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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 91 records · Page 5
All sourcesNASA NTRSDOE OSTI
DOE OSTI2026

Power performance and loads characterization of laboratory-scale cross-flow rotors fabricated using additive manufacturing

Tidal energy conversion is a relatively new application for additive manufacturing (AM), where the focus has been on fabricating axial-flow turbine blades. AM techniques add material precisely where it is needed, creating more complex shapes with less waste. Cross-flow rotor geometry presents an opportunity for AM to improve rotor performance by fabricating features that cannot be created economically via conventional manufacturing. The challenges associated with using AM in cross-flow design include water resistance and degradation over time while retaining a level of quality equivalent to conventionally machined parts. In this work, AM materials were tested by environmentally conditioning samples in a seawater tank for 5 months, followed by performance and phase-resolved load testing of laboratory-scale rotors in a hydraulic flume. We found that while metals like titanium and Inconel have excellent performance in marine environments, achieving the desired geometry and performance is difficult. Thermoplastics degraded in seawater but were easier to form into desired geometries and could exceed the performance of an aluminum control rotor. Warping and surface finish were significant detractors from AM rotor performance. These results suggest that the primary benefits of using AM for cross-flow rotors is to quickly fabricate and test unconventional rotor geometries.

16 TIDAL AND WAVE POWER↗
DOE OSTI2020

Use of hydrodynamic theory to estimate electrical current redistribution in metals

Using the analogy between hydrodynamic and electrical current flow, we study herein how electrical current density j redistributes and amplifies due to two commonly encountered inhomogeneities in metals. First, we consider flow around a spherical resistive inclusion and find significant j amplification, independent of inclusion size. Hence, even μ m-scale inclusions can affect performance in applications by creating localized regions of enhanced Joule heating. Next, we investigate j redistribution due to surface roughness, idealized as a sinusoidal perturbation with amplitude A and wavelength λ . Theory predicts that j amplification is determined by the ratio A / λ , so that even “smooth” surface finishes (i.e., small A ) can generate significant amplification, if λ is correspondingly small. We compare theory with magnetohydrodynamic simulation to illustrate both the utility and limitations of the steady-state theory.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2025

Accurate models of the added mass force of a uniform random distribution of spherical particles or bubbles

The added mass force resulting from the acceleration of a body in a fluid is of fundamental and practical interest in dispersed multiphase flows. Euler–Lagrange (EL) and Euler–Euler (EE) simulations require closure terms for the added mass force in order to accurately couple the conserved variables between phases. Presently, a more thorough understanding of the added mass force in a multi-particle system is developed based on potential flow resulting in a resistance matrix formulation analogous to Stokesian dynamics. This formulation is then used to generate a dataset of added mass resistance matrices for large systems of randomly generated particles. This methodology is used to create a volume fraction corrected binary model for predicting the added mass force in large systems as well as generate statistics of the added mass force in such systems. This work provides clarification to the theory of the added mass force for particle clouds, and modelling options that may be implemented in existing EL and EE codes.

42 ENGINEERING↗
DOE OSTI2020

Are Supercells Resistant to Entrainment because of Their Rotation?

This research investigates a hypothesis posed by previous authors, which argues that the helical nature of the flow in supercell updrafts makes them more resistant to entrainment than nonsupercellular updrafts because of the suppressed turbulence in purely helical flows. It was further supposed that this entrainment resistance contributes to the steadiness and longevity of supercell updrafts. A series of idealized large-eddy simulations were run to address this idea, wherein the deep-layer shear and hodograph shape were varied, resulting in supercells in the strongly sheared runs, nonsupercells in the weakly sheared runs, and variations in the percentage of streamwise vorticity in updrafts among runs. Fourier energy spectrum analyses show well-developed inertial subranges in all simulations, which suggests that the percentages of streamwise and crosswise vorticity have little effect on turbulence in convective environments. Additional analyses find little evidence of updraft-scale centrifugally stable flow within updrafts, which has also been hypothesized to limit horizontal mass flux across supercell updrafts. Results suggest that supercells do have smaller fractional entrainment rates than nonsupercells, but these differences are consistent with theoretical dependencies of entrainment on updraft width, and with supercells being wider than nonsupercells. Thus, while supercells do experience reduced fractional entrainment rates and entrainment-driven dilution, this advantage is primarily attributable to increased supercell updraft width relative to ordinary convection, and has little to do with updraft helicity and rotation.

