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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 73 records · Page 4
All sourcesNASA NTRSDOE OSTI
NASA NTRS1996

Numerical Investigation of Slag Behavior for RSRM

It is known that the flow field of the redesigned solid rocket motor (RSRM) is very complicated due to the complex characteristics of turbulent multi-phase flow, chemical reaction, particle combustion, evaporation, breakup and agglomeration etc. It requires multi-phase calculations, chemical reaction simulation, and particle combustion, evaporation, and breakup models to obtain a better understanding of thermophysics for the RSRM design using numerical methods. Also, the slag buildup due to the molten particles is another factor affecting the performance of the RSRM. To achieve this goal, the volume of fluid (VOF) method is used to capture the free surface motion so as to simulate the accumulation of the molten particles (slag) of the RSRM. A finite rate chemistry model is used to simulate the chemical reaction effects. For multi-phase calculations, the Hermsen combustion model is used for the aluminum particle combustion analysis and the Taylor Analogy Breakup (TAB) model is used for the particle breakup analysis. An interphase mas-exchange model introduced by Spalding is used for the evaporation calculation. The particle trajectories are calculated using a one-step implicit method for several groups of particle sizes by which the drag forces and heat fluxes are then coupled with the gas phase equations. The preliminary results predicted a reasonable physical simulation of the particle effects using a simple two dimensional solid rocket motor configuration. It shows that the AL/AL2O3 particle sizes are reduced due to the combustion, evaporation, and breakup. The flow field is disturbed by the particles. Mach number distributions in the nozzle are deformed due to the effect of particle concentrations away from the center line.

Liaw, P.↗
DOE OSTI2025

A Geometric Volume of Fluid-Based Multiphase Flow Solver Extension to the Reacting Flow Solver, PeleLM

A new algorithm is presented to simulate multiphase flows with surface tension in a pathway for spray combustion simulation. The algorithm combines capabilities from two open-source packages, including the interface reconstruction library (IRL), a library of computational geometry routines to enable the volume of fluid (VOF) method, and PeleLM, a solver for the reacting Navier-Stokes equations. Additionally, surface tension is implemented using the continuum surface force (CSF) model with an improved height function technique in the volume fraction field. Spurious errors in volume fraction arising from our combined strategy are corrected through a topology-based method that improves both numerical stability and accuracy. Multiple validation simulations are conducted, including (i) translations and rotations of Zalesak's disk, (ii) a stationary circular droplet with surface tension, (iii) an oscillating elliptical droplet, and (iv) three-dimensional deformation of a spherical droplet. Results indicate that the combined scheme retains the favorable properties of each of the component algorithms.

42 ENGINEERING↗
NASA NTRS2011

Crater Formation Due to Lunar Plume Impingement

Thruster plume impingement on a surface comprised of small, loose particles may cause blast ejecta to be spread over a large area and possibly cause damage to the vehicle. For this reason it is important to study the effects of plume impingement and crater formation on surfaces like those found on the moon. Lunar soil, also known as regolith, is made up of fine granular particles on the order of 100 microns.i Whenever a vehicle lifts-off from such a surface, the exhaust plume from the main engine will cause the formation of a crater. This crater formation may cause laterally ejected mass to be deflected and possibly damage the vehicle. This study is a first attempt at analyzing the dynamics of crater formation due to thruster exhaust plume impingement during liftoff from the moon. Though soil erosion on the lunar surface is not considered, this study aims at examining the evolution of the shear stress along the lunar surface as the engine fires. The location of the regions of high shear stress will determine where the crater begins to form and will lend insight into how big the crater will be. This information will help determine the probability that something will strike the vehicle. The final sections of this report discuss a novel method for studying this problem that uses a volume of fluid (VOF)ii method to track the movement of both the exhaust plume and the eroding surface.

