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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
DOE OSTI2021

Simulations of divertor heat flux width using transport code with cross-field drifts under the BOUT++ framework

The fluid transport code [trans-electric field (Er) module] under the BOUT++ framework has been used to simulatedivertor heat flux width and boundary Er with all drifts and the sheath potential in the scrape-off layer. The calculated steady state radial Er in the pedestal region has been compared with that of experimental measurements from the Alcator C-Mod tokamak. The magnitude and shape of Er are similar to those of the experimental data. In order to understand the relative role of cross-field drifts vs turbulent transport in setting the heat flux width, four C-Mod enhanced Dα H-mode discharges with a lower single null divertor configuration should be simulated. BOUT++ transport simulations with cross-field drifts included yield similar heat flux width λq to that of experimental measurements (within a factor of 2) from both the probe and the surface thermocouple diagnostics and show a similar trend with plasma current to that of the Eich experimental scaling. The simulations show that both drifts and turbulent transport compete to determine the heat flux width. The magnetic drifts play a dominant role in setting the divertor heat-flux width, while the E × B drift decreases the heat flux width by 10%–25%, leading to improved agreement with the experiment relative to Goldston’s model. A turbulence diffusivity scan (χ) identifies two distinct regimes: a drift dominant regime when χ is small and a turbulence dominant regime when χ is large. The Goldston heuristic drift model yields a lower limit of the width λq.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2020

Compact Diffusion Bonded Heat Exchanger Fatigue Life Simulations (Final Report)

Compact diffusion bonded heat exchangers are essential for high pressure heat exchange, but they are subject to thermal fatigue and ramp rate limitations. Simulation of these geometries is challenging with a large range of length and time scales from thousands of mm-sized microchannels inside a m-sized heat exchanger. Multi-physics simulations including thermal, fluid, and solid mechanics components are being used to predict stress within the heat exchangers under these conditions. These predictions can then be used to understand thermal ramp rate limitations while keeping maximum stresses low as well as fatigue life predictions from well-known empirical models.

42 ENGINEERING↗
DOE OSTI2023

Large Eddy Simulation of Convective Heat Transfer in a Random Pebble Bed Using the Spectral Element Method

The development of fluoride-cooled high-temperature reactors has drastically increased the demand for an in-depth understanding of the heat transfer (HT) in packed beds cooled by liquid salts. The complex flow fields and space-dependent porosity found in a pebble bed require a detailed understanding to ensure the proper cooling of the reactor core during normal and accident conditions. As detailed experimental data are complicated to obtain for these configurations, high-fidelity simulation such as large eddy simulation and direct numerical simulation (DNS) can be employed to create a high-resolution heat transfer numerical database that can assist in addressing industrial-driven issues associated with the heat transfer behavior of fluoride-cooled high-temperature reactors. In this paper, we performed a series of large eddy simulation using computational fluid dynamics (CFD) code NekRS to investigate the heat transfer for a bed of 1741 pebbles. Further, the characteristics of the flow, such as average, rms, and time series of velocity and temperature, have been analyzed. Porous media averages have also been performed. The simulation results show a good agreement between non-conjugate heat transfer and conjugate heat transfer. The generated data will be used to benchmark heat transfer modeling methods and local maxima/minima of heat transfer parameters. It will also be used for supporting convective heat transfer quantification for Kairos Power and benchmarking lower fidelity models.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2021

Investigation of Thermal-Hydraulic Effects of Dry Storage Canister Helium Backfill Loss Using the Horizontal Dry Cask Simulator