Peters, John M.↗
DOE OSTI2020

Geophysical borehole logging data of wells ER-GLS1, ER-GUM1, ER-PLM7, and ER-PLM8 at the East River Watershed, Colorado

The purpose of this data set is to provide a means of characterizing the bedrock variability both within a single borehole location and across the East River Watershed. The East River is part of the Watershed Function Scientific Focus Area (WFSFA) located in the Upper Colorado River Basin, United States, and all boreholes are located within Mancos shale bedrock. The data set contains geophysical borehole logging data acquired in October 2018 in boreholes ER-GUM1 (East River- Gothic Upper Montane Borehole #1) and ER-GLS1 (East River- Gothic Lower Subalpine Borehole #1), and acquired in October 2019 in boreholes ER-PLM7 (East River- Pumphouse Lower Montane Borehole #7) and ER-PLM8 (East River- Pumphouse Lower Montane Borehole #8). It contains depth, natural gamma ray emission, spectral gamma ray emission(Th, K, U), magnetic susceptibility, fluid temperature and electrical conductivity, electromagnetic (EM) induction derived rock electrical resistivity, heat pulse and spinner flow measurements to estimate groundwater flow, and Nuclear Magnetic Resonance (NMR) derived water content and hydraulic conductivity. Data for each borehole are provided as comma delimited text files. For each borehole accurate location information is provided (based on RTK GPS (Real Time Kinematic Global Positioning System) surveying). Borehole logging data were acquired using Mount Sopris borehole tools, and Vista Clara Javelin for NMR data.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2026

Development of a Test-Bed for Testing and Refining EarthEn’s Supercritical CO 2 Based Energy Storage System

EarthEn’s energy storage concept leverages supercritical carbon dioxide (sCO 2 ) as a working fluid and relies on compact, high-performance components operating at elevated pressures and temperatures. To accelerate component development and reduce technical risk prior to larger-scale demonstrations, Oak Ridge National Laboratory (ORNL) developed a 100 kW-scale sCO 2 test-bed under a Cooperative Research and Development Agreement with EarthEn (CRADA NO. NFE-24-10050). The objective of the work was to design and construct a flexible experimental facility capable of reproducing key thermodynamic state points and heat-transfer conditions relevant to EarthEn’s thermal energy storage (TES) cycle, with particular emphasis on enabling development and evaluation of next-generation heat exchangers and TES concepts. The test-bed consists of a closed-loop sCO 2 circulation system housed within an open-topped enclosure. In its as-installed configuration, dense-phase sCO 2 is recirculated through a printed circuit recuperator, an electrically heated section, a throttling device used to simulate turbine expansion, and a water-cooled printed circuit heat exchanger that rejects heat to the building chilled-water system before returning to the pump. The pump is driven by a variable frequency drive, enabling controlled adjustment of flow and operating point. A comprehensive instrumentation suite was integrated to support both safe operation and high-quality data collection. Installed sensors include Coriolis flow meters for sCO 2 flow rate and density, resistance temperature detectors and thermocouples distributed throughout the loop (including the heated section and key heat exchanger ports), and pressure transducers for absolute and differential pressure measurements. The facility was designed to support high-pressure (19 MPa nominal) and high-temperature (575°C nominal) operation with credited overpressure protection provided by a rupture disk. Nominal operating conditions were selected to support 100 kW-class testing while maintaining flexibility for non-heated and heated shakedown, control development, and future integration of advanced TES test sections. In parallel with facility development, a system-level thermal-hydraulic model was created using Modelica-based tools to support component sizing, anticipate performance over targeted test conditions, and establish a framework for future model calibration against experimental data. At the conclusion of the project performance period, the facility was in final assembly, and the pressure boundary was nearly completed. However, several practical challenges associated with high-pressure/high-temperature systems and specialized component procurement impacted schedule and prevented initial pump-driven operation and full commissioning within the available resources. This report documents the as-built design, operating capabilities, and instrumentation, and it summarizes key lessons learned related to heater fabrication and testing, first-of-a-kind assembly factors, specialty flange supply constraints, and fill pump corrective actions. Finally, it outlines a phased plan for future commissioning and experimental campaigns, including control and instrumentation shakedown, heater characterization, model calibration, and testing at state points representative of EarthEn’s TES cycle.