Marsell, Brandon↗
NASA NTRSDate not supplied

Development and Validation of a Slosh-Based Ullage Collapse Model

Ullage collapse modeling is an essential tool for the success of spacecraft powered by cryogenic propellants. The degree of ullage collapse can have a major impact on the design of cryogenic propellant tanks as well as the mission’s concept of operations. Additional commodities (e.g., helium gas for pressure control) and their quantities are dependent on the amount of heat transfer and phase change of propellants expected during flight. Currently, high-fidelity computational fluid dynamics (CFD) with heat transfer and phase change is the most accurate method for predicting ullage collapse. CFD simulations of this kind, however, can become very costly for problems requiring large domains, long simulation times, or significant liquid motion. Consequently, there is a need for a reduced order model to provide fast responses which can be used in engineering design decisions. The proposed numerical model is a nodal approach, augmented by outputs from CFD analyses that are generated rapidly and reliably. These outputs include transient values for liquid-vapor interface area, interface velocity, and liquid position using a volume of fluid (VoF) method. There are several benefits of combining a nodal approach with slosh predictions from CFD simulations: leveraging of the Loci/STREAM-VoF solver that has been validated in high-g and low-g environments, rapid modeling of VoF with isothermal propellant simplifications and relatively coarse meshes, and improved model predictions from the nodal tool. The nodal approach, informed by the slosh predictions from CFD, assumes uniform conditions in the liquid and gas domains. Modifications to account for temperature stratification in the liquid and gas may be implemented as a future improvement. Thermodynamic changes within the tank are solved at user-defined timesteps. First, impacts due to mass entering or leaving the control volume are captured. Second, heat transfer impacts are accounted for by tracking the volume of the gas which has been contacted by liquid in that timestep and rebalancing the internal energy. Finally, phase change is approximated using the area and velocity of the interface. The tank conditions are re-computed by conserving mass and energy. Calibration of the model to several test flights and experiments are required to baseline the predictive power and uncertainty. The final product will enable designers and engineers to create quick-turnaround predictions for ullage collapse and inform design feasibility.

Computational Fluid Dynamics↗
DOE OSTI2018

FEHM V3.0 - V3.X

The numerical background of the FEHM computer code can be traced to the early 1970s when it was used to simulate geothermal and hot dry rock reservoirs. The primary use over a number of years was to assist in the understanding of flow fields and mass transport in the saturated and unsaturated zones below the potential Yucca Mountain repository. Today FEHM is used to simulate groundwater and contaminant flow and transport in deep and shallow, fractured and un-fractured porous media throughout the US DOE complex. FEHM has proved to be a valuable asset on a variety of projects of national interest including Environmental Remediation of the Nevada Test Site, the LANL Groundwater Protection Program, geologic CO2 sequestration, Enhanced Geothermal Energy (EGS) programs, Oil and Gas production, Nuclear Waste Isolation, and Arctic Permafrost. Subsurface physics has ranged from single fluid/single phase fluid flow when simulating basin scale groundwater aquifers to complex multifluid/ multi-phase fluid flow that includes phase change with boiling and condensing in applications such as unsaturated zone surrounding nuclear waste storage facility or leakage of CO2/brine through faults or wellbores. The numerical method used in FEHM is the control volume method (CV) for fluid flow and heat transfer equations which allows FEHM to exactly enforce energy/mass conservation; while an option is available to use the finite element (FE) method for displacement equations to obtain more accurate stress calculations. In addition to these standard methods, an option to use FE for flow is available, as well as a simple Finite Difference scheme.

Pawar, Rajesh↗
DOE OSTI2022

On the Response of a Herschel–Bulkley Fluid Due to a Moving Plate

In this paper, we study the boundary-layer flow of a Herschel–Bulkley fluid due to a moving plate; this problem has been experimentally investigated by others, where the fluid was assumed to be Carbopol, which has similar properties to cement. The computational fluid dynamics finite volume method from the open-source toolbox/library OpenFOAM is used on structured quad grids to solve the mass and the linear momentum conservation equations using the solver “overInterDyMFoam” customized with non-Newtonian viscosity libraries. The governing equations are solved numerically by using regularization methods in the context of the overset meshing technique. The results indicate that there is a good comparison between the experimental data and the simulations. The boundary layer thicknesses are predicted within the uncertainties of the measurements. The simulations indicate strong sensitivities to the rheological properties of the fluid.

