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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 613 records · Page 34
All sourcesNASA NTRSDOE OSTI
DOE OSTI2017

Metal Big Area Additive Manufacturing: Process Modeling and Validation

Metal Big Area Additive Manufacturing (mBAAM) is a new additive manufacturing (AM) technology for printing large-scale 3D objects. mBAAM is based on the gas metal arc welding process and uses a continuous feed of welding wire to manufacture an object. An electric arc forms between the wire and the substrate, which melts the wire and deposits a bead of molten metal along the predetermined path. In general, the welding process parameters and local conditions determine the shape of the deposited bead. The sequence of the bead deposition and the corresponding thermal history of the manufactured object determine the long range effects, such as thermal-induced distortions and residual stresses. Therefore, the resulting performance or final properties of the manufactured object are dependent on its geometry and the deposition path, in addition to depending on the basic welding process parameters. Physical testing is critical for gaining the necessary knowledge for quality prints, but traversing the process parameter space in order to develop an optimized build strategy for each new design is impractical by pure experimental means. Computational modeling and optimization may accelerate development of a build process strategy and saves time and resources. Because computational modeling provides these opportunities, we have developed a physics-based Finite Element Method (FEM) simulation framework and numerical models to support the mBAAM process s development and design. In this paper, we performed a sequentially coupled heat transfer and stress analysis for predicting the final deformation of a small rectangular structure printed using the mild steel welding wire. Using the new simulation technologies, material was progressively added into the FEM simulation as the arc weld traversed the build path. In the sequentially coupled heat transfer and stress analysis, the heat transfer was performed to calculate the temperature evolution, which was used in a stress analysis to evaluate the residual stresses and distortions. In this formulation, we assume that physics is directionally coupled, i.e. the effect of stress of the component on the temperatures is negligible. The experiment instrumentation (measurement types, sensor types, sensor locations, sensor placements, measurement intervals) and the measurements are presented. The temperatures and distortions from the simulations show good correlation with experimental measurements. Ongoing modeling work is also briefly discussed.

Additive Manufacturing↗
DOE OSTI2015

Evaluation of D and D alternatives for a DOE nuclear material processing facility - 15265

Ten scenarios for SRS Building 235-F were evaluated relative to groundwater protection through use of a 235-F GoldSim{sup TM} fate and transport model. The scenarios included two extreme scenarios, a no action scenario, four D and D grouting scenarios, and three D and D inventory removal scenarios. The fate and transport model simulated contaminant release from four 235-F process areas and the 294-2F Sand Filter and fate and transport through the vadose zone, the Upper Three Runs (UTR) aquifer, and the UTR creek. The model was a stochastic model for which 1,000 realizations were run over 100,000 years for each scenario. In association with the seven D and D alternatives only three groundwater standards out of 25 were exceeded, with the combined radium standard showing the greatest exceedance. The standards were only exceeded at the edge of the building after 10,000 years. It was estimated that there was a 90% likelihood that the combined radium standard would be exceeded for all four D and D grouting scenarios and that a 95% inventory removal from process cells 1-5 would result in an essentially zero percent likelihood that any standards would be exceeded. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2025

Data-model files associated with the manuscript "Modeling the Effects of Wetland Restoration on Coastal Hydrology: A Case Study of Elkhorn Slough Watershed, California"