25 ENERGY STORAGE↗
DOE OSTI2023

Electrically tunable metasurfaces incorporating a phase change material

Electrically tunable metasurfaces including an array of subwavelength metasurface unit elements are presented. The unit elements include a stacked metal-insulator-metal structure within which an active phase change layer is included. A purely insulator, metal, or coexisting metal-insulator phase of the active layer can be electrically controlled to tune an amplitude and phase response of the metasurfaces. In combination with the subwavelengths dimensions of the unit elements, the phase and amplitude response can be controlled in a range from optical wavelengths to millimeter wavelength of incident light. Electrical control of the unit elements can be provided via resistive heating produced by flow of current though a top metal layer of the unit elements. Alternatively, electrical control of the unit elements can be provided via electrical field effect produced by applying a voltage differential between the top and bottom metal layers of the unit elements.

Kim, Yonghwi↗
DOE OSTI2022

Review of metal-containing resists in electron beam lithography: perspectives for extreme ultraviolet patterning

Background: Metal-containing resists entered the mainstream semiconductor industry process flow to mitigate the low absorbance of extreme ultraviolet (EUV) radiation by thin films of organic resists that lead to poor sensitivity and their inability to handle rigors of development and etching conditions. Aim: The long and rich history of using metal-containing resists in electron beam lithography can offer interesting lessons, pointers, and insights to the relatively newcomer EUV lithography, which is slightly over a decade old. Approach: Electron beam lithography has been enjoying a considerable amount of freedom in the choice of resist materials for close to 50 years; especially the use of metal-containing resists to attain not only single digit nanometer resolution, higher sensitivity, and etch resistance but also lower line-edge roughness. Here, we make a comprehensive historical review of the progress made in the patterning of metal-containing resists in electron beam lithography and derive insights that can be potentially useful in EUV patterning. Perspectives: Small molecular weight resists are proven to be crucial for achieving higher resolution with low line-edge roughness. Simplifying process flow by reducing etch-stack-layers is conceivable with metal-containing resists, along with direct-patterning of functional materials for heterogeneous integration. Efficient contact hole patterning at tighter pitches may be incumbent on progress in positive-tone resist research.

77 NANOSCIENCE AND NANOTECHNOLOGY↗
DOE OSTI2022

Flow and transport in three-dimensional discrete fracture matrix models using mimetic finite difference on a conforming multi-dimensional mesh

Here, we present a comprehensive workflow to simulate single-phase flow and transport in fractured porous media using the discrete fracture matrix approach. The workflow has three primary parts: (1) a method for conforming mesh generation of and around a three-dimensional fracture network, (2) the discretization of the governing equations using a second-order mimetic finite difference method, and (3) implementation of numerical methods for high-performance computing environments. A method to create a conforming Delaunay tetrahedralization of the volume surrounding the fracture network, where the triangular cells of the fracture mesh are faces in the volume mesh, that addresses pathological cases which commonly arise and degrade mesh quality is also provided. Our open-source subsurface simulator uses a hierarchy of process kernels (one kernel per physical process) that allows for both strong and weak coupling of the fracture and matrix domains. We provide verification tests based on analytic solutions for flow and transport, as well as numerical convergence. We also provide multiple expositions of the method in complex fracture networks. In the first example, we demonstrate that the method is robust by considering two scenarios where the fracture network acts as a barrier to flow, as the primary pathway, or offers the same resistance as the surrounding matrix. In the second test, flow and transport through a three-dimensional stochastically generated network containing 257 fractures is presented.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2022

Development and Validation of Resistance-Capacitance Model for Phase Change Material Embedded in Porous Media

A simple and effective way to enhance PCM thermal conductivity is by embedding porous materials with high thermal conductivities. In this work, CFD was used to evaluate the melting of PCM embedded in metal foam supplied with constant heat flux. Good agreement between experimental and numerical results has been found with a mean PCM local temperature deviation of 1.62K and 2.97K in two locations. The CFD simulation time was 56 hours for 6.5 hours of flow time. A computationally efficient resistance capacitance-based model (RCM) was developed to improve simulation speed. The proposed RCM exhibited mean local temperature deviations of 1.86K and 2.96K when compared against the experimental data for two thermocouple positions, however, it was approximately 2.5x10 5 times faster than CFD. The charging time deviation was less than 1% compared to CFD, and no significant change in thermal energy stored was observed since the temperature differences were small enough to result in insignificant sensible heat deviation. A simulation cost-effectiveness index (CEI) considering accuracy and computational affordability was introduced; the CEI of the RCM solver is 10 3 times better compared to CFD for the prediction of local PCM temperature.

