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At least 109 records · Page 6

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DOE OSTI2023

Apparatus for a laser welding system

A laser welding system for welding a component and reducing defects in the weld by ensuring uniform, laminar gas flow over a process area of the system. The laser welding system comprises a laser for welding the component, a platform for supporting the component, an enclosure surrounding the platform, a first actuatable barrier, a second actuatable barrier, an actuator, and a controller. The enclosure includes a plurality of walls, one of the walls having an inlet and another wall having an outlet. The inlet and outlet each having an opening having a cross-sectional area for letting gas flow through. The first and second barriers are configured to modify the cross-sectional areas of the openings when actuated. The actuator is configured to actuate the barriers, and the controller is configured to direct the actuator to actuate the barriers so that the cross-sectional area of the first opening is larger than the cross-sectional area of the second opening so that a pressure at the inlet is greater than a pressure at the outlet.

Sartin, Bryan↗

DOE OSTI2024

Flow field design for zero-gap microbial electrolysis cells using synthetic and real wastewater

Increasing performance in microbial electrolysis cells (MECs) requires the development of optimized reactor configurations with minimal internal resistance and capable to operate with real wastewater. Here, the impact of two different flow fields (serpentine and circular) was examined in zero-gap MECs with synthetic and real wastewaters. The serpentine flow field enabled a uniform distribution of the electrolyte in the anode chamber, resulting in larger current densities at lower flow rates compared to the circular flow field. Electrochemical tests using synthetic media with high buffer capacity revealed more stable and higher performance with the serpentine flow field compared to the circular flow path, producing larger current density (23.7 ± 0.8 A/m 2 vs 21.9 ± 5.6 A/m 2 ), hydrogen production rate (75.8 ± 4.1 L/L-d vs 54.3 ± 2.4 L/L-d), cathodic coulombic efficiency (>91 % vs >50 %), and an overall lower internal resistance (12.5 ± 0.5 mΩm 2 vs 14.8 ± 3.7 mΩm 2 ). Continuous operation for over 30 days with real wastewater indicated higher tolerance of the MECs with serpentine flow field toward media with large concentration of suspended solids, producing a current density of 5.4 ± 1.1 A/m 2 and a hydrogen production rate of 22.2 ± 6.2 L/L-d. Furthermore, the results presented here underscore the importance of reactor design and architecture in optimizing MEC performance for hydrogen production from liquid wastes.

flow path↗

DOE OSTI2025

Dynamic Heat Flow and Current Distribution Analysis in the Bottom Anode of an Electric Arc Furnace Using Fiber-Optic Sensors

A reliable method for monitoring bottom anode wear during DC Electric Arc Furnace (DC-EAF) operation is of critical importance for safe and efficient steel production. Underestimation of bottom wear poses a serious safety risk that must be avoided, while overestimation of bottom wear also poses challenges, as premature anode replacement is expensive and affects EAF productivity. Previously, we demonstrated that fiber-optic sensors can be successfully deployed to create a spatially distributed temperature map to monitor the health of the anode. The present work explores the heat flow and current density distribution in bottom anode pins to predict bottom wear, steel penetration events, and monitor refractory erosion. Small dynamic variations in pin temperature induced by joule heating during arcing also provide a means to observe local current flows in each pin. When mapped, these measurements provide a real-time view of the non-uniform and dynamic current flow in the bottom anode during EAF operation that can affect bottom wear.

Bottom Anode↗

DOE OSTI2023

Uniform-in-phase-space data selection with iterative normalizing flows

Improvements in computational and experimental capabilities are rapidly increasing the amount of scientific data that are routinely generated. In applications that are constrained by memory and computational intensity, excessively large datasets may hinder scientific discovery, making data reduction a critical component of data-driven methods. Datasets are growing in two directions: the number of data points and their dimensionality. Whereas dimension reduction typically aims at describing each data sample on lower-dimensional space, the focus here is on reducing the number of data points. A strategy is proposed to select data points such that they uniformly span the phase-space of the data. The algorithm proposed relies on estimating the probability map of the data and using it to construct an acceptance probability. An iterative method is used to accurately estimate the probability of the rare data points when only a small subset of the dataset is used to construct the probability map. Instead of binning the phase-space to estimate the probability map, its functional form is approximated with a normalizing flow. Therefore, the method naturally extends to high-dimensional datasets. The proposed framework is demonstrated as a viable pathway to enable data-efficient machine learning when abundant data are available.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2020

Effect of non-uniform airflow on the performance of a parallel-flow heat exchanger considering internal fluid distribution—Simulation studies and its experimental validation

Not Available

Zhao, Lanping↗

DOE OSTI2022

Qualification of ANSI/HPS N13.1-2011 Mixing Criteria by Computational Fluid Dynamics Modeling for the 3430 Building Fan Addition and Increased Ventilation Capacity

