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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
All sourcesNASA NTRSDOE OSTI
DOE OSTI2016

Characteristics Analysis of SGTR accidents under the Shutdown Conditions

The Steam Generator Tube Rupture (SGTR) accident is one of design basis accidents that could result in undesirable radiation release as it bypasses the containment. According to Ref. [1], SGTRs have been experienced in several nuclear power plants and Ulchin 4 of Korea is one of them. Basically, SGTR analysis assumes that it occurs at full power, the SGTR at Ulchin 4 in 2002, was in the shutdown condition. Therefore, the transient behavior was different from the cases in full power conditions and especially, the effectiveness of Emergency Operating Procedure (EOP) needs to be checked if it is also applicable to the shutdown conditions, because EOP is prepared for full power conditions. In this paper, we set up a MARS-KS code model for Ulchin 4 unit and simulated the SGTR accident for benchmarking the model to the actual plant behavior during the accident. And then, several case studies were done to investigate the consequence of SGTR and the effectiveness of the EOP, focusing on the amount of the primary to secondary discharge flow which was influenced by operator actions. At the end, we'll discuss about the EOP for the shutdown conditions. (authors)

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2018

Telerobotic Control of Dexterous Dual-Arm Robots for D and D Operations - 18622

Robotic systems hold the potential to significantly reduce exposure of workers to hazardous environments such as in the deactivation and decommissioning (D and D) of nuclear facilities. Our goal is to enable an operator with minimal training to easily control a remote dual-arm robot to perform demolition tasks with hand tools. We propose a system that combines semi-autonomous coordination of the robot's arms with an intuitive operator interface based on virtual reality (VR) technology. A limb coordination system enables independent control of the robot arms, as well as coupled motion required to hold and manipulate rigid bodies such as reciprocating saws, angle grinders and crow bars. Using a VR head mounted display and stereo video from the robot for situational awareness and tracked VR hand controllers to command robot arm movement, an operator will be able to walk up to the control console, pick up the controllers, engage the manipulators, fly the grippers, grasp a tool with one or both robot arms and easily move them in unison to perform tasks. We present preliminary results using simulation and a physical dual-arm platform based on the Johns Hopkins University Applied Physics Laboratory's Modular Prosthetic Limb, an anthropomorphic device that provides hyper-dexterous human-like manipulation capabilities. Anticipated benefits of the robotic system for D and D operations include improved situational awareness, increased mission complexity, and reduced operator training time, workload, and task execution times. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2021

Self-similar Reynolds-averaged mechanical–scalar turbulence models for Rayleigh–Taylor, Richtmyer–Meshkov, and Kelvin–Helmholtz instability-induced mixing in the small Atwood number limit

Analytical self-similar solutions to two-, three-, and four-equation Reynolds-averaged mechanical–scalar turbulence models describing incompressible turbulent Rayleigh–Taylor, Richtmyer–Meshkov, and Kelvin–Helmholtz instability-induced mixing in planar geometry are derived in the small Atwood number (Boussinesq) limit. The models are based on the turbulent kinetic energy K and its dissipation rate ε, together with the scalar (heavy-fluid mass fraction) variance S and its dissipation rate Χ modeled either differentially or algebraically. The models allow for a simultaneous description of mechanical and scalar mixing, i.e., mixing layer growth and molecular mixing, respectively. Mixing layer growth parameters and other physical observables relevant to each instability are obtained explicitly as functions of the model coefficients. The turbulent fields are also expressed in terms of the model coefficients, with their temporal power-law scalings obtained by requiring that the self-similar equations are explicitly time-independent. The model calibration methodology is described and discussed. Expressions for a subset of the various physical observables are used to calibrate each of the two-, three-, and four-equation models, such that the self-similar solutions are consistent with experimental and numerical simulation data corresponding to these values of the observables and to specific canonical Rayleigh–Taylor, Richtmyer–Meshkov, and Kelvin–Helmholtz turbulent flows. A calibrated four-equation model is then used to reconstruct the mean and turbulent fields, and late-time turbulent equation budgets for each instability-induced flow across the mixing layer. The reference solutions derived here can provide systematic calibrations and better understanding of mechanical–scalar turbulence models and their predictions for instability-induced turbulent mixing in the very large Reynolds number limit.