25 ENERGY STORAGE↗
DOE OSTI2020

The role of edge resonant magnetic perturbations in edge-localized-mode suppression and density pump-out in low-collisionality DIII-D plasmas

Two-fluid nonlinear MHD simulations using the TM1 code demonstrate that the formation of magnetic islands at the top and bottom of the H-mode pedestal, together with the strong screening of resonant fields in the gradient region of the pedestal, can account for ELM suppression and density pump-out by n = 2 resonant magnetic perturbations (RMPs) in low-collisionality DIII-D ITER similar shape (ISS) plasmas. Using experimentally relevant transport coefficients, neoclassical resistivity, electron collisionality, and RMP amplitudes, nonlinear MHD simulations reproduce the observed level of density reduction (density pump-out) in DIII-D due to the formation of narrow magnetic islands in the resistive foot of pedestal. For large amplitude RMPs ( B r / B t > 1 × 10 -4 ) simulations predict resonant field penetration and resulting in pressure reduction at the top of the pedestal, consistent with experimental observations at the onset of ELM suppression. The predicted reduction in the height and width of the pedestal by magnetic island enhanced collisional transport provides a quantitative mechanism for the stabilization of the peeling-ballooning mode (PBM). Importantly, these simulations predict strong screening of resonant fields in the steep gradient region of the pedestal due to strong E × B rotation and diamagnetic flows. Yet, if the plasma resistivity is made artificially larger (~ 10X) than neoclassical, the simulations predict magnetic stochasticity throughout the plasma edge and the collapse of the pedestal due to the reduction in the penetration threshold with increasing resistivity. A scaling relation for resonant field penetration at the pedestal top, using several hundred nonlinear simulations, reproduces the density and E × B rotation dependence of the ELM suppression threshold observed in DIII-D. Simulations using ITER model equilibria indicate that the penetration threshold at the top of the ITER pedestal will be lower than in DIII-D due to the anticipated lower perpendicular flow velocities in ITER, resulting in the weaker screening of resonant fields.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2024

Heat Transfer Experiments of Ribbed, Serpentine Cooling Passages with Supercritical CO2

The results of heat transfer experiments with supercritical CO2 (sCO2) to capture the performance of ribbed, serpentine cooling passages for Reynolds numbers in the range of 100,000 - 400,000 are presented. The oxy-combustion turbine operating in an Allam-Fetvedt cycle has a turbine inlet temperature exceeding 1100°C, necessitating internally cooled turbine blades due to material creep strength limits. Reynolds numbers for sCO2, with its combination of high fluid density and low viscosity, can be up to an order of magnitude higher than comparable internal cooling conditions for an air-breathing engine where the majority of experimental data exists. To improve the prediction of cooling performance through turbulated passages, a test rig was designed and constructed with interchangeable insert capability for operation in sCO2 with heat transfer from a heater outlet flow stream to a lower temperature recuperator outlet flow stream. The inserts included serpentine passage geometry with five passes, one of the inserts including chevron ribs and the other a plain wall. The multi-pass serpentine geometry allowed for the evaluation of the effects 180 deg. tip turns have on the return passage flow characteristics, as they can depart significantly from fully-developed flow characteristics. The test procedure included the use of a modified Wilson plot method, with hot flow stream conditions kept effectively constant so that monitored changes in the overall thermal resistance could be attributed to manipulations in cooling flow stream conditions. Conditions during testing consisted of test section pressures of approximately 180 bar, cooling flow stream temperature of 175°C and hot flow stream temperature of 410°C. Test points at discrete cool flow Reynolds numbers up to 400,000 demonstrated an expected trend of decreased fluid thermal resistance with increasing Reynolds number, while at comparable Reynolds number there was an exhibited lower thermal resistance and higher passage pressure drop for the ribbed insert compared to the plain-walled insert. Processing of test data included establishment of Nusselt number enhancement ratios, so that for different internal cooling passage dimensions in the actual turbine blade at comparable Reynolds number the ratio could be applied to predict cooling performance.