A previous investigation produced data sets that can be used to benchmark the codes and best practices presently used to determine cladding temperatures and induced cooling air flows in modern horizontal dry storage systems. The horizontal dry cask simulator (HDCS) was designed to generate this benchmark data and add to the existing knowledge base. The objective of the previous HDCS investigation was to capture the dominant physics of a commercial dry storage system in a well-characterized test apparatus for a wide range of operational parameters. The close coupling between the thermal response of the canister system and the resulting induced cooling air flow rate was of particular importance. The previous investigation explored these parameters using helium backfill at 100 kPa and 800 kPa pressure as well as air backfill with a series of simulated decay heats. The helium tests simulated a horizontal dry cask storage system at normal storage conditions with either atmospheric or elevated backfill pressure, while the air tests simulated horizontal storage canisters following a complete loss of helium backfill, in which case the helium would be replaced by air. The present HDCS investigation adds to the previous investigation by exploring steady-state conditions at various stages of the loss of helium backfill from a horizontal dry cask storage system. This is achieved by using helium/air blends as a backfill in the HDCS and running a series of tests using various simulated decay heats to explore the effects of relative helium/air molar concentration on the thermal response of a simulated horizontal dry cask storage system. A total of twenty tests were conducted where the HDCS achieved steady state for various assembly powers, representative of decay heat. The power levels tested were 0.50, 1.00, 2.50, and 5.00 kW. All tests were run at 100 kPa vessel pressure. The backfill gases used in these tests are given in this report as a function of mole fraction of helium (He), balanced by air: 1.0, 0.9, 0.5, 0.1, and 0.0 He. Steady-state conditions (where the steady-state start condition is defined as where the change in temperature with respect to time for the majority of HDCS components is less than or equal to 0.3 K/h) were achieved for all test cases.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2026

Two-Way Coupled CFD/DEM Simulation of Electromagnetic Heating in a Fluidized Bed Reactor

A set of tools has been developed to couple a multiphase reacting computational fluid dynamics solver (MFIX) with two computational electromagnetic solvers (COMSOL and Elmer). In contrast to several recent investigations, which calculate a single static EM field prior to the CFD calculation, in the present work the electromagnetic field is periodically updated during the simulation. This enables the EM field and associated EM heating predictions to reflect the effects of evolving material properties (temperature, composition, size etc.) and the evolving distribution of material in the system. The present work uses effective medium theory (EMT) for the electromagnetic field calculations since the goal is to apply the tool for industrial scale reacting systems. Predictions using MFIX/COMSOL and MFIX/Elmer are compared to in bed thermocouple measurements from a fluidized bed experiment and recent simulation predictions and recent experiments performed at NETL. The NETL experiments also include packed bed operating conditions. Coupled MFIX/COMSOL simulations at these conditions are compared with similar simulations using only COMSOL to measure errors due to the solver coupling approach.

CFD↗
DOE OSTI2026

Two-Way Coupled CFD/DEM Simulation of Electromagnetic Heating in a Fluidized Bed Reactor - Extended Abstract

A set of tools has been developed to couple a multiphase reacting computational fluid dynamics solver (MFIX) with two computational electromagnetic solvers (COMSOL and Elmer). In contrast to several recent investigations, which calculate a single static EM field prior to the CFD calculation, in the present work the electromagnetic field is periodically updated during the simulation. This enables the EM field and associated EM heating predictions to reflect the effects of evolving material properties (temperature, composition, size etc.) and the evolving distribution of material in the system. The present work uses effective medium theory (EMT) for the electromagnetic field calculations since the goal is to apply the tool for industrial scale reacting systems. Predictions using MFIX/COMSOL and MFIX/Elmer are compared to in bed thermocouple measurements from a fluidized bed experiment and recent simulation predictions and recent experiments performed at NETL. The NETL experiments also include packed bed operating conditions. Coupled MFIX/COMSOL simulations at these conditions are compared with similar simulations using only COMSOL to measure errors due to the solver coupling approach.

CFD↗
DOE OSTI2025

Quench process modeling & simulation in the heat-treatment of critical aerospace components