This package contains the data, simulation setups, notebooks and figures used in “Modeling the Effects of Wetland Restoration on Coastal Hydrology: A Case Study of Elkhorn Slough Watershed, California” (Xu et al., 2025). In this study, we selected Elkhorn Slough, a tidal estuary, in California, to investigate the impact of wetland restoration and sea level rise on coastal hydrology using the process-based coastal hydrologic model, Advanced Terrestrial Simulator (ATS), informed by site-specific data. We designed a novel modeling workflow for incorporating wetland restoration features into land cover and soil properties for the model parameterization. The validation results demonstrate a strong agreement between modeled and observed data. We studied the characteristics of coastal watershed hydrology, then focused on the surface water dynamics at two wetland sites within Elkhorn Slough, a reference site and a restored site. Our simulation results indicate that the restored site successfully maintains surface elevation, resulting in reduced surface inundation. We also examined the impact of wetland restoration under expected sea level rise over the next few decades. The low-lying Yampah Marsh, the reference site, is likely to be inundated due to future sea level rise when highest tides arrive; while a higher percentage of Hester Marsh, the restored site, would retain marsh vegetation in coming decades, regardless of tidal conditions. Our study provides important information for examining the outcome of restoration practices that include surface elevation in tidal wetlands under climate changes.Several files can be found from this data package.1. README.md: This file describes the title, journal, co-authors, abstract, repository structure and model version.2. Simulation_Setups.zip: The file contains the model configuration files (XML format) for ATS. 3. Notebooks.zip: The file contains the Jupyter notebooks for generating the pre- and post-restoration meshes and the meshes of future scenarios. 4. Figures.zip: The file contains the figures used in the manuscript.5. Data.zip: The file contains the data used to drive the model simulations, including watershed and wetlands boundaries, mesh files and references to additional datasets (e.g., meteorological forcing, tidal dataset, DEMs, land cover, soil properties). Also, it contains water level observations at the restored wetland.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2025

Using ARM Observations to Evaluate Process-Interactions in MCS Simulations Across Scales (Final Progress Report)

This project, funded by DOE Atmospheric System Research (DE-SC0020050), focused on improving the representation of mesoscale convective systems (MCSs) in numerical weather and climate models by leveraging high-resolution observations from the DOE Atmospheric Radiation Measurement (ARM) program. The research aimed to evaluate model sensitivities to grid spacing, microphysics, and planetary boundary layer (PBL) schemes, with a particular emphasis on improving convection parameterization for high-resolution modeling. Findings from this work highlight several key advancements. Model validation against ARM radar wind profiler data from the Southern Great Plains (SGP) and Manaus (MAO) sites revealed systematic biases in simulated convective mass flux profiles, leading to the development of an observationally constrained evaluation framework for diagnosing and improving model performance. Sensitivity analyses demonstrated that the representation of Amazonian MCSs was highly dependent on PBL scheme selection, while mid-latitude MCSs were more strongly influenced by microphysics parameterizations. A series of high-resolution WRF simulations, ranging from 4 km to 125 m grid spacing, provided insight into the behavior of convective drafts across scales. While updraft properties converged at sub-kilometer resolutions, biases in downdraft intensity persisted even at the finest resolution tested, emphasizing the need for further refinements in model physics. Additionally, comparisons of MCS vertical structures between mid-latitude and tropical environments revealed stronger updrafts and larger mass flux in mid-latitude MCSs, providing critical insights for improving climate model representations of storm-scale dynamics. The project’s findings have already contributed to advancing numerical modeling capabilities, particularly in WRF, MPAS, ICON, and DOE’s SCREAM model, by refining how convective processes are represented in high-resolution climate simulations. Results were disseminated through peer-reviewed publications, conference presentations, and ARM/ASR Research Highlights, engaging the broader scientific community. The project also provided valuable training opportunities for two postdoctoral researchers, who played central roles in model development, analysis, and dissemination of results. Their work contributed to several publications and conference presentations, helping prepare them for careers in atmospheric modeling. By improving the simulation of MCSs, this research directly supports the development of next-generation climate models capable of more accurately representing extreme precipitation and convective processes. The insights gained will inform future improvements in convective parameterization and guide the design of high-resolution weather and climate simulations, ultimately enhancing the reliability of climate projections and weather forecasts.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2017

