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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 1,063 records · Page 59
All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

Going Off Grid: A Comparative Study of the Lagrangian and Eulerian Perspectives of New Particle Formation Events

New particle formation and growth (NPF&G) is the process by which ultrafine particles are formed from gas-phase precursors. NPF&G is the dominant source of global aerosol number with important influences on climate. Most observations of NPF&G events are conducted at stationary sites; however, NPF&G observed from stationary sites is influenced by gradual or rapid changes in the air masses passing over the site, complicating NPF&G analysis. In this work, we use observations and a 3D aerosol model to compare aerosol size distributions at a stationary site (Southern Great Plains [SGP] observatory, Oklahoma, USA) and along Lagrangian trajectories crossing the site. The model simulates the NPF&G events reasonably well at SGP. Using the model to compare the Lagrangian and stationary perspectives, we can explain previously unanalyzable days with some evidence of NPF&G as either non-event or analyzable NPF&G days. We find most of the unanalyzable NPF&G days are due to isolated and inhomogeneous NPF&G occurring upwind of the stationary site, often in the outflow of urban regions. Finally, we compare formation rates of 3 nm particles, growth rates, and the survival probability of 3 nm particles growing to 25 nm between the stationary and Lagrangian perspectives. Because of the much larger number of analyzable days along the Lagrangian trajectories, this perspective potentially provides more robust statistics and better characterization of NPF&G event extremes. Our method for extracting chemical/physical properties along Lagrangian trajectories from 3D models can be applied to a wide range of science questions.

O’Donnell, Samuel E. [Colorado State Univ., Fort C↗
DOE OSTI2014

Transport and dielectric properties of water and the influence of coarse-graining: Comparing BMW, SPC/E, and TIP3P models

Long-term molecular dynamics simulations are used to compare the single particle dipole reorientation time, the diffusion constant, the viscosity, and the frequency-dependent dielectric constant of the coarse-grained big multipole water (BMW) model to two common atomistic three-point water models, SPC/E and TIP3P. In particular, the agreement between the calculated viscosity of BMW and the experimental viscosity of water is satisfactory. We also discuss contradictory values for the static dielectric properties reported in the literature. Employing molecular hydrodynamics, we show that the viscosity can be computed from single particle dynamics, circumventing the slow convergence of the standard approaches. Furthermore, our data indicate that the Kivelson relation connecting single particle and collective reorientation time holds true for all systems investigated. Since simulations with coarse-grained force fields often employ extremely large time steps, we also investigate the influence of time step on dynamical properties. We observe a systematic acceleration of system dynamics when increasing the time step. Carefully monitoring energy/temperature conservation is found to be a sufficient criterion for the reliable calculation of dynamical properties. By contrast, recommended criteria based on the ratio of fluctuations of total vs. kinetic energy are not sensitive enough.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2014

Prognostic Value and Reproducibility of Pretreatment CT Texture Features in Stage III Non-Small Cell Lung Cancer

Purpose: To determine whether pretreatment CT texture features can improve patient risk stratification beyond conventional prognostic factors (CPFs) in stage III non-small cell lung cancer (NSCLC). Methods and Materials: We retrospectively reviewed 91 cases with stage III NSCLC treated with definitive chemoradiation therapy. All patients underwent pretreatment diagnostic contrast enhanced computed tomography (CE-CT) followed by 4-dimensional CT (4D-CT) for treatment simulation. We used the average-CT and expiratory (T50-CT) images from the 4D-CT along with the CE-CT for texture extraction. Histogram, gradient, co-occurrence, gray tone difference, and filtration-based techniques were used for texture feature extraction. Penalized Cox regression implementing cross-validation was used for covariate selection and modeling. Models incorporating texture features from the 33 image types and CPFs were compared to those with models incorporating CPFs alone for overall survival (OS), local-regional control (LRC), and freedom from distant metastases (FFDM). Predictive Kaplan-Meier curves were generated using leave-one-out cross-validation. Patients were stratified based on whether their predicted outcome was above or below the median. Reproducibility of texture features was evaluated using test-retest scans from independent patients and quantified using concordance correlation coefficients (CCC). We compared models incorporating the reproducibility seen on test-retest scans to our original models and determined the classification reproducibility. Results: Models incorporating both texture features and CPFs demonstrated a significant improvement in risk stratification compared to models using CPFs alone for OS (P=.046), LRC (P=.01), and FFDM (P=.005). The average CCCs were 0.89, 0.91, and 0.67 for texture features extracted from the average-CT, T50-CT, and CE-CT, respectively. Incorporating reproducibility within our models yielded 80.4% (±3.7% SD), 78.3% (±4.0% SD), and 78.8% (±3.9% SD) classification reproducibility in terms of OS, LRC, and FFDM, respectively. Conclusions: Pretreatment tumor texture may provide prognostic information beyond that obtained from CPFs. Models incorporating feature reproducibility achieved classification rates of ∼80%. External validation would be required to establish texture as a prognostic factor.