Additional ventilation capacity has been designed for the 3430 Building filtered exhaust stack system. The updated system will increase the number of fans from two to three and include new ductwork with a larger diameter to integrate the new fan into the existing stack. Stack operations will involve running various fan combinations at any given time. The air monitoring system of the existing two-fan stack previously was found to comply with the American National Standards Institute/Health Physics Society (ANSI/HPS) N13.1-1999 standard. Full-scale, three-dimensional computational fluid dynamics (CFD) modeling was used to evaluate the modified three-fan system for compliance with the ANSI/HPS N13.1-2011 standard, which essentially is equivalent to the ANSI/HPS N13.1-1999 standard. The four mixing criteria evaluated are 1) flow angle, 2) velocity, 3) gas tracer, and 4) particle tracer. Benchmarking of the CFD modeling methodology showed good agreement with previous testing used to qualify the stack, and modeling of the existing two-fan system showed good agreement with test data collected from the 3430 Building stack. Modeling was performed to develop a suitable three-fan design. Initial modeling of the three-fan design and basic ductwork showed that flow angles and velocity uniformity were acceptable; however, the gas tracer and particle tracer mixing results were not acceptable. To meet ANSI/HPS N13.1-2011 criteria, an air blender was added to the stack design. This revision models the individual maximum fan reduced flow capacity from 38,000 cfm to 31,200 cfm; no changes to the duct design are made.

42 ENGINEERING↗

DOE OSTI2022

Wettability and CHF limits of Accident-Tolerant nuclear fuel cladding materials in light water reactor conditions

Here, we present the results of experimental investigations aimed at evaluating the thermal–hydraulic performance of chromium-coated zircaloy, i.e., one of the most promising accident tolerant fuel (ATF) cladding material for light water nuclear reactors. Precisely, we investigate the wettability and critical heat flux (CHF) limits of chromium-coated and conventional zircaloy surfaces in prototypical reactor conditions. For both surface types, we measure the contact angle in a vapor-saturated atmosphere from ambient pressure to the operating pressure of pressurized water reactors (PWRs), i.e., ~15 MPa. We measure the ambient-pressure steady-state flow boiling CHF with a spatially uniform heat flux. We measure the high-pressure steady-state flow boiling CHF with a cosine shape heat flux (up to 20 MPa) and with a uniform heat flux (up to 15 MPa), also exploring the effect of CRUD deposits on the chromium-coated surface. Our results reveal that the chromium surface and the bare zircaloy surface have similar wettability and both become super-hydrophilic in PWR conditions, and that there is practically no difference in the steady-state CHF limits, both at low-pressure and high-pressure conditions, also when the chromium-coated surface is covered by a CRUD deposit. However, while the chromium-coating does not improve the CHF compared to the bare zircaloy surface, it improves the post-CHF behavior. The chromium coating prevents the reaction between zircaloy and steam, which results in the formation of a brittle zirconium oxide through the surface of the cladding. We also measure the transient CHF under exponentially escalating heat flux inputs of a nano-smooth and a rough surface mimicking a chromium-coated zircaloy cladding. Interestingly, the results of the transient heat flux tests suggest that the CHF limit for very short periods (i.e., fast transients) is independent of the surface finish, being the same for a rough chromium surface or a nano-smooth surface.

36 MATERIALS SCIENCE↗

DOE OSTI2022

Effects of thermophoresis on high-pressure binary-species boundary layers with uniform and non-uniform compositions

Direct numerical simulations of high-pressure binary-species temporal boundary layers are performed to investigate the flow physics for three situations: (1) uniform and equal composition, (2) uniform but unequal compositions and (3) non-uniform composition. Both colder- and hotter-wall situations compared with the free stream are simulated. The working fluid is a nitrogen/methane mixture. The analysis is performed at a case-specific self-similar state. Even when the initial composition is uniform, the methane mean mass fraction decreases near the colder wall, whereas it increases near the hotter wall and the mass fraction fluctuates in the entire boundary layer. Analysis of the species-mass diffusion balance and flow structures reveal that both mass-fraction variation and fluctuations are induced by the Soret effect. When the initial composition is non-uniform and the wall is colder, the methane mean mass fraction monotonically increases from the wall akin to its initial profile. However, when the wall is hotter the mean mass fraction decreases near the wall in contrast to its initial profile, a fact traced through the species-mass diffusion balance to the Soret effect being large and enriching methane near the wall. In contrast, the direction of the Soret flux is opposite for the colder wall, thus keeping the methane concentration small. Although the initial magnitude of the difference between the wall and free-stream temperature is the same in all cases, the situation is not symmetric between colder- and hotter-wall cases; the flow structure exhibits much smaller scales when the wall is hotter than when the wall is colder.