Marshall, Michael↗
DOE OSTI2023

Additive Manufacturing for Powering the Blue Economy Applications: A Tidal Turbine Blade Case Study: Preprint

As the marine renewable energy industry continues to expand, innovation in the manufacturing space must grow accordingly to reduce costs and ensure the economic feasibility of new technologies. Additive manufacturing, more commonly known as 3D printing, provides an alternative for rapid prototyping of marine hydrokinetic technologies, particularly supporting Powering the Blue Economy initiatives of the U.S. Department of Energy Water Power Technologies Office. This study explores the application of additive manufacturing in the development of marine hydrokinetic structures, focusing on material and printing method selection, design, and analysis of a 3D-printed spar for an axial-flow tidal turbine blade. Corrosion-resistant metals were deemed ideal due to the loads and harsh marine environment the blade would experience. Laser metal deposition methods were determined to be the most effective and scalable for the considered scale. The designed spar adapts its geometry to the blade - a feature uniquely suited to additive manufacturing - and is intended to serve as the blade's primary structural component. A finite element model was used to study stresses and deformations under loading conditions. The spar was manufactured using 316L stainless steel through direct energy deposition, and defects were assessed and recorded. Future efforts will include mechanical testing of the spar. This research establishes a benchmark process for using additive manufacturing in developing marine hydrokinetic structures, paving the way for future optimization and techno-economic analysis.

additive manufacturing↗
DOE OSTI2025

Effect of nozzle translation on a bounded vortex flow

A bounded vortex flow is generated by a nozzle that combines azimuthally tilted downward jets in a circular array and a central suction port. When the nozzle is directed toward a bottom surface (called the impingement surface), the flow develops a strong intake vortex spanning from the impingement surface to the suction port, which acts to generate strong shear stress on the impingement surface. This strong shear stress can aid in removing particles attached to the impingement surface or in enhancement of heat or mass transfer, where in typical applications, the nozzle would be translated along the impingement surface. This paper reports on a computational study of the effect of nozzle translation on the bounded vortex flow field. The nozzle translation induces a bending of the bounded vortex in the downstream flow direction, which becomes larger with increase in the nozzle translation speed. We identify an interesting oscillatory phenomenon by which the bounded vortex can resist the bending induced by the translational flow and rotate about a mean position downstream of the suction port. At sufficiently high translation speeds, the oscillatory process can no longer resist the downwash effect from nozzle translation and the vortex eventually detaches from the impingement surface, limiting the effectiveness of this flow device.

42 ENGINEERING↗
DOE OSTI2024

Impact of Janssen effect on thermal transport in granular flow

Using a modulated photothermal radiometry (MPR) technique capable of measuring thermal transport in particle beds, we find asymptotically increasing effective thermal conductivity and decreasing near-wall thermal resistance along gravity-driven downward granular flows through a 1-meter-long narrow vertical channel owing to the Janssen effect. The Janssen effect is confirmed by similar asymptotic trends from particle bed apparent mass measurements as well as separate MPR heat transfer measurements on stationary particle beds under compression at different heights of the channel with and without pressure screening. Furthermore, local heat transfer coefficient along the 1-meter-long channel was modeled based on measured spatially resolved thermal conductivity and near-wall thermal resistance due to the Janssen effect. This work reveals for the first time the impact of the over century-old Janssen effect on heat transfer in granular media. Furthermore, the results from this work can lead to a better understanding of heat transfer in granular flow.

14 SOLAR ENERGY↗
DOE OSTI2021

Evaluation of a Potential Groundwater Tracer Test in the Ringold Upper Mud Aquifer at the 100-H Area of the Hanford Site

This document presents an evaluation of a potential groundwater tracer test in the uppermost RUM (Ringold Formation member of Wooded Island – upper mud unit) aquifer in the 100-H Area of the Hanford Site. The results from field electrical resistivity tomography (ERT) investigations, numerical flow and transport (F&T) modeling, coupled ERT-F&T model simulations, and laboratory resin experiments provide the technical basis for evaluating tracer test scenarios that minimize impacts to the 100-HX pump and treat (HX P&T) operations, and maximize hydrologic data acquisitions including the use of advanced surface geophysical techniques for monitoring tracer transport.

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

Heat Transfer of Supercritical Carbon Dioxide in 3D-Printed Tubes with Internal Ribs and Yttria Stabilized Zirconia Coating

This technical report describes measurements performed in NETL’s Heat Exchanger Experimental Test (HEET) facility using supercritical carbon dioxide as the working fluid. 3D printed tubes with internal ribs and yttria stabilized zirconia (YSZ) exterior coatings were employed in the heat exchanger. Heat transfer and friction factor enhancements from the internal ribs were characterized over a range of flow conditions. Additionally, the thermal resistance from the YSZ coating was characterized for both a freshly applied coating and a coating subjected to thermal aging.

36 MATERIALS SCIENCE↗