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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 955 records · Page 53
All sourcesNASA NTRSDOE OSTI
DOE OSTI2021

BISON: A Flexible Code for Advanced Simulation of the Performance of Multiple Nuclear Fuel Forms

BISON is a nuclear fuel performance application built using the Multiphysics Object-Oriented Simulation Environment (MOOSE) finite element library. One of its major goals is to have a great amount of flexibility in how it is used, including in the types of fuel it can analyze, the geometry of the fuel being modeled, the modeling approach employed, and the dimensionality and size of the models. Fuel forms that can be modeled include standard light water reactor fuel, emerging light water reactor fuels, tri-structural isotropic fuel particles, and metallic fuels. BISON is a platform for research in nuclear fuel performance modeling while simultaneously serving as a tool for the analysis of nuclear fuel designs. Recent research in BISON includes techniques such as the extended finite element method for fuel cracking, exploration of high-burnup light water reactor fuel behavior, swelling behavior of metallic fuels, and central void formation in mixed-oxide fuel. BISON includes integrated documentation for each of its capabilities, follows rigorous software quality assurance procedures, and has a growing set of rigorous verification and validation tests.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2020

High precision magnetic field measurement and mapping of the LEReC 180 degree bending magnet using very low field NMR with hall combined probe (140 - 350 gauss)

The Relativistic Heavy Ion Collider (RHIC) at BNL are using the Low Energy RHIC Electron Cooling (LEReC) to conduct experiments that search for the quantum chromodynamic (QCD) critical point. The first ever electron cooling based on the RF acceleration of electron beams was experimentally demonstrated on April 5, 2019 at LEReC at BNL. The first critical step in obtaining successful 3D non-magnetized cooling of the Au ion bunches in the RHIC cooling section was matching the electron beam energy with a relative error less than 5*10 -4 to the ion beam energy. Part of the LEReC beamline is a dipole magnet that bends the electron beam 180 degree. One of the most outstanding measurement challenges is that the dipole field is so low (≈200 G). Most of the existing NMR probes can only measure fields >400 G. Lower signal-to-noise ratio at low fields is requires the use of larger sample volumes. Working with CAYLAR, a NMR probe has been redesigned and optimized for these low field measurements with high resolution. We report the methods, challenges, and results for extensive magnetic field mappings of the 180 dipole magnet. A combination of NMR and Hall sensors has been successfully implemented to measure uniform field regimes inside the magnet center area and non-uniform field regimes at the magnet ends. Detailed measurement and mapping have been performed at five radii and five heights along the beam trajectory. Meanwhile a finite element magnetic modeling simulation of the magnet using Opera software has been performed. The calculated and measured data are compared, and the calculated data is good reference for measured data over long length mapping from magnet edge to center. The measured magnetic measurement data is directly useful for beam instrumentation, diagnostics and operation.

Magnetic Field Measurement↗
DOE OSTI2019

Combined crystal plasticity and grain boundary modeling of creep in ferritic-martensitic steels: II. The effect of stress and temperature on engineering and microstructural properties

This paper describes a series of physically-based crystal plasticity finite element method (CPFEM) simulations of long-term creep and creep rupture of Grade 91 steel. It is Part 2 of a two part series of papers. Part 1 describes the simulation framework; this part focuses on specific simulations and on how the predicted long-term creep properties of Grade 91 compare to the assumptions used in current high temperature design practices. This work extends the model developed in Part 1 to look at creep properties at different temperatures, principal stresses, and multiaxial stress states. The simulations show that empirically extrapolating creep rupture stresses from short-term experimental data may substantially over predict the actual long-term creep properties of Grade 91. Additionally, the CPFEM calculations predict a transition from notch strengthening creep behavior for high values of maximum principal stress and moderate notch severity to notch weakening behavior for low principal stresses and more severe notches. The latter regime better categorizes conditions in engineering components designed for long term elevated temperature use, which implies Grade 91 may be a notch weakening material in actual service. This would have a significant impact on high temperature design practices, though confirmatory test data on long-life, low stress notched specimens is difficult to obtain. Finally, one advantage of the physically-based modeling approach adopted here is that the simulation results also elucidate the microstructural mechanisms causing the macroscopic trends in engineering properties predicted by the simulations. This paper shows that the detailed micromechanical mechanisms predicted by the CPFEM simulations can be abstracted with a simple micromechanical model that can be used to both explain the detailed results and make improved predictions of engineering properties from experimental data.

