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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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All sourcesNASA NTRSDOE OSTI
DOE OSTI2017

Simulating Bubble Deformations Using the Intersection Marker (ISM) Front-Tracking method

Surface and volume tracking methods have been under continuous development over the last 50+ years since the first MAC (Marker and Cell) and SLIC (Simple Line Interface Calculation) methods appeared in the 1960's. The sustained interest in simulating multiphase flow stem from their many practical applications in the physical world; from biological systems, to chemical systems, to boiling dynamics and atmospheric heat and mass transfer. The ability to capture the details of interface evolution as well as the physics of interfacial heat and mass transfer has thus been a tempting goal for many numerical researchers. Numerical analysts, apart from the well-established and popular VOF PLIC (Volume of Fluid, Piecewise Linear Interface Construction) method, can now call upon even more computationally intensive options such as the LS (Level Set) method, the FT (Front Tracking) method, the MoF (Moment of Fluid) method and hybrid methods.

42 ENGINEERING↗
DOE OSTI2016

Deformation of contact surfaces in a vacuum interrupter after high-current interruptions

In a high-current interruption, the contact surface in a vacuum interrupter might be severely damaged by constricted vacuum arcs causing a molten area on it. As a result, a protrusion will be initiated by a transient recovery voltage after current zero, enhancing the local electric field and making breakdowns occur easier. The objective of this paper is to simulate the deformation process on the molten area under a high electric field by adopting the finite element method. A time-dependent Electrohydrodynamic model was established, and the liquid-gas interface was tracked by the level-set method. From the results, the liquid metal can be deformed to a Taylor cone if the applied electric field is above a critical value. This value is correlated to the initial geometry of the liquid metal, which increases as the size of the liquid metal decreases. Moreover, the buildup time of a Taylor cone obeys the power law t = k × E{sup −3}, where E is the initial electric field and k is a coefficient related to the material property, indicating a temporal self-similar characteristic. In addition, the influence of temperature has little impact on the deformation but has great impact on electron emission. Finally, the possible reason to initiate a delayed breakdown is associated with the deformation. The breakdown does not occur immediately when the voltage is just applied upon the gap but is postponed to several milliseconds later when the tip is formed on the liquid metal.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
DOE OSTI2022

Stress Birth and Death: Disruptive Computational Mechanics and Novel Diagnostics for Fluid-to-Solid Transitions

Many materials of interest to Sandia transition from fluid to solid or have regions of both phases coexisting simultaneously. Currently there are, unfortunately, no material models that can accurately predict this material response. This is relevant to applications that "birth stress" related to geoscience, nuclear safety, manufacturing, energy production and bioscience. Accurately capturing solidification and residual stress enables fully predictive simulations of the evolving front shape or final product. Accurately resolving flow of proppants or blood could reduce environmental impact or lead to better treatments for heart attacks, thrombosis, or aneurism. We will address a science question in this proposal: When does residual stress develop during the critical transition from liquid to solid and how does it affect material deformation? Our hypothesis is that these early phases of stress development are critical to predictive simulation of material performance, net shape, and aging. In this project, we use advanced constitutive models with yield stress to represent both fluid and solid behavior simultaneously. The report provides an abbreviated description of the results from our LDRD "Stress Birth and Death: Disruptive Computational Mechanics and Novel Diagnostics for Fluid-to-Solid Transitions," since we have written four papers that document the work in detail and which we reference. We give highlights of the work and describe the gravitationally driven flow visualization experiment on a model yield stress fluid, Carbopol, at various concentrations and flow rates. We were able to collapse the data on a single master curve by showing it was self-similar. We also describe the Carbopol rheology and the constitutive equations of interest including the Bingham-Carreau-Yasuda model, the Saramito model, and the HB-Saramito model including parameter estimation for the shear and oscillatory rheology. We present several computational models including the 3D moving mesh simulations of both the Saramito models and Bingham-Carreau-Yasuda (BCY) model. We also show results from the BCY model using a 3D level set method and two different ways of handling reduced order Hele-Shaw modeling for generalized Newtonian fluids. We present some first ever two-dimensional results for the modified Jeffries Kamani-Donley-Rogers constitutive equation developed during this project. We include some recent results with a successful Saramito-level set coupling that allows us to tackle problems with complex geometries like mold filling in a thin gap with an obstacle, without the need for remeshing or remapping. We report on some experiments for curing systems where fluorescent particles are used to track material flow. These experiments were carried out in an oven on Sylgard 184 as a model polymerizing system. We conclude the report with a summary of accomplishments and some thoughts on follow-on work.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Modeling curved interfaces without element‐partitioning in the extended finite element method

