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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 1,027 records · Page 57
All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

Development, validation, and verification of multi-pass thermo-mechanical welding simulations using the open-source MOOSE framework: NeT TG4 benchmark weldment

This study develops and validates a sequentially coupled thermo-mechanical welding simulation for the three-pass 316L stainless steel NeT TG4 benchmark weldment using the open-source Multiphysics Object-Oriented Simulation Environment (MOOSE) and the Nuclear Engineering Material model Library (NEML). A diffused ellipsoidal heat source was calibrated against thermocouple data and weld macrographs to accurately model the fusion zone geometry and transient thermal fields. Material hardening is represented using the Lemaitre-Chaboche mixed isotropic-kinematic hardening model, while four annealing models - no annealing, single-stage at 1050 °C and 1300 °C, and two-stage at 800 °C/1300 °C - were implemented to assess the impact of annealing models on the accuracy of the predicted welding-induced plasticity, distortions, and residual stresses. The predictions were validated against experimental measurements and benchmarked against results from commercial software, demonstrating that thermo-mechanical MOOSE welding simulations achieve comparable accuracy with enhanced computational efficiency. This work highlights the potential of using open-source finite element frameworks like MOOSE for advanced manufacturing simulations.

Ji, Wendy [Australian Nuclear Science and Technolo↗
DOE OSTI2018

A Machine Learning-Genetic Algorithm (ML-GA) Approach for Rapid Optimization Using High-Performance Computing

A Machine Learning-Genetic Algorithm (ML-GA) approach was developed to virtually discover optimum designs using training data generated from multi-dimensional simulations. Machine learning (ML) presents a pathway to transform complex physical processes that occur in a combustion engine into compact informational processes. In the present work, a total of over 2000 sector-mesh computational fluid dynamics (CFD) simulations of a heavy-duty engine were performed. These were run concurrently on a supercomputer to reduce overall turnaround time. The engine being optimized was run on a low-octane (RON70) gasoline fuel under partially premixed compression ignition (PPCI) mode. A total of nine input parameters were varied, and the CFD simulation cases were generated by randomly sampling points from this nine-dimensional input space. These input parameters included fuel injection strategy, injector design, and various in-cylinder flow and thermodynamic conditions at intake valve closure (IVC). The outputs (targets) of interest from these simulations included five metrics related to engine performance and emissions. Over 2000 samples generated from CFD were then used to train an ML model that could predict these five targets based on the nine input features. A robust super learner approach was employed to build the ML model, where results from a collection of different ML algorithms were pooled together. Thereafter, a stochastic global optimization genetic algorithm (GA) was used, with the ML model as the objective function, to optimize the input parameters based on a merit function so as to minimize fuel consumption while satisfying CO and NOx emissions constraints. The optimized configuration from ML-GA was found to be very close to that obtained from a sequentially performed CFD-GA approach, where a CFD simulation served as the objective function. In addition, the overall turnaround time was (at least) 75% lower with the ML-GA approach, as the training data was generated from concurrent CFD simulations and employing the ML model as the objective function significantly accelerated the GA optimization. Finally, this study demonstrates the potential of ML-GA and high-performance computing (HPC) to reduce the number of CFD simulations to be performed for optimization problems without loss in accuracy, thereby providing significant cost savings compared to traditional approaches.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2018

Influence of Spindle Wobble in a Lathe on the Tool’s Deformational-Displacement Trajectory

Attention focuses here on the conversion of the trajectory of spindle-group wobble in a lathe into deformational displacement of the tool and the associated modification of the shaping trajectory. This process depends on the change in dynamic properties of the system due to the wobble. On the basis of simulation and digital experiments, it may be concluded that the wobble changes the stability of the trajectories and that various attractive sets are formed in the system (such as limit cycles, invariant tori, and chaotic attractors). The wobble does not change the shaping trajectory directly, but rather through the formation of attractive deformational-displacement sets. Therefore, the attractive sets affect the geometric topology of the workpiece surface and the limiting feasible manufacturing precision.