36 MATERIALS SCIENCE↗
DOE OSTI2017

Inferred rheological structure and mantle conditions from postseismic deformation following the 2010 M w 7.2 El Mayor-Cucapah Earthquake

The 2010M w 7.2 El Mayor-Cucapah earthquake provides a unique target of postseismic study as deformation extends across several distinct geological provinces, including the cold Mesozoic arc crust of the Peninsular Ranges and newly formed, hot, extending lithosphere within the Salton Trough. We use five years of global positioning system measurements to invert for afterslip and constrain a 3-D finite-element model that simulates viscoelastic relaxation. We find that afterslip cannot readily explain far-field displacements (more than 50 km from the epicentre). These displacements are best explained by viscoelastic relaxation of a horizontally and vertically heterogeneous lower crust and upper mantle. Lower viscosities beneath the Salton Trough compared to the Peninsular Ranges and other surrounding regions are consistent with inferred differences in the respective geotherms. Our inferred viscosity structure suggests that the depth of the Lithosphere/Asthenosphere Boundary (LAB) is ~65 km below the Peninsular Ranges and ~32 km beneath the Salton Trough. These depths are shallower than the corresponding seismic LAB. This suggests that the onset of partial melting in peridotite may control the depth to the base of the mechanical lithosphere. In contrast, the seismic LAB may correspond to an increase in the partial melt percentage associated with the change from a conductive to an adiabatic geotherm.

58 GEOSCIENCES↗
DOE OSTI2017

Establishment of new design criteria for GlidCop ® X-ray absorbers

Here, an engineering research program has been conducted at the Advanced Photon Source (APS) in order to determine the thermomechanical conditions that lead to crack formation in GlidCop ® , a material commonly used to fabricate X-ray absorbers at X-ray synchrotron facilities. This dispersion-strengthened copper alloy is a proprietary material and detailed technical data of interest to the synchrotron community is limited. The results from the research program have allowed new design criteria to be established for GlidCop ® X-ray absorbers based upon the thermomechanically induced fatigue behavior of the material. X-ray power from APS insertion devices was used to expose 30 GlidCop ® samples to 10000 thermal loading cycles each under various beam power conditions, and all of the samples were metallurgically examined for crack presence/geometry. In addition, an independent testing facility was hired to measure temperature-dependent mechanical data and uniaxial mechanical fatigue data for numerous GlidCop ® samples. Data from these studies support finite element analysis (FEA) simulation and parametric models, allowing the development of a thermal fatigue model and the establishment of new design criteria so that the thermomechanically induced fatigue life of X-ray absorbers may be predicted. It is also demonstrated how the thermal fatigue model can be used as a tool to geometrically optimize X-ray absorber designs.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2023

Genetic Algorithm-Based Commutation Angle Control for Torque Ripple Mitigation in Switched Reluctance Motor Drives

This work addresses the application of the Genetic Algorithm (GA) technique to optimize the commutation angles of a 2 kW 8/6 switched reluctance machine (SRM). The primary goal is to reduce the well-known drawback of SRMs: the torque ripple. Firstly, the machine was modeled in Matlab /Simulink ® using lookup tables obtained via finite element method (FEM) simulations. Subsequently, the model was used to perform the GA routine aiming to find the optimal phase commutation angles that minimize the torque ripple factor. Notably, the torque performance of the SRM was significantly affected by the commutation angles during the search for the optimal solution. Afterwards, the GA results for four different operation points were verified experimentally through a developed drive platform with digital signal processor-based (DSP) control and an asymmetric bridge converter. As showed by the experiments, the proposed approach was suitable to reduce the torque ripple by more than 50% for one of the evaluated operating points. Furthermore, it was confirmed that the torque ripple mitigation led to acoustic noise improvement.