Summary In this paper, we model holes and material interfaces (weak discontinuities) in two‐dimensional linear elastic continua using the extended finite element method on higher‐order (spectral) finite element meshes. Arbitrary parametric curves such as rational Bézier curves and cubic Hermite curves are adopted in conjunction with the level set method to represent curved interfaces. Efficient computation of weak form integrals with polynomial integrands is realized via the homogeneous numerical integration scheme—a method that uses Euler's homogeneous function theorem and Stokes' theorem to reduce integration to the boundary of the domain. Numerical integration on cut elements requires the evaluation of a one‐dimensional integral over a parametric curve, and hence, the need to partition curved elements is eliminated. To improve stiffness matrix conditioning, ghost penalty stabilization and the Jacobi preconditioner are used. For material interface problems, we develop an enrichment function that captures weak discontinuities on spectral meshes. Taken together, we show through numerical experiments that these advances deliver optimal algebraic rates of convergence with h ‐refinement ( p =1,2,…,5) and exponential rates of convergence with p ‐refinement ( p =1,2,…,7) for elastostatic problems with holes and material inclusions on Cartesian p th‐order spectral finite element meshes.

Chin, Eric B.↗
DOE OSTI2017

An immersed boundary method for fluid–structure interaction with compressible multiphase flows

This paper presents a two-dimensional immersed boundary method for fluid–structure interaction with compressible multiphase flows involving large structure deformations. This method involves three important parts: flow solver, structure solver and fluid–structure interaction coupling. In the flow solver, the compressible multiphase Navier–Stokes equations for ideal gases are solved by a finite difference method based on a staggered Cartesian mesh, where a fifth-order accuracy Weighted Essentially Non-Oscillation (WENO) scheme is used to handle spatial discretization of the convective term, a fourth-order central difference scheme is employed to discretize the viscous term, the third-order TVD Runge–Kutta scheme is used to discretize the temporal term, and the level-set method is adopted to capture the multi-material interface. In this work, the structure considered is a geometrically non-linear beam which is solved by using a finite element method based on the absolute nodal coordinate formulation (ANCF). The fluid dynamics and the structure motion are coupled in a partitioned iterative manner with a feedback penalty immersed boundary method where the flow dynamics is defined on a fixed Lagrangian grid and the structure dynamics is described on a global coordinate. We perform several validation cases (including fluid over a cylinder, structure dynamics, flow induced vibration of a flexible plate, deformation of a flexible panel induced by shock waves in a shock tube, an inclined flexible plate in a hypersonic flow, and shock-induced collapse of a cylindrical helium cavity in the air), and compare the results with experimental and other numerical data. The present results agree well with the published data and the current experiment. Finally, we further demonstrate the versatility of the present method by applying it to a flexible plate interacting with multiphase flows.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
DOE OSTI2017

A sharp interface method for compressible liquid–vapor flow with phase transition and surface tension