Preliminary Analysis of Facility Design for Pyro-processing Safeguardability

The deployment of advanced nuclear energy systems can assure sustainable energy use worldwide. For some of these systems, nuclear fuel will be fabricated in remotely-handled facilities in which batch-type processing will occur in heavily-shielded hot cells. Because special nuclear material is in both different physical and chemical form than that of the contemporary fuel cycle, new challenges have arisen in terms of safeguards, safety, and security, integrated with facility design; i.e., safeguardability. There is a need to develop models that can quantitatively assess safeguardability from a design-driven perspective. Previously, the first build of a material throughput model was established using discrete event simulation (DES) for the fuel fabrication process. Results showed that the DES model potentially can detect diversion attempts. This paper continues the study by further developing the the model. We test the use of the probability of the false alarm; i.e., the Type I error, as a metric for safeguardability assessment. Initiating events leading to a false alarm arise from aspects of safeguards, safety, and security. Different conceptual facility designs could exhibit different frequencies for the Type I error, and this could provide a measure of the safeguardability of each design. A quantitative assessment for safeguardable facility designs has not been developed in this manner. Much of the research into safeguardability has been qualitative. Engineering design approaches for a safeguardable facility are now needed. As there are not accepted metrics for safeguardability assessment, our motivation is to develop this design facet of safeguardability further.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2025

Leveraging prior mean models for faster Bayesian optimization of particle accelerators

Tuning particle accelerators is a challenging and time-consuming task that can be automated and carried out efficiently using suitable optimization algorithms, such as model-based Bayesian optimization techniques. One of the major advantages of Bayesian algorithms is the ability to incorporate prior information about beam physics and historical behavior into the model used to make control decisions. In this work, we examine incorporating prior accelerator physics information into Bayesian optimization algorithms by utilizing fast executing, neural network models trained on simulated or historical datasets as prior mean functions in Gaussian process models. We show that in ideal cases, this technique substantially increases convergence speed to optimal solutions in high-dimensional tuning parameter spaces. Additionally, we demonstrate that even in non-ideal cases, where prior models of beam dynamics do not exactly match experimental conditions, the use of this technique can still enhance convergence speed. Finally, we demonstrate how these methods can be used to improve optimization in practical applications, such as transferring information gained from beam dynamics simulations to online control of the LCLS injector, and transferring knowledge gained from experimental measurements across different operating modes, such as accelerating different ion species at the ATLAS heavy ion accelerator.

43 PARTICLE ACCELERATORS↗
DOE OSTI2016

Nonlinear electromagnetic formulation for particle-in-cell simulation of lower hybrid waves in toroidal geometry

An electromagnetic particle simulation model has been formulated and verified for nonlinear processes of lower hybrid (LH) waves in fusion plasmas. Electron dynamics are described by the drift kinetic equation using either kinetic momentum or canonical momentum. Ion dynamics are treated as the fluid system or by the Vlasov equation. Compressible magnetic perturbation is retained to simulate both the fast and slow LH waves. Numerical properties are greatly improved by using the electron continuity equation to enforce the consistency between electrostatic potential and vector potential, and by using the importance sampling scheme. The simulation model has been implemented in the gyrokinetic toroidal code (GTC), and verified for the dispersion relation and nonlinear particle trapping of the electromagnetic LH waves.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2022

Forest regeneration within Earth system models: current process representations and ways forward

Earth system models must predict forest responses to global change in order to simulate future global climate, hydrology, and ecosystem dynamics. These models are increasingly adopting vegetation demographic approaches that explicitly represent tree growth, mortality, and recruitment, enabling advances in the projection of forest vulnerability and resilience, as well as evaluation with field data. To date, simulation of regeneration processes has received far less attention than simulation of processes that affect growth and mortality, in spite of their critical role maintaining forest structure, facilitating turnover in forest composition over space and time, enabling recovery from disturbance, and regulating climate-driven range shifts. Here, our critical review of regeneration process representations within current Earth system vegetation demographic models reveals the need to improve parameter values and algorithms for reproductive allocation, dispersal, seed survival and germination, environmental filtering in the seedling layer, and tree regeneration strategies adapted to wind, fire, and anthropogenic disturbance regimes. These improvements require synthesis of existing data, specific field data-collection protocols, and novel model algorithms compatible with global-scale simulations. Vegetation demographic models offer the opportunity to more fully integrate ecological understanding into Earth system prediction; regeneration processes need to be a critical part of the effort.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2026