36 MATERIALS SCIENCE↗
DOE OSTI2022

The role of breakup and coalescence in fine-scale bubble-induced turbulence. I. Dynamics

We study the effect of bubble breakup and coalescence on fine-scale dynamics of bubbly turbulent flows using direct numerical simulations. We perform two different simulations of dilute bubbly flows of void fraction 0.5%: one with bubbles breaking up and coalescing and the other without these physical processes. The volume of the fluid method is used for simulating bubbles undergoing breakup and coalescence while the bubbles are treated as rigid spheres in the immersed boundary method simulation. The energy spectrum in both types of simulation, consistent with previous studies, exhibits a -3 slope. We follow a single infinitesimal fluid element as it evolves to understand velocity gradient dynamics using conditional mean trajectories. We note finite-time divergence when the fluid element evolves under the action of inertial and pressure dynamics. The inertial, pressure, and viscous velocity gradient dynamics, when considered individually, produce the same results for bubble-induced turbulence (BIT) as with the classical homogeneous isotropic turbulence (HIT). Yet when the overall velocity gradient dynamics is considered, BIT results in non-cyclic trajectories moving toward stable node and unstable saddle while classical HIT shows cyclic behavior in their trajectories that move toward the origin. Interestingly, both the volume of fluid and immersed boundary simulations produce similar results. Therefore, there are two main takeaways from this research. First, new velocity gradient models are needed for BIT as their velocity gradients behavior is entirely different from the HIT. Second, we can neglect the bubble topology, breakup, and coalescence while studying or modeling the fine-scale dynamics of BIT.

42 ENGINEERING↗
DOE OSTI2024

Capturing thin structures in VOF simulations with two-plane reconstruction

A novel interface reconstruction strategy for volume of fluid (VOF) methods is introduced that represents the liquid-gas interface as two planes that co-exist within a single computational cell. In comparison to the piecewise linear interface calculation (PLIC), this new algorithm greatly improves the accuracy of the reconstruction, in particular when dealing with thin structures such as films. The placement of the two planes requires the solution of a non-linear optimization problem in six dimensions, which has the potential to be overly expensive. Further, an efficient solution to this optimization problem is presented here that exploits two key ideas: an algorithm for extracting multiple plane orientations from transported surface data, and an efficient and mass-conserving distance-finding algorithm that accounts for two planes with arbitrary orientation. Additionally, a simple and robust strategy is presented to accurately represent the surface tension forces produced at the interface of subgrid-thickness films. The performance of this new VOF reconstruction is demonstrated on several test cases that illustrate the capability to handle arbitrarily thin films.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
DOE OSTI2022

Hardness Prediction by Incorporating Heat Transfer and Molten Pool Fluid Flow in a Multi-pass, Multi-layer Weld for Onsite Repair of Grade 91 steel

Introduction: In the current fleet of fossil-fired power plants, creep strength enhanced ferritic steels (CSEF) are used to sustain the harsh service conditions. Enhanced properties of Grade 91 steel result from tempered martensite with a fine distribution of MX and M23C6 carbides. Grade 91 steel is subjected to onsite welding repair to remedy their degradation due to extreme service condition. Knowledge of weld repairability of these steels, such as as-welded hardness distribution, is essential to establishing sound repair procedures. Experimental trial and error tests can consume a lot of time as many welding variables need to be studied. For numerical modelling, most of the multi-pass multi-layer models are based on finite element method, which are limited to solve the heat conduction equation and ignore convective heat transfer due to melt flow. Moreover, the mesh has to be pre-built based on a known or assumed weld cross-section geometry. These finite element based models thus have limited predictive capability as defects are not considered and nugget size are pre-assumed. This research aims at developing a thermal and microstructure evolution model incorporating molten pool dynamics in a multi-pass multi-layer material deposition to predict the as-welded hardness distribution. Technical Approach: All the thermal, physical, and metallurgical properties of Grade 91 as a function of temperature are collected from the literature and inputted into the thermo-fluid model based on Flow-3D, a computational fluid dynamics software. A multi-pass, multi-layer material deposition is simulated where the melting of filler wire into the molten pool is directly considered based on the volume of fluid (VOF) method. The flow behaviour of the molten pool is used to understand the formation of deposition geometry and defects. The temperature profiles during the multi-pass, multi-layer welding are calculated. The results computed using the new model are compared against the experimental data of fusion zone geometry and thermal cycles. Hardness prediction in the heat-affected zone (HAZ) are made using Johnson-Mehl-Avrami (JMA) equation for solid-state phase transformation kinetics. The JMA parameters are extracted from the experimental data available in the literature. For comparison, a standard finite element heat conduction model is also developed to predict the thermal cycles and hardness distribution in the multi-pass, multi-layer weld. Expected Result: Results obtained using the molten pool dynamic simulation versus the finite element heat conduction model are compared. Specifically, the effects of convective heat transfer on the accuracy of the calculated thermal history, bead shape and size, and HAZ hardness distribution are examined.