The numerical approximation of non-isothermal liquid–vapor flow within the compressible regime is a difficult task because complex physical effects at the phase interfaces can govern the global flow behavior. We present a sharp interface approach which treats the interface as a shock-wave like discontinuity. Any mixing of fluid phases is avoided by using the flow solver in the bulk regions only, and a ghost-fluid approach close to the interface. The coupling states for the numerical solution in the bulk regions are determined by the solution of local two-phase Riemann problems across the interface. The Riemann solution accounts for the relevant physics by enforcing appropriate jump conditions at the phase boundary. A wide variety of interface effects can be handled in a thermodynamically consistent way. This includes surface tension or mass/energy transfer by phase transition. Moreover, the local normal speed of the interface, which is needed to calculate the time evolution of the interface, is given by the Riemann solution. The interface tracking itself is based on a level-set method. The focus in this paper is the description of the two-phase Riemann solver and its usage within the sharp interface approach. One-dimensional problems are selected to validate the approach. Finally, the three-dimensional simulation of a wobbling droplet and a shock droplet interaction in two dimensions are shown. In both problems phase transition and surface tension determine the global bulk behavior.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
DOE OSTI2017

Level set topology optimization of structural problems with interface cohesion

Summary This paper presents a finite element topology optimization framework for the design of two‐phase structural systems considering contact and cohesion phenomena along the interface. The geometry of the material interface is described by an explicit level set method, and the structural response is predicted by the extended finite element method. In this work, the interface condition is described by a bilinear cohesive zone model on the basis of the traction‐separation constitutive relation. The non‐penetration condition in the presence of compressive interface forces is enforced by a stabilized Lagrange multiplier method. The mechanical model assumes a linear elastic isotropic material, infinitesimal strain theory, and a quasi‐static response. The optimization problem is solved by a nonlinear programming method, and the design sensitivities are computed by the adjoint method. The performance of the presented method is evaluated by 2D and 3D numerical examples. The results obtained from topology optimization reveal distinct design characteristics for the various interface phenomena considered. In addition, 3D examples demonstrate optimal geometries that cannot be fully captured by reduced dimensionality. The optimization framework presented is limited to two‐phase structural systems where the material interface is coincident in the undeformed configuration, and to structural responses that remain valid considering small strain kinematics. Copyright © 2017 John Wiley & Sons, Ltd.

Behrou, Reza↗
DOE OSTI2017

Numerical comparison of bubbling in a waste glass melter

Radioactive tank waste is scheduled for vitrification at the Hanford Tank Waste Treatment and Immobilization Plant, also known as the Vit Plant, being constructed at the Hanford Site. Testing of the pilot-scale, joule-heated DuraMelter 1200 at the Vitreous State Laboratory has shown that bubbling increases the melt rate, and as a result, melter throughput. Computational fluid dynamics (CFD) models of this pilot-scale waste glass melter were developed to improve our understanding of the processes that occur within the melter to aid in process optimization and troubleshooting of the Vit Plant melters. Unfortunately, model validation is complicated by the difficulty of obtaining suitable experimental data for operational melters attributed to the large-scale, radioactivity and high temperatures at which these melters are operated. This study focuses on confirming the fidelity of the CFD models to accurately reproduce the bubbling behavior. Because of the paucity of experimental data at the resolution required for CFD validation, a code-to-code comparison was used to evaluate two common approaches for simulating flows of immiscible fluids on numerical grids and resolving multiphase interfaces. Here, the volume of fluid and level set methods are used to track the dynamically evolving interfaces between the molten glass and the air bubbles. To aid in the verification of the results of these codes, a comparison of the bubble behavior, growth, and frequency of bubble generation are presented and a grid convergence study is performed for the two approaches. In addition to comparing the numerical results to available experimental data and observations from pilot-scale testing, the results are evaluated in relation to laboratory experiments with bubbles injected into viscous fluids, empirical correlations obtained from the published literature, and the basic laws of fluid dynamics. Furthermore, the results of this work can assist in validating waste glass melter models and provide a better understanding of the flow patterns within the WTP melters.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2017

A broadly-applicable unified closure relation for Taylor bubble rise velocity in pipes with stagnant liquid