Mechanics↗

DOE OSTI2026

Towards High-Speed friction stir welding of 25 mm Thick AA2139-T8: tool innovation and process development

Joining thick plates (≥ 12 mm) of aluminum (Al) alloys is challenging due to high tool forces, uneven material flow, and non-uniform heat distribution through the material’s thickness. Recent advancements in tool design and welding parameters for friction stir welding (FSW) in thick plates butt joining have encountered a developmental plateau, highlighting the need for innovative approaches to overcome existing limitations. Here, this study focuses on the systematic development of single-pass and double-pass FSW processes for high-strength aluminum alloy AA2139-T8, to improve joint efficiency and enable high-speed welding capabilities. Experimental evidence is presented for a novel tool design with opposing pin threads, enabling high-speed (178 mm/min) single-pass friction stir butt welding of 25 mm thick AA2139-T8. A series of FSW trials was conducted both in air and with a trailing water spray, using steel backing plates (BPs) to investigate the impact of quenching and cooling rates on process response and joint performance. A joint efficiency of 83% was attained using the novel tool features and effectively controlling process forces and thermal boundary conditions.

AA2139-T8↗

DOE OSTI2023

Effect of non-uniform heating on temperature and velocity profiles of buoyancy driven flow in vertical channel of prismatic modular reactor core

Not provided.

Energy & Fuels↗

DOE OSTI2023

Plastic homogeneity in nanoscale heterostructured binary and multicomponent metallic eutectics: An overview

Heterostructured materials comprised of relatively soft/hard disparate phases typically exhibit composite strengthening but lack plastic deformability at ambient temperatures. However, heterostructured systems comprised of nanoscale phases can simultaneously enhance yield strength and strain hardening, thereby promoting uniform distribution of plastic flow. In this review, the atomic-scale deformation mechanisms in model systems of eutectic alloys, Al-Al 2 Cu and Al-Si, refined to nanoscales via laser rapid solidification are discussed, and compared with literature on multi-component (high entropy) eutectics such as Ni-Al-Fe-based with Cr and/or Co additions. The nano-lamellar Al-Al 2 Cu structures exhibit unit defect mechanisms not reported in monolithic Al 2 Cu intermetallic: localized shear on {0 1 1} and shear-induced faults on {1 2 1} planes, constrained by closely-spaced dislocation arrays in Al confined by Al/Al 2 Cu interfaces. The unexpected plasticity mechanisms are enabled by slip continuity in nanoscale Al-Al 2 Cu eutectics associated with the orientation relationship and interface habit planes. In nano-fibrous Al-Si eutectic, tensile ductility at strength approaching 600 MPa is observed resulting from dislocation plasticity in the nano-Al channels and cracking in Si nanofibers. Molecular dynamics simulations show that Al dislocations easily cross-slip (screw) or climb (edge) along Al-Si interfaces, making slip transmission difficult. The propagation of nano-cracks is suppressed by surrounding strain hardening Al, retaining good ductility of the sample, in spite of lack of direct slip transmission. Finally, the critical unit mechanisms of slip transmission and interface-enabled plasticity observed in nanoscale eutectic binary systems can also explain the strength-ductility relationship in multi-component eutectics and homogeneously distributed plastic flow with increasing microstructural heterogeneity.

36 MATERIALS SCIENCE↗

DOE OSTI2023

Turbulent Kinetic Energy Budgets over Gentle Topography Covered by Forests

Large-eddy simulations of flow over a “horizontally” uniform model forest are used to investigate the effects of gentle topography on the turbulent kinetic energy (TKE) budget within the canopy roughness sublayer. Despite significant differences between simulations using idealized sinusoidal topography and real topography of the Amazon forest, results indicate that the effects of topography are located predominantly in the upper canopy and above, and are mostly caused by mean advection of TKE. The “horizontally” averaged TKE budget from idealized and real gentle topographies are almost identical to that for flat terrain, including a clear inertial layer above the roughness sublayer in which shear production is balanced by local dissipation. At topography crests, where observational towers are usually located, mean vertical advection of TKE can be as important as horizontal advection. Here, we propose the use on an approximate TKE balance equation to estimate mean advection from single tower measurements, and introduce a new advection index that can be used as a proxy to quantify the importance of the topography on the TKE budget.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2022

New Improved Horizontal Electropolishing System for SRF Cavities

The best performance of niobium SRF accelerating cavities is obtained with surfaces smoothed with electropolishing chemical finishing. Jefferson Lab has recently specified, procured, installed, and commissioned a new versatile production electropolishing (EP) tool. Experience with EP research and operations at JLab as well as vendor interactions and experience guided development of the system specification. Detailed design and fabrication was awarded by contract to Semiconductor Process Equipment Corporation (SPEC). The delivered system was integrated into the JLab chemroom infrastructure and commissioned in 2020. The new EP tool provides much improved heat exchange from the circulating H₂SO₄/HF electrolyte and also the cavity via variable temperature external cooling water flow, resulting in quite uniform cavity wall temperature control and thus improved removal uniformity. With the JLab infrastructure, stabilized process temperature as low as 5 C is available. We describe the system and illustrate operational modes in this contribution.