62 RADIOLOGY AND NUCLEAR MEDICINE↗
NASA NTRS1990

Neural networks and MIMD-multiprocessors

Two artificial neural network models are compared. They are the Hopfield Neural Network Model and the Sparse Distributed Memory model. Distributed algorithms for both of them are designed and implemented. The run time characteristics of the algorithms are analyzed theoretically and tested in practice. The storage capacities of the networks are compared. Implementations are done using a distributed multiprocessor system.

Vanhala, Jukka↗
DOE OSTI2016

Turbulence Model Study for Pressure and Velocity Distributions for Molten Salts in a Crossflow Tube Bundle

Empirical pressure drop correlations for various compositions of molten salts in crossflow across tube bundles/banks are limited due to the scarcity of experimental data for these fluids. This lack of experimental data presents a limitation when designing heat exchangers for Molten Salt Reactors (MSRs) that utilize cross-flow configurations with turbulent molten salts flowing in the shell side. In an effort to provide a starting point for future design and experimental work, a computational fluid dynamics (CFD) campaign is being conducted to estimate pressure drops over a range of Reynolds numbers, pitch to diameter ratios, and for both staggered and in-line tube banks. In an effort to continue this work, the study of various turbulence models were conducted to determine the applicability for steady RANS simulations. An in-line tube bank with FLiBe (LiF-BeF{sub 2}), a frequently selected molten salt in MSRs, was selected for these simulations. The estimated pressure drops and pressure and velocity distributions for each turbulence model was compared to determine the applicability. The k-ε turbulence model family was found to be the most appropriate model for steady Reynolds averaged Navier Stokes within this type of domain. Difference turbulence models were investigated for simulation of molten salt experiencing crossflow within an in-line tube bundle. The flow was simulated using a steady RANS formulation with different families of turbulence models. The different turbulence models provide a view of this specific flow behavior potential requirements and applicable for steady RANS. Of particular note, the k-ε models were able to converge easily within this domain. The predicted behavior for both models were observed to be mostly similar for both velocity and pressure distributions. Whereas, k-ω SST and SA models did not converge well and had observable differences for the predictions of pressure and velocity distributions. The global behaviors were generally similar, but the variations occurring suggest k-ω SST and SA turbulence models are not useful in the steady RANS formulation of this domain. When comparing to the empirical pressure drop, each turbulence model resulted in overpredictions ranging from 8.7% and 19.75% difference. The standard low-Re k-ε model having the lowest difference is likely the better model for simplified predictions for pressure drops. Further investigations will be conducted to determine the convergence issues for the k-ω SST and SA turbulence models. These might be due to the flow geometry or potentially a revision of the meshing is needed. The flow behavior may not be resolved using these models in a steady formulation due to inherent unsteadiness of the flow. (authors)