Modeling, Grade 91 steel, Multi-pass multi-layer d↗
DOE OSTI2023

Numerical Simulations of High Prandtl Number Liquid Jets Impinging on a Flat Plate

In this work, 3D simulations of oil jets impinging on a flat, heated wall are presented. The numerical setup uses the Volume of Fluid (VoF) method to model the two-phase flow. A careful grid definition across the liquid film, along with the use of the Conjugate Heat Transfer (CHT) approach allowed local heat transfer to be solved with fine resolution at the wall. Variations of liquid flow rate, liquid temperature and surface temperature allow to cover a wide range of local Reynolds and Prandtl numbers (226 < Re < 2850, 77 < Pr < 161). Resulting surface-averaged heat transfer compares very well with experimental measurements conducted in a previous study. In-depth analysis of the flow has identified expected features from the literature. In particular, the impact of jet axial velocity profiles on the heat transfer distribution in the stagnation zone was clearly stated. The increase in heat transfer when warming the liquid film was also reproduced and explained by a decrease in oil viscosity and an increase in film velocity. All those effects were taken into account in correlations for stagnation and local values of Nusselt number. A grid sensitivity study was also conducted, showing that if the grid solving the thermal boundary layer in the stagnation zone can be coarsened without impacting local and surface-averaged predictions of heat transfer, a minimum resolution (2 to 3 cells) within the thermal boundary layer is however required for an accurate prediction of heat transfer.

conjugate heat transfer↗
DOE OSTI2018

Multiphase flow studies for microscale hydrodynamics in the structured packed column

Post combustion carbon capture by solvent absorption in a structured packed column is a promising technology for mitigating greenhouse gas emissions. Computational fluid dynamic (CFD) modelling of such a column is a challenging multiscale problem due to the range in length and time scales. The microscale hydrodynamics play a key role in the overall column efficiency with the interfacial area significantly influencing the mass transfer between the gas and liquid phases. In this context, multiphase flow simulations using the volume of fluid (VOF) method in a representative elementary unit (REU) of the packed column can provide fundamental insights into the microscale hydrodynamics, such as, interfacial area and liquid holdup. The present paper systematically examines the impact of various factors (e.g., physical properties and contact angle) on the interfacial area. The results are compared with existing correlations and a scaling analysis is also performed. The solvent physical properties are characterized by the Kapitza number (Ka), a dimensionless number that depends only on fluid properties. So that the Ka number decreases with increasing viscosity. At a fixed liquid load, the interfacial area and liquid holdup are observed to increase with decreasing Ka number. The impact of contact angle (i.e., solid surface characteristics) is effectively investigated by modifying the wall boundary conditions. The interfacial area and liquid holdup are found to decrease with increasing contact angle. Subsequently, a phenomenological correlation for interfacial area is proposed that includes the impact of these parameters. Finally, this correlation may be used to predict the interfacial area for gas-liquid flow in a structured packing for rivulet to fully wetted flow regimes.

