temperature internal friction (Q sup-1) values of the 0.00002-0.00003 range were achieved with lunar rock 70215,85 by thorough outgassing procedures in ultrahigh vacuum. Results are presented on the temperature dependence of Q sup -1 as measured in the range 25 C to 600 C along with some data on the change in Q sup -1 with pressure in ultrahigh vacuum. The temperature dependence shows the existence of an internal friction peak at around 200 C followed at high temperatures by an extensive region with flat Q sup -1 (approximately 0.001); the work at ultrahigh vacuum shows decreases in the internal friction with decreases in ambient pressure even in the range 10 to the -8 to 10 to the -10 power torr.

Tittmann, B. R.↗