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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 1,099 records · Page 61

Multi-Modular Coordination Control of HTR-PM600 Plant - 190

HTR-PM600 is a high temperature gas-cooled reactor plant based on the multi-modular scheme, i.e. six modular high temperature gas-cooled reactor (MHTGR) driving a common secondary loop system. Six MHTGR-based nuclear steam supplying system (NSSS) modules are tightly coupled by the secondary fluid flow network (FFN) which contains the secondary side of steam generators, feedwater system, main steam system, turbine generator system. The secondary FFN control, which focuses on the feedwater flowrates and main steam pressure, plays a central role in multi-modular coordination of HTR-PM600 plant. In this paper, a differential algebraic model of this secondary FFN is first proposed. Then, the corresponding flowrate-pressure control strategy is proposed, which takes the simple form of proportional-integral feedback laws. Numerical simulation results show both the feasibility and satisfactory transient performance of this controller. (authors)

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

Dimensionless numbers in additive manufacturing

In this paper, the effects of many process variables and alloy properties on the structure and properties of additively manufactured parts are examined using four dimensionless numbers. The structure and properties of components made from 316 Stainless steel, Ti-6Al-4V, and Inconel 718 powders for various dimensionless heat inputs, Peclet numbers, Marangoni numbers, and Fourier numbers are studied. Temperature fields, cooling rates, solidification parameters, lack of fusion defects, and thermal strains are examined using a well-tested three-dimensional transient heat transfer and fluid flow model. The results show that lack of fusion defects in the fabricated parts can be minimized by strengthening interlayer bonding using high values of dimensionless heat input. The formation of harmful intermetallics such as laves phases in Inconel 718 can be suppressed using low heat input that results in a small molten pool, a steep temperature gradient, and a fast cooling rate. Improved interlayer bonding can be achieved at high Marangoni numbers, which results in vigorous circulation of liquid metal, larger pool dimensions, and greater depth of penetration. Finally, a high Fourier number ensures rapid cooling, low thermal distortion, and a high ratio of temperature gradient to the solidification growth rate with a greater tendency of plane front solidification.

36 MATERIALS SCIENCE↗

Development of a high-resolution automatic digital (urine/electrolytes) flow volume and rate measurement system of miniature size

To aid in the quantitative analysis of man's physiological rhythms, a flowmeter to measure circadian patterns of electrolyte excretion during various environmental stresses was developed. One initial flowmeter was designed and fabricated, the sensor of which is the approximate size of a wristwatch. The detector section includes a special type of dielectric integrating type sensor which automatically controls, activates, and deactivates the flow sensor data output by determining the presence or absence of fluid flow in the system, including operation under zero-G conditions. The detector also provides qualitative data on the composition of the fluid. A compact electronic system was developed to indicate flow rate as well as total volume per release or the cumulative volume of several releases in digital/analog forms suitable for readout or telemetry. A suitable data readout instrument is also provided. Calibration and statistical analyses of the performance functions required of the flowmeter were also conducted.

Liu, F. F.↗

Analysis of permeability change in dissolving rough fractures using depth-averaged flow and reactive transport models

Many geophysical problems and engineering applications involve fluid flow through evolving faults and fractures. These situations are typical in CO 2 injection scenarios where supercritical CO 2 or CO 2 –saturated fluids are able to dissolve the solid matrix. Dissolution or precipitation within a fracture could lead to self-reinforcing or self-limiting behavior due to feedbacks from changes in permeability (k). There is limited predictive understanding of this phenomenon. Here, we investigated the case of fracture dissolution using a two-dimensional depth-averaged reactive transport model. The model simulated an acidic fluid dissolving a three-dimensional rough fracture. We observed different dissolution patterns across a wide range of geometric properties and different Peclet and Damkohler numbers (960 cases total). Despite this variation, a persistent linear increase in k with time (t) roughly manifested once the dissolution front advanced through the fracture. The time rate of change of k (k/t) is roughly constant for all simulations. The modeled rate is consistent with a theoretical value based on the parallel plates model and with experimentally derived values. Finally, the results confirm the common presence of linear time-dependence of fracture k due to self-reinforcement.

58 GEOSCIENCES↗

Flow control valve is independent of pressure drop

Remote control of fluid flow in a low-power system is established by a flow control valve with a flapper and nozzle flow control. Constant rates are maintained despite fluctuating pressure across the valve.

