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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 487 records · Page 27
All sourcesNASA NTRSDOE OSTI
DOE OSTI2020

Changes in water vapor adsorption and water film thickness in clayey materials as a function of relative humidity

Abstract Soil water, with adsorbed water being an important component, plays an important role in fluid flow and chemical movement in the unsaturated zone. The adsorbed water consists of water film and interlayer water, and its content is related to the relative humidity (RH). This study theoretically and experimentally focuses on the variation in adsorbed water content in clayey materials as the RH changes. Based on a slit‐pore model, three types of water (water film, interlayer water, and capillary water) could be present in the water vapor adsorption process. The variation of water film is obtained from the analysis of interfacial forces, and then the total water content can be quantitatively subdivided into these three types of water for different RH values. The slit‐pore adsorption model was used with experimental measurements (water vapor adsorption and N 2 physisorption) to quantify the amounts and interrelationships of these three different types of water to six clayey materials, namely three clay minerals (kaolinite, montmorillonite, and illite–smectite mixed layer) and three clay‐rich sediments from the Jianghan Plain in China. The main results are that (a) the volumes of water vapor adsorption are much greater than those of N 2 adsorption except for kaolinite; (b) interlayer water largely dominates the growth of total water content in montmorillonite and results in a concentration of 0.090 ml g −1 at 95% RH; and (c) the minimum thickness of water film is calculated to be 0.23 nm, and the maximum value is one‐third of the pore width by considering the interfacial forces.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2022

Parameter estimation from spontaneous imbibition into volcanic tuff

Two-phase fluid flow properties underlie quantitative prediction of water and gas movement, but constraining these properties typically requires multiple time-consuming laboratory methods. The estimation of two-phase flow properties (van Genuchten parameters, porosity, and intrinsic permeability) is illustrated in cores of vitric nonwelded volcanic tuff using Bayesian parameter estimation that fits numerical models to observations from spontaneous imbibition experiments. The uniqueness and correlation of the estimated parameters is explored using different modeling assumptions and subsets of the observed data. The resulting estimation process is sensitive to both moisture retention and relative permeability functions, thereby offering a comprehensive method for constraining both functions. The data collected during this relatively simple laboratory experiment, used in conjunction with a numerical model and a global optimizer, result in a viable approach for augmenting more traditional capillary pressure data obtained from hanging water column, membrane plate extractor, or mercury intrusion methods. This method may be useful when imbibition rather than drainage parameters are sought, when larger samples (e.g., including heterogeneity or fractures) need to be tested that cannot be accommodated in more traditional methods, or when in educational laboratory settings.

58 GEOSCIENCES↗
DOE OSTI2023

A data-driven framework for permeability prediction of natural porous rocks via microstructural characterization and pore-scale simulation

Understanding the microstructure–property relationships of porous media is of great practical significance, based on which macroscopic physical properties can be directly derived from measurable microstructural informatics. However, establishing reliable microstructure–property mappings in an explicit manner is difficult, due to the intricacy, stochasticity, and heterogeneity of porous microstructures. In this paper, a data-driven computational framework is presented to investigate the inherent microstructure–permeability linkage for natural porous rocks, where multiple techniques are integrated together, including microscopy imaging, stochastic reconstruction, microstructural characterization, pore-scale simulation, feature selection, and data-driven modeling. A large number of 3D digital rocks with a wide porosity range are acquired from microscopy imaging and stochastic reconstruction techniques. A broad variety of morphological descriptors are used to quantitatively characterize pore microstructures from different perspectives, and they compose the raw feature pool for feature selection. Here high-fidelity lattice Boltzmann simulations are conducted to resolve fluid flow passing through porous media, from which reliable permeability references are obtained. The optimal feature set that best represents permeability is identified through a performance-oriented feature selection process, upon which a cost-effective surrogate model is rapidly fitted to approximate the microstructure-permeability mapping via data-driven modeling. This surrogate model exhibits great advantages over empirical/analytical formulas in terms of prediction accuracy and generalization capacity, which can predict reliable permeability values spanning four orders of magnitude. Besides, feature selection also greatly enhances the interpretability of the data-driven prediction model, from which new insights into the mechanism of how microstructural characteristics determine intrinsic permeability are obtained.