42 ENGINEERING↗
DOE OSTI2018

50-kW 1kV DC bus air-cooled inverter with 1.7 kV SiC MOSFETs and 3D-printed novel power module packaging structure for grid applications

The traditional heatsink design technologies for forced air-cooling and power semiconductors with low junction temperatures have constrained the converters to be designed with massive heatsinks. The low power losses of WBG device technology and higher junction temperature operation over a wide operating range of power have not been fully utilized with liquid-cooled systems. The other major limitation has also been the traditional power module packaging “stack” approach with baseplate. This paper presents a novel power stage design which involves 1.7 kV silicon carbide (SiC) MOSFETs, a heatsink design with Genetic Algorithm (GA) and built using 3D printing technology, and a novel integrated modular power module for high power density. The air-cooled module assembly has a SiC MOSFET phase leg module with split high-side and low-side switches and a gate driver with cross-talk and short circuit protection functions. The heatsink design was modeled using a co-simulation environment with finite element analysis software and GA in MATLAB and COMSOL. The proposed concepts were verified and validated through experiments at each stage of development. The power stage was evaluated at 800V, 900 V, and 1kV for 20 kHz switching frequency and 50-kW load. The experimental results show that the CEC efficiency is 98.4 %. In addition to the efficiency, a power density of 75 W/in 3 was also achieved.

Chinthavali, Madhu Sudhan↗
DOE OSTI2024

Design of High-Power Polyphase PCB Coil Systems for Wireless Power Transfer

Printed circuit board (PCB) coils have been proposed prior for implementation as inductive wireless charging coils to minimize size and cost. Utilization of PCBs can allow for a reduced cost, improved manufacturability, and a wide range of geometric customization options. To circumvent material limitations on insulation and thermal performance, parallel paths can be implemented to divide the current per path accordingly. Within this paper, an unconventional high-power PCB coil is designed employing all possible techniques for wiring with axial and radial parallel paths with equivalent transposition to minimize circulating currents. Design studies are simulated in 3D finite element analysis (FEA) to evaluate imbalance between phases with and without transposition. Two experimental prototype coils were fabricated with measurements for self-inductance and mutual inductance between phases. These measurements were validated to be sufficiently consistent with FEA results. Additionally, a method is proposed for a two-step optimization of coupling coefficient and coil losses.

Lewis, Donovin D.↗
DOE OSTI2025

Multi-phase Wireless Power Transfer with High Power Density Inductive Coils for Electric Drone Charging

Wireless charging of unmanned ground vehi-cles and aircraft has been proposed to increase charging reliability and security, allow for autonomous functionality, and either reduce battery size or increase continuous flight time. This paper proposes a three-phase Litz wire primary and a two-phase PCB secondary for high secondary-side power density considering misalignment tolerances, surface and volumetric power density, and coil sizing. Elec-tromagnetic 3D finite element analysis (FEA) simulations are conducted to study variation in mutual inductance and coupling coefficient with different secondary coil sizes and number of turns, horizontal and vertical misalignment between the primary and secondary, and a combination of both for a set of designs with the same rated power. Results indicate that receiver coils of reduced size relative to the primary can deliver rated power for increased power density and higher tolerance to misalignment.

Gastineau, Lucas [University of Kentucky]↗
DOE OSTI2017

Design and optimization of 3D printed air-cooled heat sinks based on genetic algorithms

Enhancing power density and reliability of powerelectronics is extremely important in power electronicsapplications. One of the key challenges in the design process isto design the optimum heat sink. In this paper, an algorithm isproposed to design air-cooled heat sinks using genetic algorithm(GA) and finite element analysis (FEA) simulations. While theGA generates a population of candidate heat sinks in eachiteration, FEA simulations are used to evaluate the fitnessfunction of each. The fitness function considered in this paper isthe maximum junction temperature of the semiconductordevices. With an approach that prefers “survival of the fittest”,a heat sink providing better performance than the conventionalheat sinks is obtained. The simulation and experimentalevaluations of the optimized air-cooled heat sink are alsoincluded in the paper.

Wu, Tong↗
DOE OSTI2026

A Unified Wireless Charger, On-Board Charger, and Auxiliary Power Module for Electric Vehicle Charging Systems

This paper proposes a unified electric vehicle (EV) charging architecture that integrates wireless power transfer (WPT), an on-board charger (OBC), and an auxiliary power module (APM) within a single architecture. By sharing a multi-functional magnetic structure and active switch bridges, the proposed topology eliminates additional transformers and converter stages, reducing hardware complexity and improving power density. A multipurpose magnetic design achieves magnetic decoupling among the WPT, OBC, and APM functions while maintaining the required coupling for each mode. Through electrical reconfiguration, the WPT operates as an LCC-S converter, whereas the OBC and APM operate as dual-active-bridge (DAB) converters. The system supports multiple operating modes, including simultaneous high-voltage and lowvoltage battery charging. Finite-element and circuit simulations verify the magnetic characteristics and system operation, demonstrating the feasibility of the proposed unified architecture for EV charging applications.

