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DOE OSTI2022

Cooling rate and dendrite spacing control in direct metal deposition printed Cu-Fe alloys

Over the last several decades, additive manufacturing (AM) has been primarily used for rapid prototyping or to create novel geometries that would be difficult or impossible to create by normal manufacturing methods. More recently, research has been focused on expanding the list of materials that can be made through additive manufacturing, opening a greater range of material properties for this manufacturing method. Due to the unusual conditions during AM, including the high cooling rates and voxel by voxel method of production, AM parts often have anisotropic material microstructures and properties. In this investigation, the laser power, composition, and nozzle head speed during direct metal deposition of copper-iron alloys was varied to understand how the grain structure within the printed parts could be changed and controlled. The resulting dendrite spacing was measured and compared to calculated cooling rates from Gaussian beams on flat plates under similar material and laser properties, which resulted in a cooling rate to dendrite spacing relationship following an inverse square root, as is found in other dendritic systems [Young and Kerkwood, Metall. Trans. A 6, 197–205 (1975)]. Thus, it is demonstrated that in the Cu-Fe system, dendrite spacing can be controlled through manipulation of printing parameters.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Assessment and Improvement of the SST-Gamma Transition Model in Nalu-Wind

We conduct laminar–turbulent boundary-layer transition simulations using a local correlation-based transition model for two-dimensional incompressible flow and present enhancements to improve the accuracy of transition predictions. Menter’s Galilean-invariant 𝛾 transition model is implemented in the incompressible, unstructured-grid flow solver Nalu-Wind and is validated against experimental data and results from NASA’s flow solvers. The test cases of the AIAA Transition Prediction and Modeling Workshop are investigated, namely, the T3A/T3B flat plates and the NLF(1)-0416 and S809 airfoils. Based on the results, best practices for transition simulations, particularly for an unstructured-grid flow solver, are identified. Additional airfoil simulations are conducted for two wind turbine airfoils, S822 at Reynolds numbers of 𝑂⁡(10 5 ) and DU00-W-212 at Reynolds numbers of 𝑂⁡(10 7 ), to assess the model at low and high Reynolds numbers. Furthermore, through this work, we propose several approaches to enhance transition simulations, including 1) enforcing positivity of the implicit operator for the source terms of the transition model, 2) employing a constant turbulence intensity in stationary external flow simulations, and 3) recommending meshing for unstructured-grid flow solvers. Finally, we provide detailed documentation of the validation and data for the canonical cases to the transition modeling community.

17 WIND ENERGY↗

DOE OSTI2023

Numerical Investigation of Wall-Cooling Effect on Aero-Optical Distortions for Hypersonic Boundary Layer

Compressible wall-modeled large-eddy simulations of Mach 8 turbulent boundary-layer flows over a flat plate were carried out for the conditions of the hypersonic wind tunnel at Sandia National Laboratories. The simulations provide new insight into the effect of wall cooling on the aero-optical path distortions for hypersonic turbulent boundary-layer flows. Four different wall-to-recovery temperature ratios, 0.3, 0.48, 0.71, and 0.89, are considered. Despite the much lower grid resolution, the mean velocity, temperature, and resolved Reynolds stress profiles from the simulation for a temperature ratio of 0.48 are in good agreement with those from a reference direct numerical simulation. The normalized root-mean-square optical path difference obtained from the present simulations is compared with that from reference direct numerical simulations, Sandia experiments, as well as predictions obtained with a semi-analytical model by Notre Dame University. Here the present analysis focuses on the effect of wall cooling on the wall-normal density correlations, on key underlying assumptions of the aforementioned model such as the strong Reynolds analogy, and on the elevation angle effect on the optical path difference. Wall cooling is found to increase the velocity fluctuations and decrease the density fluctuations, resulting in an overall reduction of the normalized optical path distortion. Compared to the simulations, the basic strong Reynolds analogy overpredicts the temperature fluctuations for cooled walls. Also different from the strong Reynolds analogy, the velocity and temperature fluctuations are not perfectly anticorrelated. Finally, as the wall temperature is raised, the density correlation length, away from the wall but inside the boundary layer, increases significantly for beam paths tilted in the downstream direction.