Taylor bubble velocity in slug flow is a closure relation which significantly affects the prediction of liquid holdup (or void fraction) and pressure gradient in mechanistic models of slug flow for oil and gas pipe applications. In this work, we use a validated Computational Fluid Dynamics (CFD) approach to simulate the motion of Taylor bubbles in pipes; the interface is tracked with a Level-Set method implemented in a commercial code. A large numerical database is generated covering the most ample range of fluid properties and pipe inclination angles explored to date (Eo ∊ [10, 700],Mo ∊ [1 x 10 -6 , 5 x 10 3 , and θ ∊ [0°, 90°]). A unified Taylor bubble rise velocity correlation is extracted from that database. The new correlation predicts the numerical database with 8.6% absolute average relative error and a coefficient of determination R 2 = 0.97 and other available experimental data with 13.0% absolute average relative error and R 2 = 0.84 outperforming existing correlations and models.

Mechanics↗
DOE OSTI2021

Computational Fluid Dynamics (CFD) Simulations of Taylor Bubbles in Vertical and Inclined Pipes with Upward and Downward Liquid Flow

Summary Two-phase flow is a common occurrence in pipes of oil and gas developments. Current predictive tools are based on the mechanistic two-fluid model, which requires the use of closure relations to predict integral flow parameters such as liquid holdup (or void fraction) and pressure gradient. However, these closure relations carry the highest uncertainties in the model. In particular, significant discrepancies have been found between experimental data and closure relations for the Taylor bubble velocity in slug flow, which has been determined to strongly affect the mechanistic model predictions (Lizarraga-García 2016). In this work, we study the behavior of Taylor bubbles in vertical and inclined pipes with upward and downward flow using a validated 3D computational fluid dynamics (CFD) approach with level set method implemented in a commercial code. A total of 56 cases are simulated, covering a wide range of fluid properties, pipe diameters, and inclination angles: Eo ∈ [10, 700]; Mo ∈ [1×10–6, 5×103]; ReSL ∈ [–40, 10]; θ ∈ [5°, 90°]. For bubbles in vertical upward flows, the simulated distribution parameter, C0, is successfully compared with an existing model. However, the C0 values of downward and inclined slug flows where the bubble becomes asymmetric are shown to be significantly different from their respective vertical upward flow values, and no current model exists for the fluids simulated here. The main contributions of this work are (1) the relatively large 3D numerical database generated for this type of flow, (2) the study of the asymmetric nature of inclined and some vertical downward slug flows, and (3) the analysis of its impact on the distribution parameter, C0.

Engineering↗
DOE OSTI2024

MOSCATO Development and Integration in Fiscal Year 2024

MOSCATO (Molten Salt Chemistry and Transport) is a multiphysics code that provides high-fidelity, coupled simulations of fluid flow, heat transfer, mass transfer, chemistry, electrochemical phenomena, and alloy evolution for molten salt equipment. In FY24, significant developments were made to the code package, enhancing its capabilities in many aspects. The improvements and advancements can be summarized as follows: 1. Implementation of tritium transport capabilities and validation with experimental data: To enable modeling of tritium and other fission gases within MSRs, we implemented gas transport within MOSCATO via inclusion of couple mass transport equations within the salt and structural alloys. Comparisons to experimental data from literature showed good agreement with respect to tritium release rates. 2. Preliminary implementation of two-phase flow models in MOSCATO: To model tritium and other gases above their solubility limits, we implemented preliminary two-phase flow models within MOSCATO to account for bubble transport. The first model adopted was the Level-Set approach, which can handle the high void fraction regime, but with a requirement for high mesh resolution thus high computational expense. In this report, we present a verification of the Level-Set method using a simple benchmark case. We also performed a demonstration of the code as applied to an experimental case involving cover gas flow through salt in an experimental vessel. The second model adopted was the Eulerian-Eulerian dispersed flow model, which is computationally cheaper but limited to low void fraction regimes, such as bubbly flow. Validation and verification have not yet been performed for the Eulerian-Eulerian approach, but a preliminary implementation was completed. 3. Validation with static corrosion experiments: Static corrosion experimental data for stainless steel coupons within molten salts was used to further validate the corrosion model in MOSCATO. To do so, we leveraged the existing models in MOSCATO and simulated the sample mass loss and mass gain phenomena. Several ion species, including Cr 2+ , Fe 2+ and H + , were simulated in salt using the PNP solver, while Cr 0 and Fe 0 were simulated with a diffusion solver in stainless steel. The mass loss of the samples was compared with experimental data, and good agreement was achieved. These combined activities served to further expand the capabilities of MOSCATO and make it more generally applicable to the full range of phenomena that can control chemistry and corrosion in molten salt reactors.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2017