42 ENGINEERING↗
DOE OSTI2018

Modulating factors of hydrologic exchanges in a large-scale river reach: Insights from three-dimensional computational fluid dynamics simulations

Hyporheic exchange is a critical mechanism shaping hydrological and biogeochemical processes along a river corridor. Recent studies on quantifying the hyporheic exchange were mostly limited to local scales due to field inaccessibility, computational demand, and complexity of geomorphology and subsurface geology. Surface flow conditions and subsurface physical properties are well known factors on modulating the hyporheic exchange, but quantitative understanding of their impacts on the strength and direction of hyporheic exchanges at reach scales is absent. In this study, a high resolution computational fluid dynamics (CFD) model that couples surface and subsurface flow and transport is employed to simulate hyporheic exchanges in a 7-km long reach along the main-stem of the Columbia River. Assuming that the hyporheic exchange does not affect surface water flow conditions due to its negligible magnitude compared to the volume and velocity of river water, we developed a one-way coupled surface and subsurface water flow model using the commercial CFD software STAR-CCM+. The model integrates the Reynolds-averaged Navier-Stokes (RANS) equation solver with a realizable k-e two-layer turbulence model, a two-layer all y^+ wall treatment, and the volume of fluid (VOF) method, and is used to simulate hyporheic exchanges by tracking the free water-air interface as well as flow in the river and the subsurface porous media. The model is validated against measurements from acoustic Doppler current profiler (ADCP) in the stream water and hyporheic fluxes derived from a set of temperature profilers installed across the riverbed. The validated model is then employed to systematically investigate how hyporheic exchanges are influenced by surface water fluid dynamics strongly regulated by upstream dam operations, as well as subsurface structures (e.g. thickness of riverbed and subsurface formation layers) and hydrogeological properties (e.g. permeability). The results suggest that the thickness of riverbed alluvium layer is the dominant factor for reach-scale hyporheic exchanges, followed by the alluvium permeability, the depth of the underlying impermeable layer, and the assumption of hydrostatic pressure.

Bao, Jie↗
DOE OSTI2018

Three-Dimensional Mathematical Model of Oxygen Transport Behavior in Electroslag Remelting Process

A transient three-dimensional model has been proposed to investigate the oxygen transport behavior in electroslag remelting process. The electromagnetism, heat transfer, multiphase flow, and species transport were calculated simultaneously by finite volume method. The volume of fluid approach was adopted to trace the metal–slag–air three-phase flow. Based on the necessary thermodynamics of oxygen transport behavior, a kinetic model was established to predict the mass source terms in species transport equation. The kinetic correction factor was proposed to account for the effect of the oxide scale formed on the electrode on the FeO content in slag. Finally, the effect of applied current on the oxygen transfer was studied. The predicted result agrees well with the measured data when the kinetic correction factor is set to be 0.5. The temperature distribution that affects the thermodynamics differs at the interfaces. The oxygen in air is absorbed into slag due to the oxidation at the slag/air interface. The Fe{sub 2}O{sub 3} in slag and the oxide scale contribute to the increase of FeO content in slag, and the latter one plays the leading role. The oxygen transfer from slag to metal mainly occurs during the formation of the droplet at the slag/metal droplet interface. With the current increasing from 1200 to 1800 A, the oxygen content increases from 76.4 to 89.8 ppm, and then slightly declines to 89.2 ppm when the current increases to 2100 A.

36 MATERIALS SCIENCE↗
DOE OSTI2018

A Numerical Simulation of Transport Phenomena During the Horizontal Single Belt Casting Process Using an Inclined Feeding System