Source record↗

Thermal and flow analysis subroutines for the SINDA-version 9 computer routine

Fluid flow analysis, special thermal analysis and input/output capabilities of the MOTAR routine were incorporated into the SINDA routine. All the capabilities were added in the form of user subroutines so that they may be added to different versions of SINDA with a minimum of programmer effort. Two modifications were made to the existing subroutines of SINDA/8 to incorporate the above subroutines. These were: (1) A modification to the preprocessor to permit actual values of array numbers, conductor numbers, node numbers or constant numbers supplied as array data to be converted to relative numbers. (2) Modifications to execution subroutine CNFAST to make it compatible with the radiant interchange user subroutine, RADIR. This modified version of SINDA has been designated SINDA/version 9. A detailed discussion of the methods used for the capabilities added is presented. The modifications for the SINDA subroutines are described, as well as user subroutines. All subroutines added or modified are listed.

Oren, J. A.↗

Recent progress in numerical techniques for flow simulation

Recent developments in the use of numerical methods for fluid flow simulation show an increasing tendency to use numerical operators that can, in various ways, be factored. Use of methods having this property often increases the accuracy and efficiency of computer codes. Tracing the factorization property provides a unity to the basic concepts involved in the development of cyclic reduction, predictor-corrector, splitting, fast Fourier transform, and pseudospectral methods.-

Lomax, H.↗

Vortex tubes in turbulent flows: Identification, representation, reconstruction

In many cases the structure of a fluid flow is well-characterized by its vortices, especially for the purpose of visualization. In this paper we present a new algorithm for identifying vortices in complex flows. The algorithm produces a skeleton line along the center of a vortex by using a two-step predictor-corrector scheme. The vorticity vector field serves as the predictor and the pressure gradient (in the perpendicular plane) serves as the corrector. We describe an economical description of the vortex tube's cross-section: a 5-term truncated Fourier series is generally sufficient, and it compresses the representation of the flow by a factor of 4000 or more. We reconstruct the vortex tubes as generalized cylinders, providing a polygonal mesh suitable for display on a graphics workstation. We show how the reconstructed geometry of vortex tubes can be enhanced to help visualize helical motion in a static image.

Banks, David C.↗

Combining synchrotron X-ray diffraction, mechanistic modeling and machine learning for in situ subsurface temperature quantification during laser melting

Laser melting, such as that encountered during additive manufacturing, produces extreme gradients of temperature in both space and time, which in turn influence microstructural development in the material. Qualification and model validation of the process itself and the resulting material necessitate the ability to characterize these temperature fields. However, well established means to directly probe the material temperature below the surface of an alloy while it is being processed are limited. To address this gap in characterization capabilities, a novel means is presented to extract subsurface temperature-distribution metrics, with uncertainty, from in situ synchrotron X-ray diffraction measurements to provide quantitative temperature evolution data during laser melting. Temperature-distribution metrics are determined using Gaussian process regression supervised machine-learning surrogate models trained with a combination of mechanistic modeling (heat transfer and fluid flow) and X-ray diffraction simulation. The trained surrogate model uncertainties are found to range from 5 to 15% depending on the metric and current temperature. The surrogate models are then applied to experimental data to extract temperature metrics from an Inconel 625 nickel superalloy wall specimen during laser melting. The maximum temperatures of the solid phase in the diffraction volume through melting and cooling are found to reach the solidus temperature as expected, with the mean and minimum temperatures found to be several hundred degrees less. The extracted temperature metrics near melting are determined to be more accurate because of the lower relative levels of mechanical elastic strains. However, uncertainties for temperature metrics during cooling are increased due to the effects of thermomechanical stress.