42 ENGINEERING↗

DOE OSTI2024

Transducer Resolution Effect on Pressure Fluctuations Beneath Hypersonic Turbulent Boundary Layers

The size of a pressure transducer is known to affect the accuracy of measurements of wall-pressure fluctuations beneath a turbulent boundary layer because of spatial averaging over the sensing area of the transducer. In this paper, the effect of finite transducer size is investigated by applying spatial averaging or wavenumber filters to a database of hypersonic wall pressure generated from a direct numerical simulation (DNS) that simulates the turbulent portion of the boundary layer over a sharp 7° half-angle cone at nominally Mach 8. Here, a good comparison between the DNS and the experiment in the Sandia Hypersonic Wind Tunnel at Mach 8 is achieved after spatial averaging is applied to the DNS data over an area similar to the sensing area of the transducer. The study shows that a finite sensor size similar to that of the PCB132 transducer can cause significant attenuation in the root-mean-square and power spectral density (PSD) of wall-pressure fluctuations, and the attenuation effect is identical between cone and flat plate configurations at the same friction Reynolds number. The Corcos theory is found to successfully compensate for the attenuated high-frequency components of the wall-pressure PSD.

42 ENGINEERING↗

DOE OSTI2024

Three-Dimensional Aerodynamics and Vortex-Shedding Characteristics of Wind Turbine Airfoils over 360-Degree Angles of Attack

In this work, we present the first three-dimensional (3D) computational investigation of wind turbine airfoils over 360° angles of attack to predict unsteady aerodynamic loads and vortex-shedding characteristics. To this end, static–airfoil simulations are performed for the FFA-W3 airfoil family at a Reynolds number of 107 with the Improved Delayed Detached Eddy Simulation turbulence model. Aerodynamic forces reveal that the onset of boundary-layer instabilities and flow separation does not necessarily coincide with the onset of stall. In addition, a comparison with two-dimensional simulation data and flat plate theory extension of airfoil polars, suggest that, in the deep stall regime, 3D effects remain critical for predicting both the unsteady loads and the vortex-shedding dynamics. For all airfoils, the vortex-shedding frequencies are found to be inversely proportional to the wake width. In the case of slender airfoils, the frequencies are nearly independent of the airfoil thickness, and their corresponding Strouhal number St is approximately 0.15. Based on the calculated St, the potential for shedding frequencies to coincide with the natural frequencies of the International Energy Agency 15 MW reference wind turbine blades is investigated. The analysis shows that vortex-induced vibrations occur primarily at angles of attack of around ±90° for all airfoils.

17 WIND ENERGY↗

DOE OSTI2025

Methods for Measuring and Computing the Reference Temperature in Newton’s Law of Cooling for External Flows

Newton’s law of cooling requires a reference temperature (𝑇 𝑟𝑒𝑓 ) to define the heat-transfer coefficient (ℎ). For external flows with multiple temperatures in the freestream, obtaining 𝑇 𝑟𝑒𝑓 is a challenge. One widely used method, referred to as the adiabatic-wall (AW) method, obtains 𝑇 𝑟𝑒𝑓 by requiring the surface of the solid exposed to convective heat transfer to be adiabatic. Another widely used method, referred to as the linear-extrapolation (LE) method, obtains 𝑇 𝑟𝑒𝑓 by measuring/computing the heat flux ($𝑞^{′′}_𝑠$) on the solid surface at two different surface temperatures (𝑇 𝑠 ) and then linearly extrapolating to $𝑞^{′′}_𝑠$ = 0. A third recently developed method, referred to as the state-space (SS) method, obtains 𝑇 𝑟𝑒𝑓 by probing the temperature space between the highest and lowest in the flow to account for the effects of 𝑇 𝑠 or $𝑞^{′′}_𝑠$ on 𝑇 𝑟𝑒𝑓 . This study examines the foundation and accuracy of these methods via a test problem involving film cooling of a flat plate where $𝑞^{′′}_𝑠$ switches signs on the plate’s surface. Results obtained show that only the SS method could guarantee a unique and physically meaningful 𝑇 𝑟𝑒𝑓 where 𝑇 𝑠 =𝑇 𝑟𝑒𝑓 on a nonadiabatic surface $𝑞^{′′}_𝑠$ = 0. The AW and LE methods both assume 𝑇 𝑟𝑒𝑓 to be independent of 𝑇 𝑠 , which the SS method shows to be incorrect. Though this study also showed the adiabatic-wall temperature, 𝑇 𝐴𝑊 , to be a good approximation of 𝑇 𝑟𝑒𝑓 (<10% relative error), huge errors can occur in ℎ about the solid surface where |𝑇 𝑠 −𝑇 𝐴𝑊 | is near zero because where 𝑇 𝑠 =𝑇 𝐴𝑊 , $𝑞^{′′}_𝑠$ ≠ 0.