Horizontal single belt casting (HSBC) has great potential to replace current conventional continuous casting (CCC) processes for sheet metal production, by directly casting 3 to 1 mm sheet for the automobile industry. In the present paper, two-dimensional mathematical models were developed to study transport phenomena, for the case of an inclined wall feeding system for a liquid aluminum wrought alloy (AA6111). Based on the commercial software ANSYS FLUENT 14.5 and user-defined functions, a two-layer turbulence model was used to examine the fluid flow emanating from a slot nozzle set above a water-cooled, high-speed, steel belt. The Volume of Fluid (VOF) method was used to predict the shape of the melt-air interface. A transformed coordinate system (x′, y′) was established in order to analyze the fluid flow on the inclined wall of the feeding system. The total pressure gauge gradient (∂p{sub total}/∂x) was used to describe the behavior of the melt film inside the slot nozzle of the head box. The modeling results show that during the melt film falling process, the total gauge pressure varies within the slot nozzle, which can decrease the stability of the falling film. The first impingement between the falling film and the inclined refractory wall of the feeding system gives rise to a local oscillation, and this influences the stability of the melt film moving downwards. At the rear meniscus position between the inclined wall and the moving belt, there is a clear vibration of the air-melt interface, together with a recirculation zone. The weak vibration of the air-melt interface could be induced by the periodic variation of the melt-air interface. Moreover, the formation of tiny air pockets is predicted. Finally, on the inclined wall of the feeding system, a suitable length of the transition area is needed to avoid over-acceleration of the melt film due to the force of gravity.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Hydrodynamics of countercurrent flow in an additive-manufactured column with triply periodic minimal surfaces for carbon dioxide capture

Computational investigation of the countercurrent flows in an additively manufactured (AM) column packed with triply periodic minimal surface (TPMS) is challenging. Multiphase flow simulations using the volume of fluid (VOF) method can explain the column’s hydrodynamic characteristics, including interfacial area, liquid holdup, pressure drop, flow regime, etc. The interfacial area is a key factor dictating the mass transfer via the absorption process, and thereby the overall efficiency of the column. The impacts of a solvent's physical properties, liquid and gas loads, and contact angle on the hydrodynamics are extensively explored. The solvents include traditional solvent (monoethanolamine [MEA]) used in industry as well as a water-lean solvent (EEMPA) as prospective solvents for carbon capture. As expected, interfacial area and liquid holdup increase with increasing liquid loads (q L ). The EEMPA exhibits higher values for the interfacial area and liquid holdup compared to those for the MEA. The dry and wet pressure drops per unit length in the column at different gas loads (F G ) are calculated and further compared with the empirical correlations for traditional packings. At low gas loads, i.e., in the preloading regime, the predicted values of the wet and dry pressure drops match well with the corresponding values calculated from available correlations. The gas load has a marginal impact on the interfacial area at its lower value, but the higher value of F G (>2.18 $\sqrt{Pa}$) causes flooding in the column. The effect of varying contact angles on the interfacial area and liquid holdup in the preloading regime is also studied. Both interfacial area and liquid holdup decrease with the increase in the value of the contact angle. Altogether, the effect of the contact angle on interfacial area is more pronounced than other parameters influencing the interfacial area.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2020

3D Cell-centered hydrodynamics with subscale closure model and multi-material remap

We extend a higher-order finite volume cell-centered hydrodynamic (CCH) formulation to include an interface-aware subscale closure model and a multi-material remap for simulating 3D compressible hydrodynamic problems within an arbitrary Lagrangian-Eulerian (ALE) framework. This CCH formulation involves a multidirectional approximate Riemann solution using quadratic polynomial reconstructions of the stress tensor and the velocity. At the subscale level, we determine pair-wise material interactions by solving a distinct approximate Riemann problem at the common interface, using the volume of fluids (VOF) method to find the interface. Material interactions are constrained to ensure smooth pressure equilibration among materials. The accuracy and robustness of the ALE method is demonstrated by simulating a suite of 3D Cartesian multi-material problems covering both gas and solid dynamics, where each test case has two or more materials.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
DOE OSTI2023

Design and Testing of the Vortex Ring Facility

This document summarizes the efforts of building an experimental test facility to study the evolution of the cloud following a nuclear detonation above ground level and support the development of numerical models to describe it. The experimental facility allows nonintrusive flow visualization and measurements of buoyant vortex ring formation and evolution using background-oriented Schlieren and particle image velocimetry techniques. In addition, 3D unsteady computational fluid dynamics simulations using unsteady Reynolds-averaged Navier–Stokes and volume-of-fluid numerical methods were performed to support the experimental design as well as to provide insight about the formation and evolution of the vortex ring.

42 ENGINEERING↗