36 MATERIALS SCIENCE↗

Best-Estimate-Plus-Uncertainty-Informed Deterministic Safety Evaluation

Nuclear power plant (NPP) utilities operate contingent on receiving a favorable safety assessment from their national regulatory and safety authority. Among the many facets of NPP safety addressed is verification of integral design-basis performance - a demonstration of a plant's response to a suite of challenging transient and accident scenarios. Thermal-hydraulic system computer codes like RELAP5, TRAC, CATHARE, and ATHLET are used as the simulation engine as part of a broader evaluation model that accounts for a variety of uncertainties. It is common for these evaluation models to apply either a super-bounding/ deterministic or best-estimate plus uncertainty (BEPU) approach. The trend over the past two decades has been away from the classical deterministic methods towards methods explicitly incorporating parametric uncertainty models. These methods center upon the evaluation of parametric and system response uncertainties, where these uncertainties are derived from the convolution of one or more parametric uncertainty models. Acceptance of BEPU methods has provided the nuclear industry benefits regarding operational flexibility and, in some cases, power output. The advantage of BEPU for new NPPs is less obvious. Generally, these new designs include engineered safety features that practically eliminate fuel damage resulting from design-basis events. To substantiate such claims, applying super-bounding assumptions on uncertainties may be a more expedient demonstration of a plant's safety case than those based on BEPU. In addition, the requirements on design inputs for a deterministic evaluation model are substantially less than that for a BEPU evaluation model. As such, applying a deterministic evaluation model is expected to have the advantage of reducing the duration of the licensing review process. For the current operating fleet of light-water reactors (LWRs), the nuclear safety authorities in most countries have followed the U.S. Nuclear Regulatory Commission's rules for the preparation of safety analysis. These rules are specified in the U.S. Code of Federal Regulations, most notably in, Part 10, Section 50.46, entitled 'acceptance criteria for emergency core cooling systems for light-water nuclear power reactors' and its Appendix K. Notably, Appendix K specifies deterministic requirements for analysis of the loss-of-coolant accident (LOCA), which is generally regarded as the maximum credible accident for LWRs. Projecting 10 CFR 50, Appendix K, to new plants is not obviously applicable as it addresses light water fluid flow and heat transfer phenomena associated with core uncovery. Preventing core uncovery is a requirement for several designs in the class of small modular reactors (SMR). In doing so, the majority of phenomenological uncertainties prescribed in Appendix K are eliminated. Similarly, the impact of other phenomena to effect a change in various safety measures, i.e., figures-of-merit, is expected to be different. The implication is that development of a deterministic evaluation model must be derived with an original technical basis rather than solely rely on Appendix K. While a logical conclusion, the expectation of original bases, regardless of the treatment of uncertainties, is embodied in the U.S. NRC's Regulatory Guide (RG) 1.203, Transient and Accident Analysis. Within the evaluation model development and application process framework of RG 1.203, this paper describes a BEPU-informed deterministic evaluation model for NPPs with large inherent safety margins. (authors)

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

EGS Collab Experiment 1: TOUGH2-CSM Simulation of Embedded Natural Fractures and Chemical Tracer Transport and Sorption

The EGS Collab SIGMA-V project is a multi-lab and university collaborative research project that is being undertaken at the Sanford Underground Research Facility (SURF) in South Dakota. The project consists of studying stimulation, fluid-flow, and heat transfer processes at a scale of 10-20 m, which is readily amenable to detailed characterization and monitoring. One objective of the project is to establish circulation from injector to producer by hydraulically fracturing the injector. Data generated during these experiments is to be compared with predictions from coupled thermal, hydrological, mechanical, and chemical simulators. One such a simulator, TOUGH2-CSM, has been enhanced in order to simulate EGS Collab SIGMA-V project experiments. These modifications include adding tracers, the capability to model tracer sorption, and an embedded fracture formulation. A set of example problems validate our conservative tracer transport and sorption formulations. We then simulated tracer transport and thermal breakthrough for the first EGS Collab SIGMA-V experiment. This dataset includes the TOUGH2-CSM input and output files associated with the thermal and tracer simulations. A conference paper is included for additional context.

15 GEOTHERMAL ENERGY↗

Model Implementation of Boron Removal Using CaCl{sub 2}-CaO-SiO{sub 2} Slag System for Solar-Grade Silicon

A new CaCl{sub 2}-CaO-SiO{sub 2} slag system was recently proposed to remove boron from metallurgy-grade silicon by oxidized chlorination and evaporation. To further investigate the boron transformation process at a high temperature, a model implementation to present the transfer of boron from molten silicon to the gas phase via slag is introduced. Heat transfer, fluid flow, the chemical reactions at the interface and surface, the mass transfer and diffusion of boron in the molten silicon and slag, and the evaporation of BOCl and CaCl{sub 2} were coupled in this model. After the confirmation of the thermal field, other critical parameters, including the boron partition ratios (L{sub B}) for this slag from 1723 K to 1823 K (1450 °C to 1550 °C), the thicknesses of the velocity boundary layer at the surface and interface, the mass transfer coefficients of the boundary layer at the surface and interface, and partial pressure of BOCl in the gas phase were analyzed to determine the rate-limiting step. To verify this model implementation, boron removal experiments were carried out at various temperatures and with various initial mass ratios of slag to silicon (μ). The evaporation rate of CaCl{sub 2} was also measured by thermogravimetry analysis (TGA).