42 ENGINEERING↗
DOE OSTI2019

Progress Report on An Exascale Computational Simulation Capability for Pervasive Fracture & Failure

How does a structure fail in an explosion? Is there an engineering design opportunity to mitigate the effects of a blast? These are questions that may be addressed with simulation; however, a computational simulation capability to answer these questions must include developments in material physics modeling and numerical algorithms that we believe are possible, but do not yet exist. This LDRD project proposes to develop the physics models and computational approaches to create a computational simulation approach to answer these physics and engineering questions.

42 ENGINEERING↗
DOE OSTI2023

On the Morphodynamics of a Wide Class of Large‐Scale Meandering Rivers: Insights Gained by Coupling LES With Sediment‐Dynamics

Abstract In meandering rivers, interactions between flow, sediment transport, and bed topography affect diverse processes, including bedform development and channel migration. Predicting how these interactions affect the spatial patterns and magnitudes of bed deformation in meandering rivers is essential for various river engineering and geoscience problems. Computational fluid dynamics simulations can predict river morphodynamics at fine temporal and spatial scales but have traditionally been challenged by the large scale of natural rivers. We conducted coupled large‐eddy simulation and bed morphodynamics simulations to create a unique database of hydro‐morphodynamic data sets for 42 meandering rivers with a variety of planform shapes and large‐scale geometrical features that mimic natural meanders. For each simulated river, the database includes (a) bed morphology, (b) three‐dimensional mean velocity field, and (c) bed shear stress distribution under bankfull flow conditions. The calculated morphodynamics results at dynamic equilibrium revealed the formation of scour and deposition patterns near the outer and inner banks, respectively, while the location of point bars and scour regions around the apexes of the meander bends is found to vary as a function of the radius of curvature of the bends to the width ratio. A new mechanism is proposed that explains this seemingly paradoxical finding. The high‐fidelity simulation results generated in this work provide researchers and scientists with a rich numerical database for morphodynamics and bed shear stress distributions in large‐scale meandering rivers to enable systematic investigation of the underlying phenomena and support a range of river engineering applications.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2026

Recent progress on coarse graining simulations

We focus on coarse graining simulations based on the primary conservation equations, effectively codesigned physics and algorithms, and low-Mach-number corrected (LMC) hydrodynamics. Simulation methods involve LANL’s x-Radiation-Adaptive-Grid-Eulerian Large-Eddy Simulation, Besnard-Harlow-Rauenzahn (BHR) Reynolds-Averaged Navier-Stokes (RANS) approach, and Dynamic BHR – a paradigm bridging RANS and LES. A relevant question addressed relates to whether 3D RANS and RANS/LES hybrids – the industry standards for aerospace and automotive research, are presently relevant for practical variable-density applications involving shocked and accelerated interface instabilities. Furthermore, recent simulations of the GaTECH inclined mixing-layer shock-tube and NIF ICF-capsule experiments are used to demonstrate issues, challenges, and potential for 3D coarse grained LMC simulation strategies for robustly simulating complex transitional and coupled hydrodynamics-multiphysics with coarser resolution. Present LES readiness to provide accurate predictions at scale is demonstrated – whereas 3D RANS and RANS/LES bridging do not appear impactful in this context.

42 ENGINEERING↗
DOE OSTI2021

Towards Predictive Plasma Science and Engineering through Revolutionary Multi-Scale Algorithms and Models (Final Report)