Newton's law of cooling↗

DOE OSTI2021

Renewable Thermal Hybridization Framework for Industrial Process Heat Applications

Renewable thermal energy systems (RTES) could be hybridized with different renewable options (e.g., flat plate collectors (FPCs) with parabolic collectors), or combined with existing heat supplies (e.g., fossil fuels), to give options for targeted solar IPH applications, industrial decarbonization and the reduction of fuel consumption. Buildings and industrial thermal energy applications require different temperature ranges, quantities, and rates of thermal energy, and as such require flexible, cost competitive solutions, able to provide heat over various temperature ranges. Hybrid solutions and thermal energy storage (TES) will be important for the dispatch of heat at optimal times needed by the demand side of the buildings and industrial applications. A variety of tools and platforms, such as the System Advisor Model (SAM), can provide hourly thermal yield simulations from single renewable energy (RE) technology options, including FPCs or CSP for solar IPH. We have investigated a variety of approaches to hybrid system modeling for RTES at different temperatures or combinations of technologies and developed an initial framework. The hybridization framework starts by creating a heat stream and raising the temperature of that heat stream by various combinations of RE technologies and other sources such as fossil fuels, new fuels or electric heating in multiple stages, with options for TES and/or waste heat recovery (WHR).

43 PARTICLE ACCELERATORS↗

DOE OSTI2021

Performance Modeling of a Variable-Geometry Oscillating Surge Wave Energy Converter on a Raised Foundation: Preprint

This paper analyzes the power capture potential, structural loadings, and costs associated with an oscillating surge wave energy converter (OSWEC) operating on a raised foundation. The raised OSWEC offers opportunities for reduced installation costs, improved energy production, and greater flexibility of deployment when compared with bottom-fixed models. In this investigation, several different foundation geometries were simulated using WEC-Sim to estimate power capture and structural loads. In an effort to maximize power capture, several cases in which flat plates of varying size were attached to the top of the foundation, under and parallel with the OSWEC, were also simulated. These plates were found to enhance power capture by preventing the wave induced pressure from passing underneath the OSWEC, diverting this pressure towards the OSWEC instead. The OSWEC was simulated in the six Wave Energy Prize sea states, which were chosen as a representative sample of U.S. deployment sites. A first-order estimate of structural costs was calculated using the Wave Energy Prize ACE metric, with the foundation comprised predominantly of steel-reinforced concrete and the OSWEC comprised of A36 steel. Influence of foundation geometry on power capture, structural loadings, and ACE are topics of particular interest. This work has been inspired by advances in large scale additive manufacturing techniques that have the potential to dramatically reduce the cost of subsea foundations. These advancements may enable cost effective WEC systems to be deployed on raised foundations.