36 MATERIALS SCIENCE↗

Tempering kinetics during multilayer laser additive manufacturing of a ferritic steel

Grade 91 steel forms martensite during additive manufacturing and the extent of tempering of martensite significantly affects the mechanical properties of parts. Currently, there is a lack of quantitative understanding of the tempering kinetics for Grade 91 steel, and as a result, the effects of repeated thermal cycles on properties for different processing conditions cannot be determined. Here we evaluate the tempering kinetics by determining the constant terms in the Johnson Mehl Avrami kinetic equation from the tempering data available in the literature and the thermal cycles computed using a rigorously-tested heat and fluid flow model of multi-layer additive manufacturing. The raw tempering data are cleaned using a neural network to enhance accuracy. The lower layers experience repeating cycles of heating and cooling when the upper layers are added. As a result, the hardness is reduced owing to the tempering of martensite. In contrast, martensite formed in the upper layers is not tempered to the same extent and the hardness remains high. Therefore, the hardness of the part increases with the distance from the substrate. Variations in the heat input at different laser powers and scanning speeds significantly affect the extent of tempering. Finally, since the method used here can provide a quantitative understanding of the tempering of martensite and the spatial variation in hardness, it can be used to tailor the microstructure and hardness of heat treatable printed metallic parts.

36 MATERIALS SCIENCE↗

Modeling of Keyhole-Induced Pore Formation in Laser-Arc Hybrid Welding of Aluminum Alloy with a Horizontal Fillet Joint

A three-dimensional transient model is proposed to investigate the weld pool dynamic behavior in laser + metal inert gas (MIG) hybrid fillet welding of aluminum alloy in the horizontal position, which allows for the joint configuration and coupling of the keyhole, droplet and weld pool as well as the heat and mass exchange between gas and liquid phases and is able to simulate the temperature distribution, fluid flow and formation process of a keyhole-induced pore in hybrid welding with a horizontal fillet joint. The weld porosity is also measured using x-ray nondestructive testing technology. Keyhole behavior and the formation mechanism of keyhole-induced porosity were analyzed. The calculated results are in generally good agreement with the experimental ones. A clockwise vortex always exists at the middle part of the weld pool. The formation and growth of the molten metal bulge on the keyhole wall are responsible for the occurrence of a gas bubble, which has a variation in size and shape and can be split during welding. The keyhole collapses easily at its middle or upper part in horizontal fillet welding, and the capture of the bubble by the upper molten pool boundary enhances the possibility of porosity formation to some degree. The keyhole-induced pore is mainly formed at the regions near the keyhole bottom and the upper fusion line of the weld pool.

36 MATERIALS SCIENCE↗

Stress and Friction Distribution around Slab Corner in Continuous Casting Mold with Different Corner Structures

The non-uniform friction and thermal stress in the mold are important as causes of the transverse cracks around strand corner. To analyze the stress distribution features around strand corner, a three-dimensional thermo-elastoplastic finite-element mold model with different corner structures (right-angle, big-chamfer, multi-chamfer, and fillet) was established. The temperature field in the mold was indirectly coupled through a three-dimensional fluid flow and heat transfer model. In addition, the non-uniform mold friction stress loaded on the strand surface was calculated through a friction model. The results show that the stress distribution on the shell is similar to the temperature distribution. The stress concentration appears in the strand corner and the lower part of wide face. The friction stress enhances the corner stress around the edge of the air-gap. For chamfered molds, the stress around the corner between the wide face and chamfer face is larger than that between the narrow face and chamfer face. Around the corner region, both the stress peak and the area of the large stress zone of the right-angle strand are the largest, while those of big-chamfered, multi-chamfered, and fillet strands decrease in that order. The stress peak position of the chamfered strands is closer to the mold exit than that of the right-angle strand. Compared with the use of the right-angle mold, the application of chamfered molds is able to reduce the stress concentration around the strand corner.

36 MATERIALS SCIENCE↗

System and method for controlling metal oxide gel particle size

Metal oxide gel particles, may be prepared with a desired particle size, by preparing a low-temperature aqueous metal nitrate solution containing hexamethylene tetramine as a feed solution; and causing the feed solution to flow through a first tube and exit the first tube as a first stream at a first flow rate, so as to contact a high-temperature nonaqueous drive fluid. The drive fluid flows through a second tube at a second flow rate. Shear between the first stream and the drive fluid breaks the first stream into particles of the metal nitrate solution, and decomposition of hexamethylene tetramine converts metal nitrate solution particles into metal oxide gel particles. A metal oxide gel particle size is measured optically, using a sensor device directed at a flow of metal oxide gel particles within the stream of drive fluid. The sensor device measures transmission of light absorbed by either the metal oxide gel particles or the drive fluid, so that transmission of light through the drive fluid changes for a period of time as a metal oxide gel particle passes the optical sensor. If a measured particle size is not about equal to a desired particle size, the particle size may be corrected by adjusting a ratio of the first flow rate to a total flow rate, where the total flow rate is the sum of the first and second flow rates.

Linneen, Nicholas N.↗