Reece, C. E.↗

DOE OSTI2022

Qualification of ANSI/HPS N13.1-2011 Mixing Criteria by Computational Fluid Dynamics Modeling for the 3430 Building Fan Addition and Increased Ventilation Capacity

42 ENGINEERING↗

DOE OSTI2023

Optimization and Physics Informed AI/ML on the Cooling Tower Power Output and the One-Dimensional Model

Graduate Research at Missouri S&T Thesis: Theoretical Study of Magnetic Particles in a Shear Flow Subjected to a Uniform Magnetic Field. • Published several journal articles. • Presented at the Indiana University Purdue University Indianapolis graduate seminar. • Presented research findings at American Physical Society: Division of Fluid Dynamics and poster sessions at Missouri S&T for the Chancellor's Distinguished Fellowship.

Sobecki, Christopher A.↗

DOE OSTI2025

Tool Chain for Simulations of Bi-Filar Coil Winding for Fast Quench Protection

The advancement of high-field magnets utilizing high-temperature superconductors (HTS) brings about complex challenges, especially in quench detection and protection. Traditional methods often fall short due to the inherently slow quench propagation in HTS materials. One promising approach to overcome this involves using a bifilar winding configuration, where two conductors are placed side by side. Under normal operation, they function in series, but during a quench event, they switch to an anti-parallel mode. This shift reduces the differential inductance of the coil to near zero, enabling rapid current oscillations through a capacitor discharge. The resulting high-frequency current flow leads to swift, uniform heating, triggering a full-coil quench within microseconds. Moreover, the strong mutual coupling between the two windings significantly reduces electrical noise in voltage measurements. In this work, we explore the viability of this concept by designing, constructing, and testing a REBCO bifilar racetrack coil in liquid nitrogen. We also present a validated simulation model that closely mirrors the coil's dynamic behavior under these conditions, aligning well with experimental observations.

Jayathilaka, Rehan [Northern Illinois U.]↗

DOE OSTI2023

A Conservative Finite-Volume Based Interface-Tracking Algorithm Using the Signed Distance Function

Methods for tracking an interface between two fluid phases are developed to ensure desired fluid properties, conservation, and stability are preserved in a finitevolume (FV) discretization. Here, the interface is tracked using a level set method where the signed distance function implicitly defines the interface. Marching methods are used to evaluate the value of the signed distance function, including a novel initialization method to initialize any implicit function to the signed distance function around sharp corners in the level set. Global conservation and consistency with a set of governing equations is enforced by a compression coefficient that measures the volumetric compression or expansion due to inaccuracies in the level set evaluation. A redistribution method is integrated into the volume correction to eliminate the small-cell instability while maintaining global conservation. This suite of methods is implemented and tested using static uniform velocity, and potential flow cases with multiple interface geometries. Results show these methods achieve up to second order accuracy, and are conservative. The application for these methods is intended to track the interface of a 3D printing filament in a finite-volume discretization of the all-speed Navier-Stokes equations.

42 ENGINEERING↗

DOE OSTI2021

The impact of magnetic fields on momentum transport and saturation of shear-flow instability by stable modes

The Kelvin–Helmholtz (KH) instability of a shear layer with an initially uniform magnetic field in the direction of flow is studied in the framework of 2D incompressible magnetohydrodynamics with finite resistivity and viscosity using direct numerical simulations. The shear layer evolves freely, with no external forcing, and thus broadens in time as turbulent stresses transport momentum across it. As with hydrodynamic KH, the instability here features a conjugate stable mode for every unstable mode in the absence of dissipation. Stable modes are shown to transport momentum up its gradient, shrinking the layer width whenever they exceed unstable modes in amplitude. In simulations with weak magnetic fields, the linear instability is minimally affected by the field, but enhanced small-scale fluctuations relative to the hydrodynamic case are observed. These enhanced fluctuations coincide with increased energy dissipation and faster layer broadening, with these features more pronounced in simulations with stronger fields. These trends result from the magnetic field reducing the effects of stable modes relative to the transfer of energy to small scales. As field strength increases, stable modes become less excited, thus transporting less momentum against its gradient. Furthermore, the energy that would otherwise transfer back to the driving shear because of the stable modes is instead allowed to cascade to small scales, where it is lost to dissipation. Approximations of the turbulent state in terms of a reduced set of modes are explored. While the Reynolds stress is well-described using just two modes per wavenumber at large scales, the Maxwell stress is not.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