Development of a deep potential model for F and CF 2 etching of Si and SiO 2

An understanding of plasma-surface interactions at increasingly smaller scales is invaluable for the development of novel technologies and processing techniques. Molecular dynamics (MD) simulations can provide insights into atomic-scale interactions, though they are restricted by the availability of interatomic potentials. Machine learning methods, such as Deep Potential Molecular Dynamics (DeepMD), provide a systematic framework for the development of accurate and flexible ab initio-based models. In this work, we develop DeepMD models for the ion-enhanced etching of Si and SiO 2 by F and CF 2 radicals. We employ an active learning process to expand the data set on which the model is trained and demonstrate its effect on the model accuracy. The DeepMD results are compared to data from classical MD simulations and experiments. Physical sputtering yields of SiO 2 by Ar + ions show good agreement with previous simulation results using conventional interatomic potentials, though the predicted depth profiles are different. Etching yields are calculated as a function of ion energy and neutral to ion flux ratio for the Ar + ion-enhanced etching of SiO 2 and Si by F atoms, as well as for etching of SiO 2 by CF 2 radicals, showing reasonable agreement with experimental data. Finally, an ion-enhanced surface kinetic model is fitted to the DeepMD etch yields, and the fitted parameters are compared to quantities computed directly from DeepMD simulations. This study illustrates how molecular dynamics simulations using machine learning potentials can provide an accurate model of etching processes relevant to device manufacturing.

Kounis-Melas, Andreas [Princeton Univ., NJ (United↗
DOE OSTI2022

An Open-Source Framework for the Computational Analysis and Design of Autothermal Chemical Processes

The main project object was to develop software tools for simulating non-equilibrium autothermal processes, improving the prospects for identifying and designing such systems. The project demonstrates the use of these tools to simulate autothermal pyrolysis, a process recently developed at the pilot-plant scale at Iowa State University. In such process, instead of externally heating a reactor to pro-vide the enthalpy of pyrolysis, sufficient oxygen in the form of air is introduced into the reactor to support partial oxidation of reactants and products with the exothermic energy released supporting endothermic pyrolysis reactions. A fluidized bed is used to assure good mixing of biomass and oxidant and provide an isothermal reaction environment. The amount of oxygen required depends upon the kind of biomass being pyrolyzed and parasitic heat losses from the reactor. For example, for woody biomass pyrolyzed under conditions that simulate adiabatic operation, equivalence ratios can be as low as 0.06, compared to 0.20 or higher for autothermal gasifiers. By removing the heat transfer bottleneck of conventional pyrolysis, operation in autothermal mode allowed a significant increase in reactor throughput process, approaching five times the throughput of the conventionally operated pyrolyzer. Different simulation strategies were considered and developed: a zero-dimensional chemistry model was used to verify the applicability of kinetic schemes to predict biomass fast pyrolysis in autothermal conditions. Conventional chemical reactor models such as the plug flow reactor and the partially stirred reactor were used to investigate the role of mixing in the fluidized bed pyrolyzer and to establish the impact of mixing time on the gas-phase reactions. A comprehensive multiphase computational fluid dynamics (mCFD) framework, including polydisperse granular phase modeling and detailed chemical kinetics was formulated and used to model the experimental setup for autothermal biomass fast pyrolysis at ISU. Multiphase CFD was also used to investigate the role of biomass feed positioning on the mixing of biomass in the pyrolizer. Finally, a reduced order model (ROM), suitable to be implemented in process simulators was obtained. Both the mCFD and the ROM were validated against experiments.

09 BIOMASS FUELS↗
DOE OSTI2026

Control and Real-Time Simulation of Microgrids with EV Fast-Charging and Grid-Forming Resources

Fast charging stations (FCSs) for electric vehicles (EVs) can behave as constant power loads, which is problematic for the operation of grid-forming (GFM) inverter-based resources (IBRs). To tackle this problem, this paper proposes a control suite that makes FCSs responsive to ac voltage and frequency disturbances. To test the performance of the FCS controls, the paper also sets forth theory to compensate for time-delays appearing in the real-time simulation of microgrid models divided into several central processing units (CPUs). Furthermore, these contributions are showcased via multi-CPU real-time simulations of a faulted microgrid having EV FCSs and GFM IBRs powered by photovoltaic solar arrays as well as power hardware-in-the-loop experiments. These contributions are significant to address NERC recommendations and IEEE standards.