42 ENGINEERING↗
DOE OSTI2019

Pumped Storage Hydro Model Evaluation Report Task 1: Tool Assessment

Pumped storage hydro (PSH) projects support various aspects of power system operations. However, determining the value of PSH projects and the many services and contributions to the system they provide can be a challenge. The PSH techno-economic studies being carried out by a 5-lab consortium are defining extensive modeling approaches for evaluating the economic benefits of PSH projects. To enhance the impact of the valuation approach and follow-on techno-economic studies, Pacific Northwest National Laboratory (PNNL) will be developing a set of online tools that industry could adopt and use to advance PSH projects in the US. The problem is that the research team is not entirely clear on the features of the tools that would offer the most significant impact to industry. Thus, year one of this effort is designed to first define the needs of industry before developing the PSH valuation tool. The first step in defining industry needs is to evaluate existing tool packages, including those created by DOE and those by industry groups, to both measure usage levels and define tool attributes that maximize industry impact. The second step in this process will be to hold a workshop designed to elicit direct industry input. Given the breadth and nature of the task, which is to define ideal model attributes, the research team did not constrain the assessment to storage valuation tools. Several tools were assessed, and their characteristics compared against a list of “ideal” attributes that included ease of use, generalizability of results, and analytical flexibility. Information regarding usage and impact were then compared to specific model attributes to define which attributes appear to drive success. The following key lessons and implications can be drawn from the analysis: Models with high ease of use were often the most adopted by industry, though they did not necessarily have high publication reference records, meaning a published article made direct reference to the tool. For example, REScheck TM and COMcheck TM , two tools which share a site, have seen a high amount of web traffic and usage. Similarly, Storage Value Estimate Tool (StorageVET®), an energy storage valuation model, has a large number of organizations using it despite a low publication reference record. A common feature between these models is that they are web-hosted, theoretically making them more easily accessible with graphic user interfaces (GUIs) that are more navigable; Models with higher usage statistics were typically free and/or open source. While it may be unsurprising that this attribute could be considered a draw for users, there is the potential for overestimating the tool's value based on popularity due to the fact that some users may have used the model simply because it was free and not because it is the best model; Models that offer more in-depth analysis and a wide coverage of applications (e.g. VOLTTRON™, GridLAB-D™, and Integrated Valuation of Ecosystem Services and Tradeoffs (InVest)) have shown a high number of publication references as well as showing a high number of downloads in the case of GridLAB-D™. It should be noted that the figure below does not include the model with the highest number of publication references (EnergyPlus™) as it has been removed to show clearer distinction between the remaining tools; The most popular model within the evaluation list was EnergyPlus™. This tool has the highest number of publication references (2,034) of all models considered and contains both a high ease of use level as well as broad application flexibility. Its high usage may be correlated, however, with the presumed wider audience conducting energy consumption modeling compared to the audiences for some of the other tools in this list; Models that were low in both general usage and publication reference generally did not exhibit characteristics considered ideal by the research team. Some of these models offered a narrower range of analytical applications or lower generalizability of results. This would automatically restrict the pool of potential users to those who fall within a narrow range of specific technologies or applications. This report also explores two model structures for the PSH tool: decision tree-based, which would guide the user through the valuation methods defined in the PSH techno-economic studies currently being carried out by DOE, and an all-inclusive comprehensive model. The strengths of each were explored and a hybrid approach was defined that would embed a price taker model into the decision tree approach. Such an approach would provide a comprehensive approach for modeling small-scale PSH while recognizing the challenges associated with implementing a price-maker approach in an all-inclusive model. Insight gained in this analysis of other models can aid in narrowing down the list of effective and sought-after attributes, and in defining model structure. Next steps toward developing a model for storage valuation will be to gain direct industry input through workshops.

13 HYDRO ENERGY↗
DOE OSTI2016

Analytic study of the effect of dark energy-dark matter interaction on the growth of structures

Large-scale structure has been shown as a promising cosmic probe for distinguishing and constraining dark energy models. Using the growth index parametrization, we obtain an analytic formula for the growth rate of structures in a coupled dark energy model in which the exchange of energy-momentum is proportional to the dark energy density. We find that the evolution of f σ{sub 8} can be determined analytically once we know the coupling, the dark energy equation of state, the present value of the dark energy density parameter and the current mean amplitude of dark matter fluctuations. After correcting the growth function for the correspondence with the velocity field through the continuity equation in the interacting model, we use our analytic result to compare the model's predictions with large-scale structure observations.