An arbitrary-order Runge–Kutta discontinuous Galerkin approach to reinitialization for banded conservative level sets

Here, we present a Runge-Kutta discontinuous Galerkin method for solving conservative reinitialization in the context of the conservative level set method. This represents an extension of the method recently proposed by Owkes and Desjardins [21], by solving the level set equations on the refined level set grid and projecting all spatially-dependent variables into the full basis used by the discontinuous Galerkin discretization. By doing so, we achieve the full k+1 order convergence rate in the L1 norm of the level set field predicted for RKDG methods given kth degree basis functions when the level set profile thickness is held constant with grid refinement. Shape and volume errors for the 0.5-contour of the level set, on the other hand, are found to converge between first and second order. We show a variety of test results, including the method of manufactured solutions, reinitialization of a circle and sphere, Zalesak's disk, and deforming columns and spheres, all showing substantial improvements over the high-order finite difference traditional level set method studied for example by Herrmann. We also demonstrate the need for kth order accurate normal vectors, as lower order normals are found to degrade the convergence rate of the method.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2024

Level-set topology optimization with PDE generated conformal meshes

This paper presents a level-set topology optimization approach that uses conformal meshes for the analysis of the displacement field. The structure’s boundary is represented by the iso-contour of a level-set field discretized on a fixed background design mesh. The conformal mesh is updated for each design iteration via a PDE based mesh morphing process that identifies the set of facets in the background mesh that are homeomorphic to the boundary and relaxes the homeomorphic mesh to conform to the structure’s boundary and ensure high element quality. The conformal mesh allows for a more accurate computation of the response versus density and some level-set based methods which interpolate material properties using the volume fraction. Numerical examples illustrate the proposed approach by optimizing linear-elastic two- and three-dimensional structures, wherein insight into the performance of the mesh morphing process is provided. The examples also highlight the scalability of the approach.

42 ENGINEERING↗
DOE OSTI2022

High-fidelity pool boiling simulations on multiple nucleation sites using interface capturing method

Boiling has proved to be one of the most efficient means for heat transfer and is a very important phenomenon during severe accident scenarios in light water reactors. High-fidelity pool boiling simulations can provide a numerical database for improving mechanistic boiling models by allowing for specific evaluation of interactions among bubbles. Previously published pool boiling simulations investigated two nucleation sites in which bubble growth at one site suppressed nucleation at the other site. Based on previous study results, more complicated interface-capturing simulations on pool boiling were conducted using PHASTA code with locally refined unstructured mesh. First, different boundary conditions (BCs) were assessed to support robustness and reproducibility of the boiling model. Then, a scale study was conducted at a larger domain with nine nucleation sites where either nine or four nucleation sites are activated. Involving more nucleation sites increased the complexity of bubble interactions from surrounding sites. Finally, bubble departure behavior influenced by wall heat flux was investigated. In this work, when heat flux was increased, the order of bubble departure changed, but diagonal bubbles always departed after one another. The departure time interval between the first and second bubble reduced as heat flux increased. The corresponding frequency was almost linearly proportional to the heat flux. In addition, bubble departure behavior was found to be greatly influenced by the nucleation site pattern. Multiple nucleation sites resulted in superimposed inhibitive effects from surrounding sites to each bubble, which extensively delayed the departure. This new observation was not discussed in previously published works. The work presented here provides new insight on the fundamental understanding of boiling phenomena, contributes to the development of a 3D multiphase computational fluid dynamics (M-CFD) model, and provides a more comprehensive database for data-driven pool boiling studies.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