50 EE - Wind and Water Power Program - Water (EE-4↗

DOE OSTI2022

NCSU Industrial Assessment Center

Renewable energy technologies are becoming more attractive and gaining more attention as the world becomes increasingly aware of the negative impacts of global warming and greenhouse gas (GHG) emissions. Two such emerging technologies are geothermal heat pumps (GHP) and solar thermal heating which can be used for heating and cooling of buildings. GHP systems are a well-studied technology that have been proven to be more efficient than traditional air-source heat pumps for space conditioning of buildings. Solar thermal heating has become more common as a way to heat domestic hot water (DHW) in homes, but the two technologies are not often combined. This study presents the findings of combining an open-loop GHP with 100 ft2 of flat plate solar thermal panels and a 5,655-gallon sensible water storage tank for space heating and DHW heating needs of a residential home in Bozeman, MT, USA. The goal of this system was to use energy from the solar panels and storage tank first to decrease pumping energy from the GHP well. The open loop system was designed to be a backup system to the solar thermal panels and sensible storage tank. An actual home was modeled to determine potential energy and cost savings of such a system compared to a traditional propane boiler. Then, a case study was performed on the installed system from January to June 2021. Results obtained from April 2nd to June 5th, 2021 indicated that the combination system supplied all necessary heat, and that heat was supplied from the thermal storage tank 55% of the time. This represents a savings of 330 kWh of energy and $36 compared to operating just the open loop geothermal system. From April 2nd to June 5th the combination system consumed a total of 2,510 kWh of energy and cost $274 to operate. Based on data obtained, there is significant potential for energy savings compared to a propane boiler, however only small potential for cost savings.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2022

System and method of water purification utilizing an ionomer membrane

A water purification system utilizes an ionomer membrane and mild vacuum to draw water from source water through the membrane. A water source may be salt water or a contaminated water source. The water drawn through the membrane passes across the condenser chamber to a condenser surface where it is condensed into purified water. The condenser surface may be metal or any other suitable surface and may be flat or pleated. In addition, the condenser surface may be maintained at a lower temperature than the water on the water source side of the membrane. The ionomer membrane may be configured in a cartridge, a pleated or flat plate configuration. A latent heat loop may be configured to carry the latent heat of vaporization from the condenser back to the water source side of the ionomer membrane. The source water may be heated by a solar water heater.

Bahar, Bamdad↗

DOE OSTI2022

Low-Carbon District Heating: Performance Modeling of Hybrid Solar, Heat Pump, and Thermal Storage Systems for District Thermal Energy in the United States

District heating requires thermal energy in the temperature range of 40 degrees C - 120 degrees C. Typically, the thermal energy input for these systems has largely been met through fossil energy. However, the temperature range is low enough that it presents an opportunity for low-carbon technologies such as solar thermal and electrified thermal generators like heat pumps to decarbonize the heat generation. In this paper, a heat pump model was applied to estimate the performance and economics of a real-world low-carbon district heating substation. This system is comprised of a flat plate solar collector field paired with a mechanical vapor compression heat pump and hot water thermal storage, augmented by gas-fired boilers. Plant data was used to tune the model and estimate the system's benefits in terms of both standard financial metrics (IRR and payback), and environmental metrics, including avoided CO2 emissions. The model is subsequently employed to estimate the technical and economic potential of solar + heat pump + ther-mal storage hybrid systems as retrofits for district heating systems in eight US Markets.

district heating↗

DOE OSTI2025

Simplified Model and Approach to Transform Infrared Surface Temperature to Film Effectiveness in a Conjugate Heat Transfer Experiment

This paper describes a simplified engineering model based on a one-dimensional thermal resistance network. The model is used to develop a new method to relate film cooling effectiveness and heat transfer augmentation to local overall cooling effectiveness in a conjugate flat plate experiment. This paper presents experimental proof-of-concept data to demonstrate the potential for this model. In contrast to previous approaches, neither the wall heat flux nor the adiabatic wall temperature is required to estimate the local film cooling performance parameters. The model predicts surface temperatures that are within the experimental uncertainties over the range for which the model is trained, and to within five percent when the model is extrapolated to higher coolant channel Reynolds numbers. This paper is relevant to conjugate test rigs that can measure the hot surface temperature distribution with and without film cooling. This information may also be relevant to designers as a method to approximate surface temperatures or used as an approximate heat transfer model for optimization studies.