14 SOLAR ENERGY↗
DOE OSTI2020

A numerical study of the meso-structure variability in the compaction process of prepreg platelet molded composites

Compaction deformations in a thermoplastic composite system molded from chopped prepreg platelets were analyzed to obtain statistical distributions of local distortions that define the final consolidated meso-structure. This study provides an insight into and allows quantification of the intrinsic geometric variability of the composite meso-structure that controls the variability of the effective composite mechanical properties. A two-phase viscoelastic finite element model was utilized to treat the behavior of molten prepreg platelets, which were assumed to be incompressible and inextensible in the fiber direction during processing. A two-step simulation procedure with discretely modeled platelets and platelet-to-platelet contacts is proposed. The analysis begins with a drop simulation of the uncontrolled material deposition followed by a 3D finite element analysis of the preform compaction and bulk material flow. The proposed model provides a method for generating a composite meso-structure ab initio starting from a statistical sampling of the initial conditions for platelet deposition. The predicted platelet thickness distribution, intra-platelet fiber waviness and out-of-plane platelet undulations were found to be in good agreement with experimental measurements. An estimate of the volume of resin pockets was inferred from the compaction simulation.

36 MATERIALS SCIENCE↗
DOE OSTI2016

Improved representations of coupled soil–canopy processes in the CABLE land surface model (Subversion revision 3432)

CABLE is a global land surface model, which has been used extensively in offline and coupled simulations. While CABLE performs well in comparison with other land surface models, results are impacted by decoupling of transpiration and photosynthesis fluxes under drying soil conditions, often leading to implausibly high water use efficiencies. Here, we present a solution to this problem, ensuring that modelled transpiration is always consistent with modelled photosynthesis, while introducing a parsimonious single-parameter drought response function which is coupled to root water uptake. We further improve CABLE's simulation of coupled soil–canopy processes by introducing an alternative hydrology model with a physically accurate representation of coupled energy and water fluxes at the soil–air interface, including a more realistic formulation of transfer under atmospherically stable conditions within the canopy and in the presence of leaf litter. The effects of these model developments are assessed using data from 18 stations from the global eddy covariance FLUXNET database, selected to span a large climatic range. Here, marked improvements are demonstrated, with root mean squared errors for monthly latent heat fluxes and water use efficiencies being reduced by 40 %. Results highlight the important roles of deep soil moisture in mediating drought response and litter in dampening soil evaporation.

58 GEOSCIENCES↗
DOE OSTI2023

Using Co-Optimized Machine Learned Manifolds for Modeling Chemically Reacting Flows

Chemically reacting flows play a key role in a wide range of engineered systems, from chemical and polymer processing to combustion-based energy conversion technologies. Simulations of these flows involve solving a coupled set of partial differential equations for mass, momentum, energy, and all relevant chemical species in the system. Chemical reaction pathways may be extremely complex and involve hundreds or more intermediate species, with reactions that occur over timescales varying by several orders of magnitude - presenting a significant numerical stiffness challenge. The combination of these factors makes simulation of chemically reacting flows vastly more expensive than nonreactive simulations, and often makes direct solution of the governing equations intractable. It is necessary to apply lower-fidelity models in place of the detailed governing equations in order to reduce computational cost to enable reacting flow simulation tools to be used in the engineering design process. Many of the models employed for this purpose are based on reducing the dimension of the thermochemical state, motivated by the observation that the observed thermochemical states in a system lie on a low-dimensional manifold in thermochemical state space. This behavior occurs due to the fast equilibration of certain reactive and transport processes, and physics-based manifold models rely on idealized assumptions about the balance of timescales and the way in which chemistry and transport are coupled. In this work, we apply a novel method for data-driven manifold-based modeling that can leverage data from high-fidelity reacting flow simulations to improve model accuracy in cases where the physics-based modeling assumptions break down. The approach is designed to be broadly applicable across chemically reacting flow systems but is applied here to turbulent combustion modeling.

