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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 1,117 records · Page 62

Integrated modeling of cracking during deep penetration laser welding of nickel alloys

During deep penetration laser welding of nickel alloys, interactions between composition and processing conditions can lead to the formation of defects. Inconel 740H, for example, has demonstrated a susceptibility to horizontal fusion zone cracking at locations between 70% and 80% of the weld depth during laser welding at powers above 5 kW. Coupling three-dimensional heat transfer, fluid flow, and stress modeling tools allowed that both the strain rate and stress normal to the solidification direction to be calculated. In the Inconel 740H welds, cracks formed at locations where the strain rate and stress simultaneously reached critical levels. No cracking was observed in the Inconel 690 welds, since the strain rate and stress did not simultaneously reach these critical levels.

36 MATERIALS SCIENCE↗

Numerical Simulation of V-shaped Segregation in Continuous Casting Blooms Based on a Microsegregation Model

This study establishes a volume-averaged model for transport phenomena to study V-shaped segregation in continuous casting blooms with different superheating and cooling rates by coupling fluid flow, macro-scale heat transfer, and solute transport. The results demonstrate that the modified Won–Thomas model considering back diffusion in the solid phase corresponds well with the measured carbon segregation. V-shaped segregation decreases with decreasing superheating and increases slightly with decreases in the cooling rate. The results of original position statistical distribution analysis correspond well with the simulation results. This phenomenon can be exploited to improve the quality of bloom.

42 ENGINEERING↗

Qualification of Numerical and Semi-Analytical Modeling Codes for Thermal Design of HLW Repository - 18455

Disposal in a geological repository is a viable option for safely isolating high-level radioactive waste. Thermal processes induced by decay heat from the radioactive waste may impact the integrity of the engineered barrier system, and may lead to fluid flow and transport; and the associated migration of radionuclides. This study looks at an analysis of thermal conduction for the emplacement of high-level waste in a repository located in bedded salt. The simulations used analytical and numerical methods to study conductive heat transport in a repository. This study concentrated on heat flow in a central waste package with contributions from adjacent waste packages and drifts. Of particular importance to this work is comparison of predictions of peak temperature at the drift wall and at the waste package surface using different solution methods. Simulation results of analytical and numerical modeling methods are compared. The results show that predictions of the codes were comparable under identical initial and boundary conditions. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

Review of heat transfer enhancement techniques for single phase flows

The thermal energy exchange between a flowing fluid and its confining channel is a ubiquitous process in modern society. To enhance the fluid-to-wall or wall-to-fluid heat transfer, several techniques have been developed to maximize the contact area between the fluid and the inner wall and/or disrupt the flow to enhance circulation or induce turbulence. Deployment of channels having features capable of enhancing heat transfer enables the reduction of heat exchanger size while maintaining performance. Reduction in equipment size is critical due to the ability to minimize the required volume of costly working fluids and to mitigate potential safety concerns associated with total system fluid volume. Here, a comprehensive review of single-phase heat transfer enhancement techniques is presented. The article provides a thorough comparison by analyzing the heat transfer rate, pressure drop, and other operational aspects. Single-phase heat transfer enhancement methods are divided into active and passive techniques. Active methods such as electrohydrodynamic (EHD), magnetohydrodynamics (MHD), or mechanical motion require external power to create enhancement. Passive methods such as dimples, fins, or tape inserts do not require external input and rely only on surface modification. Although active methods are more expensive and difficult to implement compared to passive techniques, it enables active control of heat transfer augmentation. Finally, this review develops and summarizes key learning data for design optimization enabled by additive manufacturing and machine learning algorithms, helping to inform these next-generation heat exchanger design methodologies for a plethora of modern applications such as electrification of vehicles, computing, and classical industries.

42 ENGINEERING↗

Computer simulation of reaction and transport of core-scale serpentinization of Fe-bearing olivine and evolution of geological hydrogen

We present reactive flow and transport simulations of core-scale serpentinization of forsteritic, Fe-bearing olivine under hydrothermal conditions. The model captures fluid flow, evolving porosity–permeability, and redox-controlled H 2 production in a cylindrical core over 55 days at 245 °C and 37 bar. Key processes include olivine dissolution, precipitation of serpentine and magnetite, and oxidation of Fe2+ to Fe 3+ . Here, results show strong coupling among flow velocity, alteration front propagation, and spatially heterogeneous H 2 generation. Elevated H2 concentrations align with inlet-localized magnetite precipitation, consistent with experiments. Secondary mineral formation reduces porosity and permeability, altering transport pathways. Reactive flow at the fluid–solid interface governs H 2 generation rates and distribution. Dissolved SiO2 promotes serpentine and talc formation by suppressing brucite, while bicarbonate extends reaction duration and moderates surface complexation effects.

Geologic hydrogen↗

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↗

Exact coherent structures and chaotic dynamics in a model of cardiac tissue

Unstable nonchaotic solutions embedded in the chaotic attractor can provide significant new insight into chaotic dynamics of both low- and high-dimensional systems. In particular, in turbulent fluid flows, such unstable solutions are referred to as exact coherent structures (ECS) and play an important role in both initiating and sustaining turbulence. The nature of ECS and their role in organizing spatiotemporally chaotic dynamics, however, is reasonably well understood only for systems on relatively small spatial domains lacking continuous Euclidean symmetries. Construction of ECS on large domains and in the presence of continuous translational and/or rotational symmetries remains a challenge. This is especially true for models of excitable media which display spiral turbulence and for which the standard approach to computing ECS completely breaks down. This paper uses the Karma model of cardiac tissue to illustrate a potential approach that could allow computing a new class of ECS on large domains of arbitrary shape by decomposing them into a patchwork of solutions on smaller domains, or tiles, which retain Euclidean symmetries locally.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗

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↗