advanced gas turbines↗

DOE OSTI2024

HEU Pancake (Jemima) Plate Preliminary Characterization Report

The HEU pancake (Jemima) plates have been used in multiple International Criticality Safety Benchmark Evaluation Project (ICSBEP) evaluations, including: HEU-MET-FAST-072, HEU-MET-FAST-073, HEU MET-FAST-102, HEU-MET-INTER-006, HEU-MET-INTER-011, HEU-MET-MIXED-021, and IEU MET-FAST-025. This report only focuses on the physical dimension characterization, since concerns have been identified about reliable diameter and height measurements. Historically, height measurements with calipers and mass measurements have been performed for every plate. However, the combination of previous measurements (mass and caliper height measurements) with the drawing dimensions for the diameters led to unrealistic densities (>19 g/cm 3 ) or large ranges of densities for parts that were manufactured at the same time (17 g/cm 3 to >19 g/cm 3 ). Due to the oxidation of the plates, questions about the flatness of each plate and what gaps are introduced into the system have been discussed, since gaps tend to be one of the largest sources of uncertainty in stacked benchmark experiments. The purpose of this report is to characterize a subset of this commonly used fuel. A uniform method for how to define the HEU pancake plates for ICSBEP evaluations will also be proposed with a discussion on what measurements should be performed on the remaining HEU pancake plates in the NCERC inventory.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2026

Visualization of Two-phase Flow Maldistribution in Brazed Plate Heat Exchangers

Brazed plate heat exchangers (BPHEs) are widely used in refrigeration and HVAC applications, but are susceptible to two-phase flow maldistribution especially when operated as evaporators. Existing visualization approaches are either limited to idealized conditions or suffer from poor optical transparency. This paper presents a novel visualization method in which one edge of a BPHE, parallel to the refrigerant inlet or outlet port, is removed by wire electrical discharge machining and replaced with a flat, transparent plate. The planar geometry allows the use of optically and infrared (IR)-transparent materials, enabling both high-speed videography and IR thermography of the two-phase flow at the channel entrances and exits. Preliminary tests with R134a and R1234ze(Z) at saturation temperatures between 5 °C and 15 °C demonstrate that distinct two-phase flow patterns in the inlet header can be clearly identified and differentiated under realistic operating conditions. Potentials of optical flow analysis of high-speed videos are shown to provide objective, quantitative indicators for flow regime characterization and comparison. IR imaging of the outlet port reveals non-uniform temperature distributions at the channel exits, providing independent evidence of maldistribution across the channel stack. Limitations of IR temperature accuracy due to the spectral properties of the sapphire window are discussed, and directions for improvement are identified.

Hausherr, Carsten [Technical University of Berlin ↗

DOE OSTI2026

Calculating the space-charge-limited current density for nonplanar geometries by simulating the charge-free electric field

Calculating the space-charge-limited-current density (SCLCD) for a complicated diode geometry often requires computationally expensive particle-in-cell (PIC) codes. Here, this paper addresses this issue by using the charge-free electric field $E_0$ calculated using COMSOL Multiphysics to determine local and global SCLCD. The SCLCD obtained by using the surface average of $|E_0|^2$ on the cathode recovers theoretical results for one-dimensional (1D) planar, cylindrical, and tip-to-tip geometries in appropriate limits. We next compared tip-to-tip calculations with the SCLCD obtained using the PIC code Empire. The SCLCD calculated using COMSOL agreed well with Empire for flatter 1D tip-to-tip geometries and diverged with increasing sharpness. Physically, Empire predicts lower SCLCD than COMSOL because the electrons spread due to concentrated space-charge at the tip, whereas theory assumes that the electrons follow the charge-free electric field lines. We further assess the behavior of the SCLCD for tips protruding from the centers of flat, circular plates of various areas. Larger plate areas with constant tip size recover the 1D planar SCLCD globally and 1D tip-to-tip SCLCD locally, while reducing the difference between Empire and COMSOL calculations since larger plates capture more of the emitted electrons, reducing SCLCD suppression due to beam spreading. These results show that charge-free electric field simulations can be used to determine the SCLCD without needing to simulate particle dynamics in PIC.