58 GEOSCIENCES↗
DOE OSTI2021

Crystal plasticity model of residual stress in additive manufacturing using the element elimination and reactivation method

Selective laser melting is receiving increasing interest as an additive manufacturing technique. Residual stresses induced by the large temperature gradients and inhomogeneous cooling process can favour the generation of cracks. In this work, a crystal plasticity finite element model is developed to simulate the formation of residual stresses and to understand the correlation between plastic deformation, grain orientation and residual stresses in the additive manufacturing process. The temperature profile and grain structure from thermal-fluid flow and grain growth simulations are implemented into the crystal plasticity model. An element elimination and reactivation method is proposed to model the melting and solidification and to reinitialize state variables, such as the plastic deformation, in the reactivated elements. The accuracy of this method is judged against previous method based on the stiffness degradation of liquid regions by comparing the plastic deformation as a function of time induced by thermal stresses. The method is used to investigate residual stresses parallel and perpendicular to the laser scan direction, and the correlation with the maximum Schmid factor of the grains along those directions. The magnitude of the residual stress can be predicted as a function of the depth, grain orientation and position with respect to the molten pool. The simulation results are directly comparable to X-ray diffraction experiments and stress–strain curves.

316 stainless steel↗
DOE OSTI2023

Using defects as a ‘fossil record’ to help interpret complex processes during additive manufacturing: as applied to raster-scanned electron beam powder bed additively manufactured Ti–6Al–4V

Abstract Defects in parts produced by additive manufacturing, instead of simply being perceived as deleterious, can act as important sources of information associated with the complex physical processes that occur during materials deposition and subsequent thermal cycles. Indeed, they act as materials-state ‘fossil’ records of the dynamic AM process. The approach of using defects as epoch-like records of prior history has been developed while studying additively manufactured Ti–6Al–4V and has given new insights into processes that may otherwise remain either obscured or unquantified. Analogous to ‘epochs,’ the evolution of these defects often is characterized by physics that span across a temporal length scale. To demonstrate this approach, a broad range of analyses including optical and electron microscopy, X-ray computed tomography, energy-dispersive spectroscopy, and electron backscatter diffraction have been used to characterize a raster-scanned electron beam Ti–6Al–4V sample. These analysis techniques provide key characteristics of defects such as their morphology, location within the part, complex compositional fields interacting with the defects, and structures on the free surfaces of defects. Observed defects have been classified as banding, spherical porosity, and lack of fusion. Banding is directly related to preferential evaporation of Al, which has an influence on mechanical properties. Lack-of-fusion defects can be used to understand columnar grain growth, fluid flow of melt pools, humping, and spattering events. Graphical abstract

36 MATERIALS SCIENCE↗
DOE OSTI2021

Propagation of Input Uncertainties in Numerical Simulations of Laser Powder Bed Fusion

Laser powder bed fusion has the potential of redefining state-of-the-art processing and production methods, but defect formation and inconsistent build quality have limited the implementation of this process. Numerical models are widely used to study this process and predict the formation of these defects. Presently, the uncertainties of model input parameters and thermophysical properties used by these numerical simulations have not been investigated. In the present study, the uncertainty in these input parameters and material properties are quantified for laser powder bed fusion, with and without a simulated powder bed, to determine their influence on the predictive accuracy of an experimentally validated numerical model. Accounting for all possible sources of uncertainty quickly becomes computationally expensive on account of the curse of dimensionality. Uncertainty in laser absorption, solid, and liquid specific heat of the metal were found to have the largest effect on model prediction reliability with or without the use of a powder bed. Results also illustrate that accounting for these three uncertain parameters still captures the majority of model prediction uncertainty. Furthermore, the methodology of this study may be used to understand the uncertainty in as-built microstructure through propagation to microstructure prediction models, or applied under processing conditions where high Péclet numbers are observed and the thermal convection and fluid flow within the molten pool are substantial.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2019

Multiscale Modeling of Microstructural Evolution in Fused-Coating Additive Manufacturing