To manufacture light-weight, advanced metal alloy components for gas turbine engines, quench heat-treatment processes are typically used. By quenching the component from elevated temperatures, the alloy sometimes undergoes a solid-state phase transformation which produces special microstructures with the required, enhanced mechanical properties. However, the quenching can also lead to cracks forming in the component. Addressing the quench cracking problems adds a significant burden to the cost, schedule, and energy demand of manufacture. Currently, optimizing the quench process to mitigate or avoid the cracking is performed largely by trial-and-error, relying heavily on costly experimental (thermocouple)trials to understand the local thermal gradients which cause the cracks to form. In this first part (Phase 1) of the work, high-performance computing is employed to establish the ability of modern CFD (computational fluid dynamics) to alleviate or wholly replace the experimental quenching trials by virtual testing. A Baseline CFD model is defined and its accuracy established to be comparable to(and which usually exceeds) the accuracy of existing HTC (heat-transfer coefficient) based simulation methods of quenching. As a first-principles based approach, “calibration” of the Baseline CFD model is independent of the quench process itself, but instead relies on the accuracy of the underlying (modeled),generic two-phase fluid processes which cannot be currently resolved by CFD for large, industrial-scale cases. A novel, high-fidelity DNS capability has been developed and verified to examine and further improve upon the mean-field closure submodels on which the Baseline CFD approach is based.1

99 GENERAL AND MISCELLANEOUS↗
DOE OSTI2024

Quench process modeling & simulation in the heat-treatment of critical aerospace components

To manufacture light-weight, advanced metal alloy components for gas turbine engines, quench heat-treatment processes are typically used. By quenching the component from elevated tempera-tures, the alloy sometimes undergoes a solid-state phase transformation which produces special microstructures with the required, enhanced mechanical properties. However, the quenching can also lead to cracks forming in the component. Addressing the quench cracking problems adds a significant burden to the cost, schedule, and energy demand of manufacture. Currently, optimizing the quench process to mitigate or avoid the cracking is performed largely by trial-and-error, relying heavily on costly experimental (thermocouple) trials to understand the local thermal gradients which cause the cracks to form. In this first part (Phase 1) of the work, high-performance computing is employed to establish the ability of modern CFD (computational fluid dynamics) to alleviate or wholly replace the experimental quenching trials by virtual testing. A baseline CFD model is defined and its accuracy established to be comparable to (and which usually exceeds) the accuracy of existing HTC (heat-transfer correlation) based simulation methods of quenching. As a first-principles based approach, “calibration” of the Baseline CFD model is independent of the quench process itself, but instead relies on the accuracy of the underlying (modeled), generic two-phase fluid processes which cannot be currently resolved by CFD for large, industrial-scale cases. A novel, high-fidelity DNS capability has been developed and verified to examine and further improve upon the mean-field closure submodels on which the Baseline CFD approach is based.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Artificial correlation heating in PIC simulations

The Particle-in-Cell (PIC) method, a cornerstone in plasma modeling, is widely employed for its ability to simulate kinetic phenomena in device-scale domains. Part of what makes this possible is that computational macroparticles represent many physical particles. It converges under certain constraints, including a grid spacing that resolves the Debye length and a time step small enough to respect the Courant–Friedrichs–Lewy condition and plasma frequency stability limit. Here, we introduce a new constraint necessary to avoid Artificial Correlation Heating (ACH). This requires that the macroparticle coupling strength be smaller than one, Γ ω < 1, where Γ ω ≡ Γω 2/3 ⁠, Γ = Z 2 e 2 /(4πε 0 ak B T) is the physical coupling strength, and w is the macroparticle weight. This is particularly relevant to 3D simulations of dense plasmas, which are becoming common with modern computing power. If this condition is violated, the finite macroparticle weight artificially enhances the coupling strength and causes the plasma to heat until the macroparticle coupling strength is near unity, depending on the grid resolution. A comprehensive model of ACH is developed that incorporates electron density, temperature, macroparticle weight, and grid resolution. It is then tested using PIC simulations, delineating the boundaries of the method's applicability and offering a predictive framework for ACH. Moreover, the research explores a runaway heating process induced by ACH in the presence of ionization, which can lead to numerical instability. A conclusion of this study is that the onset of ACH can impose a more stringent constraint on the macroparticle weight and average number of macroparticles per cell than what is typically expected, particularly in 3D simulations of dense plasmas.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2022

Microstructure and creep strength of simulated intercritical heat-affected zone of grade 91 steel

