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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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DOE OSTI2021

The role of ion and electron-scale turbulence in setting heat and particle transport in the DIII-D ITER baseline scenario

In this work, the heat and particle transport in a DIII-D ITER Baseline Scenario (IBS) discharge has been investigated using both linear and nonlinear gyrokinetic simulations performed with the CGYRO code [J. Candy et al: Journal Comp. Phys. (2016)].These simulations were used to investigate the role that ion-scale ($k_θp_s$ < 1:0) and electron-scale ($k_θp_s$ > 1:0) turbulence play in determining heat and particle transport in the core of conditions believed to directly extrapolate to ITER operation. This investigation spans over nearly half of the plasma minor radius, from ρ = 0:45 - 0:85. To probe the nature of the transport and turbulence in these conditions and to validate the model against experimental fluxes, scans of $a/L_{T_i}$, $a/L_{T_e}$, and $a/L_n$ were performed at all radial locations. Long wavelength turbulence is found to be dominated by ITG modes with strong non-adiabatic electron effects and appears unable to reproduce ion and electron heat fluxes and electron particle fluxes simultaneously at most radial positions when single parameter scans are performed. To investigate the potential role of short wavelength turbulence, a series of electron-scale simulations are performed that indicate that experimentally relevant levels of electron heat flux could arise at sub-ion scales. Quantitative comparison of the simulated fluxes obtained from ion and electron-scale simulations with experimental levels along with the sensitivity of simulations results to changes in inputs is presented. Through extensive sensitivity scans and comparison with multiple transport channels, this work demonstrates a clear need for self-consistent modification of multiple inputs and suggests multi-scale interactions play a significant role at many of the radial locations studied. The results of this analysis help shape our understanding of the model fidelity needed to predict turbulence and transport reactor-relevant conditions and have important implications for the prediction of future fusion devices.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2023

Predictive Modeling of Electrodeposition in a Single Pore Flow-Through Electrode: From Electronucleation to Coating Thickness Uniformity

The emergence of advanced manufacturing methods capable of producing porous three-dimensional structures has expanded the design space for next-generation functional components. The ability to fabricate ordered 3D foams for use in electrocatalysis reactors has increased the need for controlled deposition of catalytic metals onto porous support materials, such as carbon. However, there is a lack of clear design guidelines for electrodeposition onto 3D substrates, due to the geometric complexity and multi-scale nature of the problem. Furthermore, electro-nucleation phenomena are often overlooked in macro-scale models of current distribution during deposition. Here, a graphite flow-through electrode (FTE) is used as a model system for copper deposition within a single pore. Potential distributions and electro-nucleation phenomena are coupled in a continuum level model by incorporating nucleation size and density as a function of overpotential, determined experimentally using in situ atomic force microscopy (AFM). The model predictions are validated by measuring the coating uniformity in the pore using micro-computed X-ray tomography (μCT). A scaling analysis comprising dimensionless parameters such as the Wagner number is presented. The simplified scaling relationship framework can guide the electrodeposition process and electrode design to optimize plating of porous substrates under fluid flow conditions.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2022

Development of Integrated Thermal Fluids Modeling Capability for MSRs

The DOE Nuclear Energy Advanced Modeling and Simulation (NEAMS) program supports a full range of computational thermal fluids analysis capabilities and code developments for a broad class of light-water and advanced reactor concepts. The research and development approach under thermal fluids technical area synergistically combines three length and time scales in a hierarchal multi-scale approach. To demonstrate the feasibility and capabilities of a multi-scale thermal fluids capability using these codes, a key joint effort has been pursued to develop an integrated system-and engineering-scale thermal fluids analysis capability with the MOOSE-based codes, through integration of SAM and Pronghorn, both based on the MOOSE framework. This report summarizes the progress in developing an integrated system- and engineering-scale thermal fluids analysis capability based on SAM and Pronghorn for molten salt reactors (MSRs), which gained significant interest in recently years. Two coupling approaches were studied, i.e. separate domain or domain-segregated coupling approach and the domain-overlapping approach. A series of coupled multi-physics models have been developed for a common reference molten salt fast reactor (MSFR) concept, ranging from standalone SAM system model to integrated SAM-Pronghorn-Griffin models. Both the steady state and the transient simulations are performed to the state-of-the-art simulation capabilities of NEAMS software suite in MSFR system applications. This report also covers further development and testing of the gas transport model in SAM for MSR modeling support. The presence of noncondensable gas in MSR systems would have strong impacts on fission gas removal and transport of noble metals throughout the system. Fission products removed through the off-gas system can also impact reactivity and can act as an additional point of heat removal. To ensure that the gas transport model is adequately tested, the supported modeling capabilities and features of SAM were identified, and a suite of tests were developed to test the model for each identified feature. Validation and UQ testing were also performed for the model and demonstrated that the buoyancy term, which was originally developed using non-salt/helium gas experimental data, can capture the experimental gas bubble velocity and diameter to within experimental and code uncertainty. An existing MSRE model was also modified in this work to include the gas transport model and to demonstrate the gas model behavior for realistic conditions of interest.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2025