This report describes the high-level accomplishments from the Plasma Science and Engineering Grand Challenge LDRD at Sandia National Laboratories. The Laboratory has a need to demonstrate predictive capabilities to model plasma phenomena in order to rapidly accelerate engineering development in several mission areas. The purpose of this Grand Challenge LDRD was to advance the fundamental models, methods, and algorithms along with supporting electrode science foundation to enable a revolutionary shift towards predictive plasma engineering design principles. This project integrated the SNL knowledge base in computer science, plasma physics, materials science, applied mathematics, and relevant application engineering to establish new cross-laboratory collaborations on these topics. As an initial exemplar, this project focused efforts on improving multi-scale modeling capabilities that are utilized to predict the electrical power delivery on large-scale pulsed power accelerators. Specifically, this LDRD was structured into three primary research thrusts that, when integrated, enable complex simulations of these devices: (1) the exploration of multi-scale models describing the desorption of contaminants from pulsed power electrodes, (2) the development of improved algorithms and code technologies to treat the multi-physics phenomena required to predict device performance, and (3) the creation of a rigorous verification and validation infrastructure to evaluate the codes and models across a range of challenge problems. These components were integrated into initial demonstrations of the largest simulations of multi-level vacuum power flow completed to-date, executed on the leading HPC computing machines available in the NNSA complex today. These preliminary studies indicate relevant pulsed power engineering design simulations can now be completed in (of order) several days, a significant improvement over pre-LDRD levels of performance.

42 ENGINEERING↗
DOE OSTI2019

Gating System Design Optimization for Investment Casting Process

This article aims to optimize specific castings, characterized as an element of the continuous track for armored vehicle. During the primary melts, defects in the form of oxide films and shrinkage porosity occurred. Steel 20ChGSNM described by the Russian GOST standard was used as a batch material, and the investment casting method was selected for production. To eliminate the above-mentioned defects, only changes in the gating system were allowed, because the interference with an ongoing production regarding technical and technological parameters was unacceptable by the manufacturer. Numerical simulation, x-ray, macro-structural and micro-structural analysis were used during the optimization process. The three variants were analyzed, and the achieved results demonstrated that it is possible to significantly affect the casting internal homogeneity by modifying the gating system individual parts. The final variant ensured a decrease in defects by up to 90% and the production of casting having the quality required by the customer.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Security enrichment of optical image cryptosystem based on superposition technique using fractional Hartley and gyrator transform domains deploying equal modulus decomposition

In this paper, a symmetric cryptosystem has been suggested to increase security of double random phase encoding using superposition technique in fractional Hartley transform (FrHT) and gyrator transform (GT) domains. It uses structured phase mask (SPM) and hybrid mask (HM) deploying equal modulus decomposition (EMD). Related to original phase truncated Fourier transform (PTFT) based cryptosystem, the security of encoding and decoding is upgraded by using the superposition technique. With the usage of SPM we can increase the key space while encoding and can also overcome the axis alignment difficulty. Decoding is just the reversal of the encoding method. The proposed scheme has robustness against common attacks like: noise and occlusion attacks. With the help of numerical simulation results we also show that our cryptosystem is vulnerable to various attacks. Performance of the suggested method is calculated in terms of Mean Square Error (MSE) between original and decoded image and also the sensitivity of the SPM parameters and rotational angles of GT is investigated. The competence of the suggested method includes analysis on EMD, histogram and correlation coefficient. The suggested cryptosystem is also open to the occlusion attack and noise attack to analyze its performance and evenness.

42 ENGINEERING↗
DOE OSTI2021

Nonintrusive manufactured solutions for ablation

The study of heat transfer and ablation plays an important role in many problems of scientific and engineering interest. As with the computational simulation of any physical phenomenon, the first step toward establishing credibility in ablation simulations involves code verification. Code verification is typically performed using exact and manufactured solutions. However, manufactured solutions generally require the invasive introduction of an artificial forcing term within the source code such that the code solves a modified problem for which the solution is known. In this paper, we present a nonintrusive method for manufacturing solutions for a non-decomposing ablation code, which does not require the addition of a source term.