The intercritical heat affected zone (ICHAZ) has been reported as one of the most Type IV cracking susceptible regions in 9Cr creep-resistant steel weldments. However, creep degradation mechanisms within the ICHAZ itself need further clarifications. In this work, two ICHAZ specimens of Grade 91 steel, low-temperature ICHAZ (LT-ICHAZ) and high-temperature ICHAZ (HT-ICHAZ), were simulated using the Gleeble thermomechanical system by exposing to two peak temperatures (860 °C and 900 °C) between $A_{C1}$ and $A_{C3}$. Dramatically different creep strengths of two simulated ICHAZs were observed and studied. We report dilation curve analysis indicates a high fraction of newly transformed martensite formed in the HT-ICHAZ, which results in a much higher hardness (360 HV0.5) of the HT-ICHAZ than 266 HV0.5 of LT-ICHAZ. Precipitates, especially $M_{23}C_6$ carbides, were not fully dissolved in both ICHAZ specimens. After a typical postweld heat treatment (760 °C-2 hours), the faster recovery of low-carbon martensite and reduced precipitation strengthening due to $M_{23}C_6$ carbides coarsening in the HT-ICHAZ led to a significant hardness reduction. These microstructural degradations in the HT-ICHAZ made its creep lifetime about 36 times shorter than that of the LT-ICHAZ tested at 650 °C. The remaining tempered martensite from base metal in the LT-ICHAZ was the primary contributor to maintain its high creep resistance.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Hardware-Based Demonstration of Temperature Control Functions for Reactor Systems

Establishing autonomy in reactor control systems has become essential for the expansion of nuclear technologies. Thermal regulation in particular remains crucial for maintaining stable operation and ensuring the integrity of fuel. To alleviate public skepticism of the safety of nuclear reactors, demonstrating control over this key factor is pivotal. Utilizing electric heat pads to simulate the heat released in a reactor core, thermocouples for temperature monitoring, and an Arduino micro programmable logic controller (PLC) for control, a hardware-based demonstration of a reactor heating system validates the efficacy of reactor control over this key parameter. To improve precision, a proportional-integral-derivative (PID) algorithm was implemented in the heating control loop to ensure meticulous control of reactor functions. In addition, the integration of this physical system with a digital simulator tool such as RELAP5-3D establishes a foundation for a comprehensive testing environment. This allows for a refinement of temperature control under various simulated reactor conditions, bringing another layer of reliability to the operation of the system. By facilitating a physical demonstration of reactor thermal management and control strategies, this project provides a foundation for expanded testing and educational outreach. Ultimately, this system advances the broader goal of demonstrating the safety and viability of autonomous reactor operations, contributing to public trust and future reactor deployment.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2026

Simulations of ICRF Heating for SPARC during First Campaign and Primary Reference-Like Discharge using the Stix Code

High magnetic field tokamaks, like SPARC, rely on ion cyclotron radio frequency heating (ICRF) to reach fusion relevant temperatures. The SPARC tokamak will have 14 ICRF antennas in 7 toroidal locations delivering > 20 MW of power to the plasma. New capabilities with the full wave cold plasma solver, Stix, now allow for resolving the wave-particle resonances using lower order thermal corrections to capture core absorption of Landau damping and ion resonances in devices like SPARC. Favorable comparisons to the TORIC codes give confidence in the single pass absorption of this model to accurately capture the strength of edge interactions of the RF. Using this new dielectric formulation in the Stix code, simulations of the 2D poloidal cross section of SPARC are completed for the first campaign and primary reference-like discharges (PRD-like). A scan of the minority ion concentrations of helium-3 is performed and shows the expected behavior that as the helium-3 decreases the amount of single pass absorption also decreases which is seen in both scenarios. Additionally, both scenarios show only slight differences in single-pass absorption for the range of 3% to 5% helium-3 allowing for more flexibility in experiments. This study also highlights the differences between the first campaign and PRD-like with the first campaign discharges showing much more multi-pass absorption and an effect of confining the wave to a smaller portion of the cross-section due to the fast wave cut-off. This latter result suggests that far-field sheath rectification at the high-field side would be minimal for the first campaign scenario.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2020