79 ASTRONOMY AND ASTROPHYSICS↗
NASA NTRS2016

Comparing Potential Recharge Estimates From Three Land Surface Models Across the Western US

Groundwater is a major source of water in the western US. However, there are limited recharge estimates available in this region due to the complexity of recharge processes and the challenge of direct observations. Land surface Models (LSMs) could be a valuable tool for estimating current recharge and projecting changes due to future climate change. In this study, simulations of three LSMs (Noah, Mosaic and VIC) obtained from the North American Land Data Assimilation System (NLDAS-2) are used to estimate potential recharge in the western US Modeled recharge was compared with published recharge estimates for several aquifers in the region. Annual recharge to precipitation ratios across the study basins varied from 0.01-15% for Mosaic, 3.2-42% for Noah, and 6.7-31.8% for VIC simulations. Mosaic consistently underestimates recharge across all basins. Noah captures recharge reasonably well in wetter basins, but overestimates it in drier basins. VIC slightly overestimates recharge in drier basins and slightly underestimates it for wetter basins. While the average annual recharge values vary among the models, the models were consistent in identifying high and low recharge areas in the region. Models agree in seasonality of recharge occurring dominantly during the spring across the region. Overall, our results highlight that LSMs have the potential to capture the spatial and temporal patterns as well as seasonality of recharge at large scales. Therefore, LSMs (specifically VIC and Noah) can be used as a tool for estimating future recharge rates in data limited regions.

groundwater↗
DOE OSTI2019

The reconstructed power spectrum in the Zeldovich approximation

Density-reconstruction sharpens the baryon acoustic oscillations signal by undoing some of the smoothing incurred by nonlinear structure formation. Here, we present an analytical model for reconstruction based on the Zeldovich approximation, which for the first time includes a complete set of counterterms and bias terms up to quadratic order and can fit real and redshift-space data pre- and post-reconstruction data in both Fourier and configuration space over a wide range of scales. We compare our model to n-body data at $z = 0$ from the ${\tt DarkSky}$ simulation, finding sub-percent agreement in both real space and in the redshift-space power spectrum monopole out to $k = 0.4\ h$ Mpc$^{-1}$, and out to $k = 0.2\ h$ Mpc$^{-1}$ in the quadrupole, with comparable agreement in configuration space. We compare our model with several popular existing alternatives, updating existing theoretical findings for exponential damping in wiggle/no-wiggle splits of the BAO signal and discuss the usually-ignored effect of higher bias contributions on the reconstructed signal. In the appendices, we re-derive the former within our formalism, present exploratory results on higher-order corrections due to nonlinearities inherent to reconstruction, and present numerical techniques with which to calculate the redshift-space power spectrum of biased tracers within the Zeldovich approximation.

79 ASTRONOMY AND ASTROPHYSICS↗
DOE OSTI2014

Comparing the line broadened quasilinear model to Vlasov code

The Line Broadened Quasilinear (LBQ) model is revisited to study its predicted saturation level as compared with predictions of a Vlasov solver BOT [Lilley et al., Phys. Rev. Lett. 102, 195003 (2009) and M. Lilley, BOT Manual. The parametric dependencies of the model are modified to achieve more accuracy compared to the results of the Vlasov solver both in regards to a mode amplitude's time evolution to a saturated state and its final steady state amplitude in the parameter space of the model's applicability. However, the regions of stability as predicted by LBQ model and BOT are found to significantly differ from each other. The solutions of the BOT simulations are found to have a larger region of instability than the LBQ simulations.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2020

Comparing event generator predictions and ab-initio calculations of $\nu$-$^{12}$C neutral current quasi-elastic scattering at 1 GeV