42 ENGINEERING↗
DOE OSTI2015

Computational fluid dynamics modeling of high level waste plug formation - 15228

At Hanford, an extensive network of pipelines traversing several miles is used to transfer the high level radioactive nuclear waste from tanks to the treatment facilities. During transfer operations, however, there is a potential risk for the transport lines to plug, causing significant delays, increasing operation costs and creating hazardous conditions for personnel and the environment. In this study we investigate the phenomena of plug formation in the pipelines due to solids depositing during the waste transfer process. A three-dimensional (3-D) Computational Fluid Dynamics (CFD) model has been developed using Comsol Multiphysics 4.3b by Florida International University (FIU) to evaluate the factors that can contribute to pipeline plug formation. Several virtual scenarios are developed simulating the settling mechanics as a function of particle size, solids volume fraction and solids density. The numerical results are validated with the available experimental results and the established critical velocity correlations. The 3-D numerical results were also compared with the previous 2-D numerical studies to understand the trade-off between the two studies in terms of computing speed and numerical accuracy. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2018

Numerical Simulation of Ion Transport in a Nano-Electrospray Ion Source at Atmospheric Pressure

Understanding ion transport properties from the ion source to the mass spectrometer (MS) is essential for optimizing device performance. Numerical simulation helps in understanding of ion transport properties and, furthermore, facilitates instrument design. In contrast to previously reported numerical studies, ion transport simulations in a continuous injection mode whilst considering realistic space-charge effects have been carried out. The flow field was solved using Reynolds-averaged Navier-Stokes (RANS) equations, and a particle-in-cell (PIC) method was applied to solve a time-dependent electric field with local charge density. A series of ion transport simulations were carried out at different cone gas flow rates, ion source currents, and capillary voltages. A force evaluation analysis reveals that the electric force, the drag force, and the Brownian force are the three dominant forces acting on the ions. Both the experimental and simulation results indicate that cone gas flow rates of ≤250 slph (standard liter per hour) are important for high ion transmission efficiency, as higher cone gas flow rates reduce the ion signal significantly. The simulation results also show that the ion transmission efficiency reduces exponentially with an increased ion source current. Additionally, the ion loss due to space-charge effects has been found to be predominant at a higher ion source current, a lower capillary voltage, and a stronger cone gas counterflow. The interaction of the ion driving force, ion opposing force, and ion dispersion is discussed to illustrate ion transport mechanism in the ion source at atmospheric pressure. .

42 ENGINEERING↗
DOE OSTI2020

Engineering the electronic and strained interface for high activity of PdM core @Pt monolayer electrocatalysts for oxygen reduction reaction

Alloyed nanoparticles with core-shell structures provide a favorable model to modulate interfacial interaction and surface structures at the atomic level, which is important for designing electrocatalysts with high activity and durability. Herein, core-shell structured Pd 3 M@Pt/C nanoparticles with binary PdM alloy cores (M = Fe, Ni, and Co) and a monolayer Pt shell were successfully synthesized with diverse interfaces. Among these, Pd 3 Fe@Pt/C exhibited the best oxygen reduction reaction catalytic performance, roughly 5.4 times more than that of the commercial Pt/C catalyst used as reference. The significantly enhanced activity is attributed to the combined effects of strain engineering, interfacial electron transfer, and improved Pt utilization. Density functional theory simulations and extended X-ray absorption fine structure analysis revealed that engineering the alloy core with moderate lattice mismatch and alloy composition (Pd 3 Fe) optimizes the surface oxygen adsorption energy, thereby rendering excellent electrocatalytic activity. Finally, future researches may use this study as a guide on the construction of highly effective core-shell electrocatalysts for various energy conversions and other applications.

25 ENERGY STORAGE↗
DOE OSTI2019

Thermo-chemical Fluid Flow Simulation in Hot-Dip Galvanizing: The Evaluation of Dross Build-Up Formation

This paper presents a new computational framework to investigate the driving force for the formation of intermetallic dross particles in the zinc bath and dross build-up on the bath hardware. This is a major problem in continuous hot-dip galvanizing lines. The Computational Fluid Dynamics (CFD) model calculates the turbulent thermo-chemical flow conditions within the liquid melt. A detailed modeling of the steel strip–liquid interface enhances this approach, by means of a conjugated heat transfer calculation and a spatially resolved, temperature- and concentration-dependent iron dissolution and aluminum uptake. The heart of the computational framework is a thermodynamic model, which assesses the driving force for the formation or dissolution of dross particles in the bath and dross build-up on stationary and rotating equipment. The simulation results are validated with temperature and species depth profile measurements. The applicability of the CFD model is shown by investigating the locally resolved aluminum uptake and iron dissolution at the steel-strip surface, and the multi-physics conditions in the region near the roll. The novel approach of evaluating the thermodynamic driving force enables the assessment of the formation of dross build-up at the roll surface.