A quantitative phase field model with adaptive-computational-domain-expansion (ACDE) method was developed to simulate the microstructural evolution in fused-coating additive manufacturing process. A heat transfer and fluid flow model was established to investigate the solidification behavior of the molten pool in a single deposited layer. The solidification parameters such as temperature gradient and solidification rate were calculated from the macroscopic model and then fed into the phase field model to get the microstructure at different positions within a single deposited layer. Columnar dendrites were formed at the bottom of the deposited layer, and equiaxed dendrites appeared in the upper part of the layer. The ACDE method is used to improve the simulation efficiency. The metallographic experiments and energy-dispersive spectrometer analysis for composition were conducted on the fused-coating specimen, and the results were in good accordance with the simulations.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Effect of natural fractures on determining closure pressure

Abstract In Utah FORGE reservoir, eight pressure transient tests (microhydraulic fracturing and DFIT™) show natural fracture/pressure-dependent leakoff. This behavior may lead to misinterpretation of the closure pressure (proxy for minimum principal stress). The closure pressures obtained from DFIT™ (or microhydraulic fracturing) testing may reflect shear failure along natural fractures or discontinuities rather than tensile failure and lead to inaccurate estimates of the minimum principal stress. In pressure tests conducted at the Utah FORGE site showed that reactivation or opening of natural fractures intersecting the wellbore and were suggested by multiple closure events in DFIT™ tests. In addition, comparisons between the pre- and post-well-tests FMI logs show that there are populations of induced fracture and reactivated natural fractures which are mostly vertical and sub-vertical. In this study, DFIT™ (or microhydraulic fracturing) test analysis and numerical simulations were used to suggest that hydraulic shearing of critically stressed natural fractures can contribute to multiple closure signatures and possibly lead to incorrect determination of the minimum principal stress. As other authors have previously advocated, the DFIT™ test analyses and numerical simulations suggest that better estimations of minimum principal stress may be derived by injecting at relatively high rate and pressure and insuring that tensile breakdown is reached. In addition, extended shut-in period is required to determine accurate reservoir characteristics and fluid flow regime.

Nadimi, S.↗
DOE OSTI2022

RFB Side Effects - Shunt Currents

The various models related to fluid flow, electrochemistry and shunt current, and their interactions are reviewed, and gaps identified in the development of flow battery holistic models. In a flow battery stack, the cells are electrically connected through the manifolds via the electrolyte. This results in shunt current through the electrolyte, which is a source of loss in the battery stack. This issue is examined in depth with a mathematical method of calculating shunt current distribution, the associated losses, and strategies to mitigate shunt current losses, along with the trade-offs.

Crawford, Aladsair J.↗
DOE OSTI2020

On the competition between mixing rate and uniformity in a coaxial hydrodynamic focusing mixer

Fast microfluidic mixers for use with line-of-sight integrating detection schemes pose unique challenges. Such detectors typically cannot discriminate signal from slow moving (e.g. near internal walls) and fast-moving portions of the fluid stream. This convolves reaction rate dynamics with fluid flow residence time dynamics. Further, the small cross sections of typical three-dimensional hydrodynamic focusing devices lead to lower detection signals. The current study focuses on achieving both small time scales of mixing and homogenous residence times. This is achieved by injecting sample through a center capillary and hydrodynamically focusing using a sheath flow within a tapered second capillary. The current design also features a third, larger coaxial capillary. The mixed stream flows into the large cross-section of this third capillary to decelerate and expand the stream by up to 14-fold to improve line-of-sight signal strength of reaction products. Hydrodynamic focusing, mixing, and expansion are studied using analytical and numerical models and also studied experimentally using a fluorescein-iodide quenching reaction. The experimentally validated models are used to explore trade-offs between mixing rate and uniformity. For the first time, this work presents detailed analysis of the Lagrangian time history of species transport during mixing inside coaxial capillaries to measure mixing nonuniformity. The mixing region enables order 100 μs mixing times and residence time widths of the same order (140 μs).