Unraveling fundamental mechanisms of silicon nitride crystallization in microelectronics manufacturing

This research project investigates the fundamental mechanisms of silicon nitride (SiN) crystallization, aiming to enhance the understanding of this critical material in microelectronics manufacturing. Through a collaborative effort between Sandia National Laboratories, the University of Tennessee, and the University of Florida, we developed a comprehensive framework that integrates experimental techniques, atomistic modeling, meso-scale simulations, and an integrated multi-scale model to capture this physical phenomenon on multiple time and length scales . The project developed a new machine learning based atomistic potential and utilized advanced phase field modeling to capture the complexities of polycrystalline growth and the influence of mechanical stresses on crystallization dynamics. By employing a grain tracker algorithm, the meso-scale model effectively identified and tracked individual crystal grains, enabling the simulation of anisotropic growth behaviors reflective of SiN’s physical properties. The integration of atomistic simulations with meso-scale modeling created a powerful multi-scale framework that validated atomistic inputs and enhanced predictive accuracy for crystallization dynamics at larger scales, validated experimentally. This adaptable modeling capability not only accelerates development times by informing manufacturing processes but also serves as a valuable starting point for understanding crystallization physics in similar materials. The insights gained from this research unlock new opportunities for the development of advanced materials tailored for future microelectronics and photonics applications. Overall, this project represents a significant advancement in understanding of fundamental physics of SiN and establishes a foundation for future research in material science, bridging the gap between atomic-level phenomena and macroscopic material behaviors for practical applications.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Macro-micro multiscale modeling to assist the design of HPDC Al castings microstructure and alloys for EV super-large body structures (Phase 1)

Implementation of High Pressure Die Casting (HPDC) Aluminum (Al) body structures for high volume electrified vehicles (EV) to improve electric efficiency remains a key strategy within many original equipment manufacturer (OEM)s. In addition to high strength for safety requirements, superior Self-Piercing Riveting (SPR) performance is demanded for HPDC Al alloys to be compatible with high volume SPR joining. In this work, it is proposed to extend and validate an existing Contractor finite element multiscale macro-micro modeling approach to quantify the influence of the microstructure of HPDC alloys on the fracture strain/displacement under 3-point bend and clinch testing. The success of this work will allow to replace solution treatment stage with low energy consumption heat treatment (HT) processes, or to design new non heat treatable (NHT) HPDC Al alloys to eliminate HT requirements. Ultimately, this project will facilitate the application of HPDC Al alloys for super-large vehicle structures to significantly reduce vehicle weight, and thus improving energy efficiency. The purpose of this project is to extend and validate an existing finite element code, which is based on the Contractor developed macro-micro multi-scale modeling approach, to numerically simulate the three-point bending and clinch test and study the influences of material microstructural characteristics and phase properties on the rivetability. The macro-micro modeling approach begins with a sample scale model and identify the location, which is mostly prone to failure, the deformation history of the boundaries of that location calculated will be used to drive a microstructure-based sub-models where the material microstructure and microscale properties are considered. Using this approach, the wrap-bending failure for two Al alloys are correctly predicted for the first time. This will start with phase I effort of building a framework of macro-micro three point bending test and clinch test of Al10SiMgMn HPDC alloy in the as-cast and T7 heat treated conditions. Those results will then be validated with experimental test results. The phase II effort will involve the utilization of the knowledge learned in phase I to establish the quantitative correlation between the microstructure characteristics and the riveting performance, which will be further used to guide the optimization of HPDC Al alloy microstructure using heat treatment process to achieve sufficient rivetability to join large thin-wall HPDC alloys.