The measurement of neutrino oscillations and exotic physics searches are important parts of the physics program in the near future, with new state-of-the-art experiments planned within the next decade. Future and modern experiments in these fields will make use of nuclear targets. Event Generators (EGs) are software used in the analysis of neutrino oscillation experiments. EGs use to predict kinematic observables for a range of neutrino energies. These simulations may lack physics captured by more rigorous theoretical calculations. This work compares EG performance to nuclear theory calculations by comparing observables generated in the two frameworks. We provide a common set of definitions between theory and experiment and assess the physics contained in EG simulations. Neutral current quasi-elastic (NCQE) scattering events for neutrinos and anti-neutrinos on a $^{12}$C target are simulated with a specific EG, NEUT, used by the T2K experiment for its analysis. The simulated cross sections are compared to analytic calculations from nuclear theory within the factorization scheme. We compare the NEUT implementation of two different models on nuclear spectral functions: the Relativistic Fermi Gas (RFG) and the correlated basis spectral function (CBF) to analytic calculations of the same models in the factorization scheme. For both nuclear physics models, we compare the appearance of features in the distributions relevant to experimental analyses. Qualitatively, the shape of the simulated distribution is similar to the one obtained through theory calculations; however, there are some discrepancies between the theory calculations and the NEUT simulation. While the EG simulations and analytic calculations with the same model of nuclear dynamics show similar overall features, there are still differences between the two.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗
NASA NTRS2002

A Particle and Energy Balance Model of the Orificed Hollow Cathode

A particle and energy balance model of orificed hollow cathodes was developed to assist in cathode design. The model presented here is an ensemble of original work by the author and previous work by others. The processes in the orifice region are considered to be one of the primary drivers in determining cathode performance, since the current density was greatest in this volume (up to 1.6 x 10(exp 8) A/m2). The orifice model contains comparatively few free parameters, and its results are used to bound the free parameters for the insert model. Next, the insert region model is presented. The sensitivity of the results to the free parameters is assessed, and variation of the free parameters in the orifice dominates the calculated power consumption and plasma properties. The model predictions are compared to data from a low-current orificed hollow cathode. The predicted power consumption exceeds the experimental results. Estimates of the plasma properties in the insert region overlap Langmuir probe data, and the predicted orifice plasma suggests the presence of one or more double layers. Finally, the model is used to examine the operation of higher current cathodes.

Domonkos, Matthew T.↗
DOE OSTI2015

Vibrational modes of ultrathin carbon nanomembrane mechanical resonators

We report measurements of vibrational mode shapes of mechanical resonators made from ultrathin carbon nanomembranes (CNMs) with a thickness of approximately 1 nm. CNMs are prepared from electron irradiation induced cross-linking of aromatic self-assembled monolayers and the variation of membrane thickness and/or density can be achieved by varying the precursor molecule. Single- and triple-layer freestanding CNMs were made by transferring them onto Si substrates with square/rectangular orifices. The vibration of the membrane was actuated by applying a sinusoidal voltage to a piezoelectric disk on which the sample was glued. The vibrational mode shapes were visualized with an imaging Mirau interferometer using a stroboscopic light source. Several mode shapes of a square membrane can be readily identified and their dynamic behavior can be well described by linear response theory of a membrane with negligible bending rigidity. By applying Fourier transformations to the time-dependent surface profiles, the dispersion relation of the transverse membrane waves can be obtained and its linear behavior verifies the membrane model. By comparing the dispersion relation to an analytical model, the static stress of the membranes was determined and found to be caused by the fabrication process.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2016

Techno-economic analysis of biodiesel and ethanol co-production from lipid-producing sugarcane: Biodiesel and Ethanol Co-Production from Lipid-Producing Sugarcane