Jo, Cheolhui [ORNL] (ORCID:0000000322692434)↗
DOE OSTI2023

Cryogenic System Preliminary Design for a 0.5m-Long, Conduction-Cooled Nb3Sn Undulator Magnet Prototype

There are several NbTi superconducting undulator (SCU) magnets currently in operation at the Advanced Photon Source (APS) at Argonne National Laboratory (ANL). The development on Nb3Sn-based superconducting undulator magnets at APS is underway due to the potential to further enhance the performance of the SCUs. Superconducting undulator magnets need to keep temperature gradients minimized in order to retain thermal and operating current margin. We have designed the thermal links for efficient heat conduction using 3D finite element analysis (FEA) simulation in COMSOL Multiphysics software, which was later used for the calculation of the temperature distribution across a 0.5 m long, conduction-cooled, Nb3Sn undulator magnet prototype that includes both conductive heat transfer and radiative heating components. We have modelled the evolution of the thermal properties of the magnet winding as well as other cold parts during cool-down from ambient temperature with the operation of a SHI RDK-415D cryocooler to examine the estimated time that is needed for the cooldown as well as the baseline temperature we could achieve. A key result was that a maximum coil delta T = 0.11 K along the designed thermal links and a temperature range of 3.42 K-3.53 K for the winding were predicted at steady state. A pair of G10 support rods for carrying the magnet as well as a pair of current leads made of metals were also designed and optimized for the testing system, targeting for an operation temperature of 4 K and a coil current of 950 A DC.

Zhang, Danlu↗
DOE OSTI2017

Investigation of Gallium Nitride Devices in High-Frequency LLC Resonant Converters

Newly emerged gallium nitride (GaN) devices feature ultrafast switching speed and low on-state resistance that potentially provide significant improvements for power converters. Here, this article investigates the benefits of GaN devices in an LLC resonant converter and quantitatively evaluates GaN devices' capabilities to improve converter efficiency. First, the relationship of device and converter design parameters to the device loss is established based on an analytical model of LLC resonant converter operating at the resonance. Due to the low effective output capacitance of GaN devices, the GaN-based design demonstrates about 50% device loss reduction compared with the Si-based design. Second, a new perspective on the extra transformer winding loss due to the asymmetrical primary-side and secondary-side current is proposed. The device and design parameters are tied to the winding loss based on the winding loss model in the finite element analysis (FEA) simulation. Compared with the Si-based design, the winding loss is reduced by 18% in the GaN-based design. Finally, in order to verify the GaN device benefits experimentally, 400- to 12-V, 300-W, 1-MHz GaN-based and Si-based LLC resonant converter prototypes are built and tested. One percent efficiency improvement, which is 24.8% loss reduction, is achieved in the GaN-based converter.

30 DIRECT ENERGY CONVERSION↗
DOE OSTI2015

Lattice Rotation Patterns and Strain Gradient Effects in Face-Centered-Cubic Single Crystals Under Spherical Indentation

Strain gradient effects are commonly modeled as the origin of the size dependence of material strength, such as the dependence of indentation hardness on contact depth and spherical indenter radius. However, studies on the microstructural comparisons of experiments and theories are limited. First, we have extended a strain gradient Mises-plasticity model to its crystal plasticity version and implemented a finite element method to simulate the load-displacement response and the lattice rotation field of Cu single crystals under spherical indentation. The strain gradient simulations demonstrate that the forming of distinct sectors of positive and negative angles in the lattice rotation field is governed primarily by the slip geometry and crystallographic orientations, depending only weakly on strain gradient effects, although hardness depends strongly on strain gradients. Second, the lattice rotation simulations are compared quantitatively with micron resolution, three-dimensional X-ray microscopy (3DXM) measurements of the lattice rotation fields under 100mN force, 100 mu m radius spherical indentations in < 111 >, < 110 >, and < 001 > oriented Cu single crystals. Third, noting the limitation of continuum strain gradient crystal plasticity models, two-dimensional discrete dislocation simulation results suggest that the hardness in the nanocontact regime is governed synergistically by a combination of strain gradients and source-limited plasticity. However, the lattice rotation field in the discrete dislocation simulations is found to be insensitive to these two factors but to depend critically on dislocation obstacle densities and strengths.