machine learning↗
DOE OSTI2025

A Multichannel Silicon Package for Large-Scale Skipper-CCD Experiments

The next generation of experiments for light-dark-matter and neutrino searches based on skipper charge-coupled devices (skipper-CCDs) introduces new challenges for the sensor packaging and readout architecture. Scaling the active mass while simultaneously reducing the experimental backgrounds in orders of magnitude requires a novel high-density silicon-based package that must be massively produced and tested. In this work, we present a silicon multichip module design capable of hosting up to 16 skipper-CCDs, along with the fabrication process for the first prototypes. We thoroughly tested and characterized the assembled prototypes to build an empirical model for the video output signal of skipper-CCDs integrated into the silicon package. We then used this model in simulations to optimize the fabrication process and achieve the robust performance required for the full-scale array, which we validated through a new round of prototype fabrication. We outline the specifications selected for the ongoing production of 1500 silicon wafers that will ultimately add up to a 10-kg skipper-CCD array with 24000 readout channels.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2021

Assessment of Turbulent Combustion Models for Simulating Prechamber Ignition in a Natural Gas Engine

Lean combustion is a promising strategy to increase thermal efficiency in an internal combustion engine, by exploiting a favorable specific heat ratio of the fresh mixture while simultaneously suppressing the heat losses to the cylinder wall. However, unstable ignition and slow flame propagation at fuel-lean conditions lead to large cycle-to-cycle variability and limit the high-efficiency engine operating range. Prechamber ignition is considered an effective concept to extend the lean operating limit, by providing spatially distributed ignition with multiple turbulent flame-jets and enabling a faster combustion rate compared to the conventional spark ignition approach. From a numerical modeling standpoint to date science base and available simulation tools are inadequate to properly understand and predict the combustion processes in prechamber ignited engines. In this paper, conceptually different Reynolds-averaged Navier–Stokes (RANS) combustion models widely adopted in the engine modeling community are used to simulate the ignition and combustion processes in a medium-duty natural gas engine with a prechamber spark-ignition system. Here, a flamelet-based turbulent combustion model, i.e., G-equation, and a multizone well-stirred reactor model are employed for this modeling study. Simulation results are compared with experimental data in terms of in-cylinder pressure and heat release rate. Finally, the analysis of the performance of the two models is carried out to highlight the strengths and limitations of the two evaluated approaches.

42 ENGINEERING↗
DOE OSTI2020

Optimal pumping schedule with high-viscosity gel for uniform distribution of proppant in unconventional reservoirs

Hydrocarbon recovery from a hydraulic-fractured unconventional reservoir can be enhanced by replacing slickwater with non-Newtonian high-viscosity gel as a fracturing fluid. However, in the literature, the role of gel rheology on hydrocarbon production from a fractured reservoir is not very well understood. This lack of understanding makes it difficult for the industry to choose appropriate viscosity parameters of fracturing gels. Motivated by these limitations, first, we have developed a high-fidelity model of non-Newtonian fluid flow to simulate fracture propagation, fluid leak-off, and gel flowback processes to predict the oil production from a hydraulic fractured reservoir. Simulation results of the high-fidelity model show how fracture geometry, formation damage, and gel cleanup process varies with the fracturing fluid rheology. Therefore, the developed model is used to understand the effect of gel rheology on hydrocarbon production via a sensitivity analysis, which provides a set of rheological parameters that maximize the cumulative amount of oil production. Finally, utilizing this optimal high-viscosity gel, a model predictive controller is designed to obtain an optimal pumping schedule necessary for producing a target fracture geometry and proppant concentration. The closed-loop simulation results demonstrate that the obtained pumping schedule successfully achieved the desired fracture geometry and proppant concentration at the end of pumping, leading to the maximum oil production from an unconventional reservoir.

13 HYDRO ENERGY↗
DOE OSTI2022

A Hands-on Course on Intensified Membrane Processes for Sustainable Water Purification

The lack in process intensification (PI) training may be limiting processes to achieve sustainability goals. Furthermore, this project developed a hands-on course on intensified membrane processes to address knowledge gaps in PI. Bench-scale activities introduced concepts of membrane separation, operating engineering-scale modules provided a near-industrial experience, and simulation software allowed modeling and optimization of a process. Student evaluations showed that the combination of modeling, experimental, and peer-instruction work helped them understand the application of theoretical concepts.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