42 ENGINEERING↗
DOE OSTI2025

Experimental investigation on phase change material–based finned tube heat exchanger for thermal energy storage and building envelope thermal management

Phase change materials (PCMs) are attractive solutions for thermal energy storage (TES) applications by absorbing and releasing large amounts of latent heat during solid–liquid phase transitions. However, their relatively low thermal conductivity requires novel heat exchanger–based solutions to improve the power density and overall energy storage efficiency of the TES system. This work presents the design and experimental results of a finned tube heat exchanger to store collected natural thermal energy from a building envelope in a latent-based TES and to release it later for building heating/cooling applications. We experimentally evaluate the finned tube heat exchanger and evaluate the performance of TES in reducing building heating and cooling loads over 3–4 h of desired time of operation (e.g., peak load). The optimized design allows for maximum energy density by minimizing the heat exchanger volume, and the system is evaluated experimentally using commercially available heat exchanger materials and an organic PCM. Here, the experimental results reveal that the TES system is able to charge and discharge stored latent energy within 3–4 h, matching peak building electricity demand duration under an average fluid flow rate of 0.136 kg/s and temperature difference of 5.55 °C. Importantly, such optimized designs illuminate a path toward TES designs that are low-cost, scalable, and optimized for thermal energy and power availability under the desired time of operation.

25 ENERGY STORAGE↗
DOE OSTI2022

Application of reference-free natural background–oriented schlieren photography for visualizing leakage sites in building walls

Air leakage in buildings can cause health and comfort concerns for occupants and can contribute to mold growth on building materials, or in extreme conditions, rot of building materials. Unwanted air leakage through the building envelope also contributes to approximately 4 quadrillion Btu (1172 TWh) of energy consumption per year in the building sector in the United States. Locating and sealing leakage sites can improve the energy efficiency, comfort, air quality, and moisture durability of the building stock. Typical methods of finding leakage sites, such as infrared imaging and smoke tracing, rely on concurrent blower door operation, which can also measure the total leakage rate of the building. Smoke tracing can be disruptive to occupants, and infrared imaging and smoke tracing cannot measure the contribution of individual leaks to prioritize sealing efforts. Here, an optical fluid flow imaging technique, reference-free natural background–oriented schlieren imaging, was adapted to visualize air exfiltration. This is the first step in developing a method to noninvasively locate and measure exfiltration or infiltration sites so that sealing efforts can be prioritized. Experimental results of this technique are presented, demonstrating the method's applicability to visualizing exfiltration through three common building claddings in an outdoor environment. Key variables impacting the performance of this technique when applied to building leakage are also discussed.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2021

Process intensification of CO 2 capture by low-aqueous solvent

Low-energy solvent-based CO 2 absorption processes have drawn attention as a next-generation post-combustion CO 2 capture technology to reduce CO2 emissions from fossil fuel– or biomass-fired power generation and industrial flue gas streams. A low-aqueous (or water-lean) solvent process may substantially reduce the thermal energy consumption for solvent regeneration. Low-aqueous solvent–based processes are thermally sensitive, requiring a delicate temperature control within the absorber because of the fast exothermic amine-CO 2 reaction and low heat capacity organic diluent. This reaction may result in heat accumulation in a packed absorption column and undesirable CO 2 desorption occurring as the solvent moves through the column, reducing the solvent’s CO 2 capture efficiency if its temperature is not controlled. Using a 3D printed intensified packing device, enhanced heat and mass transfer were demonstrated in an amine-CO 2 scrubbing process using low-aqueous solvent. The multifunctional intensified device facilitates contact of the reactive solvent and gas phases in a single stage and heat removal by a cooling fluid flowing through channels in the interior of the corrugated plates of the device. These functionalities led to effective thermal management along the column via intrastage cooling and significant improvement in CO 2 uptake under a wide range of operating conditions. Intrastage cooling effectively reduced the solvent average temperature along the column by ~10 °C and, as a result, the solvent’s capture efficiency improved by up to 25%.