Gao, Y. F.↗
DOE OSTI2020

Mesoscale Effects of Composition and Calendering in Lithium-Ion Battery Composite Electrodes

Macrohomogeneous battery models are widely used to predict battery performance, necessarily relying on effective electrode properties, such as specific surface area, tortuosity, and electrical conductivity. While these properties are typically estimated using ideal effective medium theories, in practice they exhibit highly non-ideal behaviors arising from their complex mesostructures. In this paper, we computationally reconstruct electrodes from X-ray computed tomography of 16 nickel–manganese–cobalt-oxide electrodes, manufactured using various material recipes and calendering pressures. Due to imaging limitations, a synthetic conductive binder domain (CBD) consisting of binder and conductive carbon is added to the reconstructions using a binder bridge algorithm. Reconstructed particle surface areas are significantly smaller than standard approximations predicted, as the majority of the particle surface area is covered by CBD, affecting electrochemical reaction availability. Finite element effective property simulations are performed on 320 large electrode subdomains to analyze trends and heterogeneity across the electrodes. Significant anisotropy of up to 27% in tortuosity and 47% in effective conductivity is observed. Electrical conductivity increases up to 7.5× with particle lithiation. We compare the results to traditional Bruggeman approximations and offer improved alternatives for use in cell-scale modeling, with Bruggeman exponents ranging from 1.62 to 1.72 rather than the theoretical value of 1.5. We also conclude that the CBD phase alone, rather than the entire solid phase, should be used to estimate effective electronic conductivity. This study provides insight into mesoscale transport phenomena and results in improved effective property approximations founded on realistic, image-based morphologies.

25 ENERGY STORAGE↗
DOE OSTI2024

Characterization of latent image of electron beam resist via critical-dimension resonant soft X-ray scattering

Metrology plays a crucial role in semiconductor manufacturing by providing accurate and precise measurement and characterization of critical parameters. With the development of high-resolution extreme ultraviolet lithography (EUVL) processes, critical dimensions are shrinking to sub-10 nm. Resist materials encounter the challenge of providing heightened sensitivity and a handle on exacerbating stochastic variations. A comprehensive understanding of the chemical profile of the latent image is pivotal for mitigating stochastic effects and optimizing pattern quality. However, the subtle differences in chemistry between the exposed and unexposed regions of the resists make it extremely challenging to characterize the latent images with sub-nanometer precision. Here, we develop the metrology with critical-dimension resonant soft X-ray scattering (CD-RSoXS) to probe the chemical profiles of latent images stored in resist after exposure. The combination of absorption spectroscopy and enhanced scattering contrast makes it possible to characterize the subtle structural and chemical variations in the latent image. Moreover, the results of the measurements are compared with the simulations with a finite element method–based Maxwell solver to extract a detailed profile of the latent and developed images. We demonstrate that the CD-RSoXS technique can provide valuable insights into the high spatial resolution and local chemical sensitivity simultaneously, which is crucial to understanding the resolution limits and stochastic effects in EUVL processes.

36 MATERIALS SCIENCE↗
DOE OSTI2023

A Three-Dimensional, Thermodynamically and Variationally Consistent, Fully Coupled, Electro-Chemo-Thermo-Mechanical Model of Solid-State Batteries

Here we present a theoretical framework for high fidelity modeling of three-dimensional electro-chemo-thermo-mechanical coupled systems such as solid-state batteries. The framework provides a useful means of utilizing molecular level information to predict the overall performance of the system at the continuum level. The central statement of the theoretical framework is a thermodynamically consistent inf-sup problem. The total potential of the coupled system consists of the Helmholtz free energy, the electrical kinetic potential, the chemical potential, the Fourier potential, the chemical reaction potential, and the external power expenditure. All governing equations derive from variational principles. We also show that the resulting initial-boundary-value problem (IBVP) is consistent with existing, widely adopted equations for modeling batteries. Moreover, the IBVP can be naturally discretized using the (variational) finite element method to simulate practical solid-state batteries with arbitrary geometries. Several examples illustrate multiphysics coupling between pairs of the physical field equations, culminating in a comprehensive three-dimensional model of charge-discharge in a solid state battery.

25 ENERGY STORAGE↗
DOE OSTI2019

SCPACK vR1.0

User-defined elements in ANSYS enable programming of the finite element method to simulate the unique behavior of superconducting magnets. A set of electromagnetic and thermal user elements incorporate both quench and interfilament coupling current (IFCC) effects in a consistent manner, allowing for simulation of strongly coupled, multiphysics behavior typical of superconducting devices.

Brouwer, Lucas↗