Brine Availability Test in Salt: Thermal-Hydrological-Mechanical-Chemical Simulations of a Heated Borehole in Salt - 20239

The Brine Availability Test in Salt (BATS) is a collaboration between Los Alamos, Sandia, and Lawrence Berkeley National Laboratories that is being conducted to reduce the uncertainties associated with disposal of spent nuclear fuel (SNF) and high-level radioactive waste (HLW) in a hypothetical bedded salt repository. Bedded salt formations may be an acceptable host rock for disposal of nuclear waste due to salt's high thermal conductivity, extremely low permeability, and self-healing capability. In this paper, we report on the first round of the BATS project, a 'shakedown test' known as Phase 1s, with an emphasis on the supporting numerical modeling. The experiment was conducted at the Waste Isolation Pilot Plant (WIPP) using previously drilled horizontal boreholes. The test included a heater borehole in which temperature, pressure, and moisture was monitored, and two nearby temperature monitoring boreholes. Numerical simulations that reflect the 36-year-long history of activity at the WIPP site are necessary to develop the appropriate initial conditions. Testing with different heater designs reveals that a 750 W radiative heater within a borehole can achieve the 120 deg. C borehole wall temperature goal. (authors)

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

ExaCA v2.0: A versatile, scalable, and performance portable cellular automata application for additive manufacturing solidification

The previously established ExaCA software for performance portable alloy grain structure simulation has been updated to better represent the solidification behavior during complex alloy processing conditions, such as those encountered during metal additive manufacturing (AM), and for improved performance and scalability. Here, an extension to the time–temperature history input data format and the core ExaCA algorithm to include an arbitrary number of melting and solidification events yielded improved prediction of texture for various melt pool geometries, expanding the range of AM-relevant conditions that can be accurately simulated. Improved heat transport process simulation coupling, including the creation of large raster datasets from single track time–temperature history data and in-memory coupling with the new, performance portable finite difference code Finch, were also demonstrated in example studies on the effect of multilayer AM microstructure predictions on hatch spacing and cell size, respectively. Additional new features are detailed and demonstrated, including the ability to perform simulations using various interfacial response function forms, execute simulations on state-of-the-art hardware, improved usability through post-processing versatility, and improved strong and weak scaling performance. The performance, physics, and versatility improvements demonstrated here will further enable large-scale studies on AM process–microstructure relationships that were not previously possible. Furthermore, the usability improvements and ability to run coupled AM process–microstructure simulations using the Finch-ExaCA workflow will facilitate broader use of this open-source software by the computational materials community.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Pore Resolved Simulations of Joule Heating in Fibrous Media using an Embedded Boundary Method

Joule heating has been regarded as an energy-efficient and sustainable method for heating materials and gases at large scales. The modeling of local temperature effects at pore-resolved scales for such systems, however, has been difficult to achieve due to challenges in coupling thermo-chemical processes in complex porous media and in large representative volume elements (RVEs). To this end, we developed an electro-thermal model at the pore scale to study Joule heating effects in large heterogeneous systems with different microstructures. This was achieved using the level set method to implicitly delineate distinct regions within the domain, and an embedded boundary method to facilitate heat exchange across the fluid-solid interface. Moreover, we applied this method to investigate unsteady non-linear electro-thermal effects in non-woven fibrous graphite conductors for RVEs with characteristic lengths of 2 mm, with different fiber orientations, porosity (80% – 90%) and fiber diameters (10 – 20µm). The coupled equations were solved numerically and they produced peak temperatures greater than 2000 K resulting in heating rates as high as 80,000 K/s. Moreover, the results depended strongly on the microstructure of the fiber skeleton and current density. Geometries with large fibers (∼ 20µm) had the highest average and peak temperatures with the mean temperature increasing by 3.9 % while the peak temperature increased by 9.9 %. Anisotropic domains on the other hand had the lowest mean and peak temperatures with peak and mean temperatures of 2293 K and 1437.7K respectively representing a corresponding 12.1% and 5.1% drop in the temperatures. An increase in porosity from 80% to 90%, however, led to an increase in the peak temperature by 5.1%.

Joule heating↗