36 MATERIALS SCIENCE↗

DOE OSTI2026

Multi-Scale Modeling and Prototype Development for Electrochemical CO2 Reduction (CRADA Final Report)

In this CRADA project, Lawrence Livermore National Laboratory, Stanford University, SLAC National Laboratory, and TotalEnergies collaboratively executed a multidisciplinary investigation of electrochemical reduction of CO2 to produce sustainable fuels and chemicals. Overall, the project led to an increased understanding of the fundamental processes involved in CO2 electrolysis, from the atomistic scale to the full electrolyzer device scale, ultimately leading to design guidelines for CO2 electrolyzers that will help in their future commercialization. As the model systems, Ag- and Cu-based catalysts were investigated in various forms depending on the electrochemical platform that was utilized to study the activity, selectivity, and durability towards electrochemical CO2 reduction. By employing experimental, theoretical, and computational techniques, the project team experimentally validated multi-physics models, evaluated the experimental levers that lead to increased electrolyzer reaction selectivity and energy efficiency, and used computational optimization to design higher performance electrodes. The learnings of this project were extensively documented in publicly available peer-reviewed journal publications and conference presentations, which serve as a foundation for further work to build from.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2026

Tachyon: Intelligent Multi-Scale Modeling of Distributed Resilient Infrastructure and Workflows for Data Intensive HEP Analyses

The DOE High Energy Physics (HEP) program in Neutrino and Collider science drives data-intensive science and simulation on extreme-scale platforms. Modeling and optimizing the complex distributed components from experimental to leadership computing facilities are essential for HEP workflows to achieve required response times and resilience under various conditions. Tachyon proposes a framework for scalable modeling, simulation, and validation of key performance characteristics for the distributed infrastructure between FNAL and ALCF, along with associated HEP workflows.

Carothers, Chris [Rensselaer Poly.]↗

DOE OSTI2026

Tachyon: Intelligent Multi-Scale Modeling of Distributed Resilient Infrastructure and Workflows for Data Intensive HEP Analyses

Carothers, Chris [Rensselaer Poly.]↗

DOE OSTI2020

Final Technical Report for the SciDAC Center for the Study of Plasma Microturbulence

This final technical report for the SciDAC Center for the Study of Plasma Microturbulence documents contributions from MIT to the project over the period of the award (February 15, 2011 to February 14, 2020). This project focused on the development of neoclassical and gyrokinetic simulation capabilities relevant for the description of particle, momentum and energy transport in tokamak fusion plasmas. Extensive validation against experimental results from Alcator C-Mod and DIII-D experiments was performed. Overall areas of emphasis included gyrokinetic simulations, experiments, and observation of density gradient driven Trapped Electron Mode (TEM) turbulence relevant to burning plasmas; theory and gyrokinetic simulations of the parametric variation of the nonlinear upshift of the TEM critical density gradient; identification of a new mechanism for the isotope effect due to density gradient driven TEM turbulence; new synthetic diagnostics based on full-wave simulations which enabled unprecedented agreement between gyrokinetic simulations and measured fluctuation spectra with and without strong electron heating; development of new continuum pedestal neoclassical and turbulence codes; formulation and implementation of the first gyrokinetic exact Fokker-Planck collision operator in gyrokinetic turbulence simulations; development of new spectral approaches in velocity space for highly efficient treatments of collisions; new model collision operators implemented in the discontinuous Galerkin gyrokinetic edge turbulence code GKEYLL; and a new model and spectral code to study the interaction of ion- and electron-scale turbulence, which will serve as an efficient test-bed for multi-rate and multi-scale methods. These fundamental advances contribute to the development of a validated, predictive capability for turbulent and collisional particle, momentum and energy transport in both the core and edge of magnetically confined fusion plasmas.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