Wright, Jack K. [Purdue Univ., West Lafayette, IN ↗

DOE OSTI2025

Code Verification of Multiple Physics-Fidelity Models in Hypersonic Aerodynamics

Hypersonic aerodynamics models exist across a range of physics fidelities with associated computational expenses. These models may be run independently or in a multifidelity framework that leverages their complementary strengths of speed for lower-fidelity and accuracy for higher-fidelity models. This work presents applied code verification of two lower-fidelity models contained within the Sandia hypersonic aerodynamics code. Each model has a different form that requires individualized verification approaches, including comparison to analytical solutions as well as manufactured solutions with order-of-accuracy testing. In conclusion, results of this effort include the identification and resolution of code errors and shortcomings, as well as the demonstration of code correctness and consistency for both models.

Aerodynamics↗

DOE OSTI2024

Jemima Plate Characterization

The HEU Jemima plates have been utilized in numerous International Criticality Safety Benchmark Evaluation Project (ICSBEP) evaluations. ICSBEP evaluations are a vital com ponent of nuclear data validation for applications across the nuclear community. In the past, different combinations of mass, caliper measurements, and drawing dimensions have been used to define the HEU Jemima plates in ICSBEP evaluations. Some of these combinations result in large density ranges (17 g/cm 3 to 19 g/cm 3 ) or unrealistic densities (greater than 19 g/cm 3 ). Additionally, oxidation of the plates has led to questioning the flatness of each plate, which can add additional gaps in experiment configurations. This work proposes a standardized method of defining the commonly used HEU Jemima plates across different experiments.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2022

Magnetic cores with high reluctance differences in flux paths

Embodiment of the present invention includes a magnetic structure and a magnetic structure used in a direct current (DC) to DC energy converter. The magnetic structure has an E-core and a plate, with the plate positioned in contact or in near contact with the post surfaces of the E-core. The E-core has a base, a no-winding leg, a transformer leg, and an inductor leg. The no-winding leg, the transformer leg, and the inductor leg are perpendicular and magnetically in contact with the base. The plate is a flat slab with lateral dimensions generally larger than its thickness. The plate has a plate nose that overlaps a top no-winding leg surface of the no-winding leg with a no-winding gap area to form a no-winding gap with a no-winding gap reluctance. The plate also has a plate end that overlaps a top inductor leg surface of the inductor leg with an inductor gap area to form an inductor gap with an inductor gap reluctance. In some embodiments, e.g., where the duty cycle is less than 50 percent, the inductor gap reluctance will be designed to be less than the no-winding gap reluctance. In these cases, the majority of the magnetic flux that passes through the transformer leg will return through the inductor leg, instead of through the no-winding leg. The inductor and no-winding gap reluctances can he adjusted, so that the electromotive force applied to a charge passing through the inductor will partially cancel the electromotive force applied by the transformer secondary. The gap reluctance ratio can be defined, so that the difference in secondary and inductor electromotive forces is equal to the output voltage defined by an optimal no-ripple duty cycle. In this way no changing current is required through the inductor to create a dI/dt inductive voltage drop across the output inductor. Zero output current ripple is achieved.Various embodiments of the plate, plate shape, and no-winding leg are disclosed. These embodiments allow achieving a high ratio of no-winding gap reluctance to inductor gap reluctance, for practical, affordable magnetic material structures and aspect ratios. A high gap reluctance ratio enables zero output current ripple for the high transformer turns ratios that are needed to achieve high input to output voltage ratios. The embodiments therefore allow achieving low output current ripple for 48 V or higher input voltages, 1 V or lower output voltages, and high output currents.

Yao, Yuan↗