36 MATERIALS SCIENCE↗
DOE OSTI2014

Critical point analysis of phase envelope diagram

Phase diagram or phase envelope is a relation between temperature and pressure that shows the condition of equilibria between the different phases of chemical compounds, mixture of compounds, and solutions. Phase diagram is an important issue in chemical thermodynamics and hydrocarbon reservoir. It is very useful for process simulation, hydrocarbon reactor design, and petroleum engineering studies. It is constructed from the bubble line, dew line, and critical point. Bubble line and dew line are composed of bubble points and dew points, respectively. Bubble point is the first point at which the gas is formed when a liquid is heated. Meanwhile, dew point is the first point where the liquid is formed when the gas is cooled. Critical point is the point where all of the properties of gases and liquids are equal, such as temperature, pressure, amount of substance, and others. Critical point is very useful in fuel processing and dissolution of certain chemicals. Here in this paper, we will show the critical point analytically. Then, it will be compared with numerical calculations of Peng-Robinson equation by using Newton-Raphson method. As case studies, several hydrocarbon mixtures are simulated using by Matlab.

36 MATERIALS SCIENCE↗
DOE OSTI2017

Light Water Reactor Sustainability Program Modeling of Cu Precipitate Contributions to Reactor Pressure Vessel Steel Microstructure Evolution and Embrittlement

This report summarizes the lower-length-scale effort during FY 2017 in developing simulation capabilities for the mesoscale: models for microstructure evolution and plasticity in reactor pressure vessel steels. During operation, reactor pressure vessels undergo hardening and embrittlement caused by irradiation induced defect accumulation and irradiation enhanced solute precipitation. Both defect production and solute precipitation initiate on the atomic scale and manifest their eventual effects as degradation in the engineering scale properties. To predict the engineering scale property degradation, multiscale modeling and simulation capabilities are needed to better understand the microstructure evolution and to connect the microstructure feature evolution to the engineering scale material properties. In this report the development of coupling across different length scale models to understand the multi-physics property dedgration problem is discussed. The development of coupling a lattice kinetic Monte Carlo code to cluster dynamics to capture irradiation enhanced diffusion in the formation of defects is summarized. The implementation of a cluster dynamics model with Grizzly to predict Cu percipitate formation is discussed. A summary of the coupling of crystal plasticity and cluster dynamics to predict the effect on reactor pressure steel hardening is given.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2016

Blade Load Unsteadiness and Turbulence Statistics in an Actuator-Line Computed Turbine–Turbine Interaction Problem

The objective of this study is to investigate how different volumetric projection techniques used in actuator-line modeling affect the unsteady blade loads and wake turbulence statistics. The two techniques for the body-force projection radius are based on either (i) the grid spacing or (ii) the combination of grid spacing and an equivalent elliptic blade planform. An array of two National Renewable Energy Laboratory 5-MW turbines separated by seven rotor diameters is simulated for 2000s (about rotor 300 revolutions) within a large-eddy simulation (LES) solver of the neutral and moderately convective atmospheric boundary layer (ABL). The statistics of sectional angle of attack (AOA), blade loads, and turbine power histories are quantified. Moreover, the degree of unsteadiness of sectional blade loads in response to atmospheric and wake turbulence is computed via a reduced frequency based on the rate-of-change in sectional AOA. Finally, the goal of this work is to make the wind energy community aware of the uncertainties associated with actuator-line modeling approaches.

17 WIND ENERGY↗