Biodiesel production from vegetable oils has progressively increased over the past two decades. However, due to the low amounts of oil produced per hectare from temperate oilseed crops (e.g. soybean), the opportunities for further increasing biodiesel production are limited. Genetically modified lipid-producing sugarcane (lipid-cane) possesses great potential for producing biodiesel as an alternative feedstock because of sugarcane’s much higher productivity compared with soybean. In this study, techno-economic models were developed for biodiesel and ethanol coproduction from lipid-cane, assuming 2, 5, 10, or 20% lipid concentration in the harvested stem (dry mass basis). The models were compared with a conventional soybean biodiesel process model to assess lipid-cane’s competiveness. In the lipid-cane process model, the extracted lipids were used to produce biodiesel by transesterifi cation, and the remaining sugar was used to produce ethanol by fermentation. The results showed that the biodiesel production cost from lipid-cane decreased from $0.89/L to $0.59 /L as the lipid content increased from 2 to 20%; this cost was lower than that obtained for soybeans ($1.08/L). The ethanol production costs from lipid-cane were between $0.40/L and $0.46/L. The internal rate of return (IRR) for the soybean biodiesel process was 15.0%, and the IRR for the lipid-cane process went from 13.7 to 24.0% as the lipid content increased from 2 to 20%. Because of its high productivity, lipid-cane with 20% lipid content can produce 6700 L of biodiesel from each hectare of land, whereas soybean can only produce approximately 500 L of biodiesel from each hectare of land. This would indicate that continued efforts to achieve lipid-producing sugarcane could make large-scale replacement of fossil-fuel-derived diesel without unrealistic demands on land area.

09 BIOMASS FUELS↗
DOE OSTI2022

Developing a Consistent Travel-Time Framework for Comparing Three-Dimensional Velocity Models for Seismic Location Accuracy

Abstract Location algorithms have historically relied on simple, one-dimensional (1D) velocity models for fast seismic event locations. 1D models are generally used as travel-time lookup tables, one for each seismic phase, with travel-times pre-calculated for event distance and depth. These travel-time lookup tables are extremely fast to use and this fast computational speed makes them the preferred type of velocity model for operational needs. Higher-dimensional (i.e., three-dimensional—3D) seismic velocity models are becoming readily available and provide more accurate event locations over 1D models. The computational requirements of these 3D models tend to make their operational use prohibitive. Additionally, comparing location accuracy for 3D seismic velocity models tends to be problematic, as each model is determined using different ray-tracing algorithms. Attempting to use a different algorithm than the one used to develop a model usually results in poor travel-time prediction. We demonstrate and test a framework to create first-P and first-S 3D travel-time correction surfaces using an open-source framework ( PCalc + GeoTess , https://www.sandia.gov/salsa3d/software/geotess ) that easily stores 3D travel-time and uncertainty data. This framework produces fast travel-time and uncertainty predictions and overcomes the ray-tracing algorithm hurdle because the lookup tables can be generated using the exact ray-tracing algorithm that is preferred for a model.

3D velocity models↗
DOE OSTI2022

Contrasting Stratospheric Smoke Mass and Lifetime From 2017 Canadian and 2019/2020 Australian Megafires: Global Simulations and Satellite Observations

Stratospheric injections of carbonaceous aerosols and combustion gases by extreme wildfires have become increasingly common. Recent “megafires,” particularly large and intense fires, delivered particulate burdens to the lower stratosphere comparable to those of moderate volcanic eruptions. The 2017 Canadian megafire generated four large Pyrocumulonimbi (pyroCbs), injecting up to ≈0.3 Tg of smoke in the lower stratosphere. Even more extreme, the 2019/2020 Australian event produced a pyroCb activity resulting in stratospheric smoke intrusions of ≈1 Tg. To understand their contrasting behavior, we present global climate simulations of the atmospheric response to these events, applying smoke burdens informed by remote observations. Model outcomes, compared to satellite data of smoke transport, reproduce reasonably well the initial plume rise, at 0.2–0.3 km/day, attaining heights of ≈20 km in Canada and above 30 km in Australia. Global dispersal of the plume occurs within about 3 weeks in both cases, consistent with observations. Smoke removal timescales, ≈5 months for the Canadian megafire, agree with remote measurements. During the Australian megafire, observations indicate stratospheric injections three times as large, and models predict comparatively longer smoke lifetimes, ≈16 months. After the latter event, atmospheric optical depths and radiative cooling achieved values close to those measured following the Pinatubo eruption. Sensitivity tests of model assumptions indicate, in accord with prior studies, that smoke burden, injection heights, and black carbon content can determine plume evolution and possible climate impacts. An empirical relation between peak heights of stratospheric plumes and lifetimes is derived that can help assess megafire impacts on the stratosphere, climate and the Earth system

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2022

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

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

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