42 ENGINEERING↗
DOE OSTI2021

A dissolution model of alite coupling surface topography and ions transport under different hydrodynamics conditions at microscale

Portland cement is the most produced material in the world. The hydration process of cement consists of a group of complex chemical reactions. In order to investigate the mechanism of cement hydration, it is vital to study the hydration of each phase separately. An integrated model is proposed in this paper to simulate the dissolution of alite under different hydrodynamic conditions at microscale, coupling Kinetic Monte Carlo model (KMC), Lattice Boltzmann method (LBM) and diffusion boundary layer (DBL). The dissolution of alite is initialised with KMC. Two Multiple-relaxation-time (MRT) LB models are used to simulate the fluid flow and transport of ions, respectively. For solid-liquid interface, DBL is adapted to calculate the concentration gradient and dissolution flux. The model is validated with experiment from literature. The simulation results show good agreements with the results published in the literature.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Anisotropic elastoplastic response of double-porosity media

Here we present a continuum framework to simulate fluid flow through anisotropic elastoplastic media with double porosity. Two effective stress measures σ' and δ" emerge from the thermodynamic formulation, which are energy-conjugate to the elastic and plastic components of strain, respectively. Both effective stress measures can be expressed as a combination of the total Cauchy stress σ and the average pore pressure $\bar{p}$ in the two pore scales. In the effective stress for elasticity, $\bar{p}$ is scaled with a rank-2 Biot tensor, whereas the effective stress for plasticity follows the Terzaghi form in which $\bar{p}$ is scaled by the Kronecker delta. The Biot tensor and storage coefficients are derived as functions of elasticity parameters and porosities. A mixed finite element formulation is introduced to discretize the domain and solve initial boundary-value problems. A stabilization scheme is employed on equal-order interpolation for both displacement and pressure fields throughout the entire range of drainage responses. Numerical simulations reproduce the hydromechanical response of Opalinus shale in one-dimensional consolidation tests throughout the range of primary and secondary consolidation under different external loads. Numerical simulations of the consolidation of a rectangular domain subjected to a strip load demonstrate the efficacy of the proposed stabilization scheme, as well as illustrate the impacts of stress history, mass transfer, and different pore systems on the hydromechanical response.

42 ENGINEERING↗
DOE OSTI2021

Phase field benchmark problems for nucleation

In this work, we present nucleation phase field model benchmark problems, expanding on our previous benchmark problems on diffusion, precipitation, dendritic growth, linear elasticity, fluid flow and electrochemistry. Nucleation is the process in which either a new thermodynamic phase or a new structure is created, such as solidification from the melt, or self-assembly of particulates. Based on where the nucleation occurs, it can be divided into two main categories: homogeneous nucleation and heterogeneous nucleation. In the first nucleation benchmark problem, we focus on homogeneous nucleation for both single seed under different initial conditions and multiple seeds. The second nucleation benchmark problem focuses on athermal heterogeneous nucleation and nucleation behavior near the free growth limit with different undercooling driving forces.

36 MATERIALS SCIENCE↗
DOE OSTI2021

A crystal plasticity model with an atomistically informed description of grain boundary sliding for improved predictions of deformation fields

Crystal plasticity (CP) is a powerful meso-scale technique for deformation modeling in polycrystalline materials. Crystal plasticity models typically do not include an explicit description of grain boundary (GB) sliding, which could lead to inaccurate predictions of strain distributions, especially in the vicinity of GBs. In the present study, a CP model is developed that includes GB sliding as an additional deformation mechanism and models the interaction between slip and GB sliding. Atomistic simulations are used to formulate the constitutive model for GB sliding and its interaction with incident slip. The deformation fields and structure of the GBs are obtained directly from experimental characterization and are faithfully reproduced as bicrystal systems for molecular dynamics simulations. The GBs are modeled as random-type (non-coincidence, asymmetrical) boundaries as observed from experimental data. The underlying atomistic-scale mechanism for pure sliding of random GBs was found to be analogous to fluid-flow. The interaction between incident slip and a sliding GB caused local increases in stress concentration, which further led to a momentary increase in the local sliding rate. The displacement profiles at the sliding GBs computed from the CP model with sliding accommodation are 38% more accurate than the baseline CP model as quantified by the mean squared error between the simulations and experiment. Here these results help improve the sophistication and accuracy of deformation modeling by including physics-based descriptions for GB sliding and its interaction with slip, eventually leading to more reliable predictions of micromechanical quantities.

36 MATERIALS SCIENCE↗