42 ENGINEERING↗
DOE OSTI2016

Failure Diagnosis for the Holdup Tank System via ISFA

This paper discusses the use of the integrated system failure analysis (ISFA) technique for fault diagnosis for the holdup tank system. ISFA is a simulation-based, qualitative and integrated approach used to study fault propagation in systems containing both hardware and software subsystems. The holdup tank system consists of a tank containing a fluid whose level is controlled by an inlet valve and an outlet valve. We introduce the component and functional models of the system, quantify the main parameters and simulate possible failure-propagation paths based on the fault propagation approach, ISFA. The results show that most component failures in the holdup tank system can be identified clearly and that ISFA is viable as a technique for fault diagnosis. Since ISFA is a qualitative technique that can be used in the very early stages of system design, this case study provides indications that it can be used early to study design aspects that relate to robustness and fault tolerance. (authors)

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2024

Integrating Multi-Source Data for Bi-Level Traffic Simulator Calibration: A Literature Review and Highway Case Study

Traffic simulation serves as a powerful tool for pre-evaluating policies and technologies. In this context, simulation-based Dynamic traffic assignment (DTA) models are capable of capturing traffic dynamics. They are well-known as critical tools in controlling and predicting traffic situations. The reliability of simulation results heavily depends on the calibration process. Most studies in the literature formulate and calibrate simulators based on a single source of collected data or multiple data sets with the same spatiotemporal characteristics. However, in practice, traffic data is collected by various tools with usually different spatial and temporal resolutions. This study introduces a novel approach to taking into account diverse input data from a variety of sources. An iterative bi-level solution is proposed. to equally treat traffic flow and speed data. The upper level solves flow calibration with the exact solution method, and the lower level calibrates the speed with the simultaneous perturbation stochastic approximation (SPSA) algorithm. Subsequently, the effectiveness of the proposed model is investigated using data from a six-mile section of Nashville's I-24 highway in Tennessee. The results demonstrate that our proposed model creates an effective feedback loop between the optimizer and the simulator for calibrating flow and speed to reduce the error between simulated and real data.

42 ENGINEERING↗
DOE OSTI2017

Computation of Air Discharge into a Water Pool by Using Volume-of-Fluid Method

Suppression tanks, in-containment refueling water storage tanks (IRWSTs) and filtered containment venting systems (FCVSs) of nuclear power plants use water pools to accommodate high-pressure and high-temperature discharge of non-condensable gases and/or steam. Dynamic behavior of gas bubbles inside a water pool determines pressure and temperature loading to the system and thus we need validated method for applications. The underlying physics relevant to these problems is still a difficult issue due to the complicated nature of gas- liquid interfacial transfers of mass, momentum, and energy in a two-phase flow. Therefore, notwithstanding many studies performed over the past two or three decades, two-fluid theory is still a formidable task and direct numerical simulation (DNS) needs huge computing cost. Pellegrini et al. analyzed steam condensation and chugging in the water pool of the PPOOLEX STB-24 test by using STAR-CCM+ code implemented with two-phase interface model based on the Rayleigh-Taylor instability theory (RTI) which triggers steam depressurization. For the solution of the fine interface, they used Eulerian-Eulerian model for the fluid domain since the volume-of-fluid (VOF) model requires larger mesh points. The RTI resulted in complete steam condensation consistent with the experiment. The fluid tank was open to the atmosphere. They reported the volume fraction distributions in the pool, not the pool temperature or pressure history. For non-condensing gas discharges, however, the VOF is still a good alternative to the Eulerian two-fluid or the DNS approaches. The spatial distribution of each phase is defined in terms of volume fractions and the cell physical properties are obtained from linear combinations of those of constituent phases weighted by each volume fraction. Therefore, conditions where thermal and phase change effects become important are less likely to be simulated realistically. The VOF model is suited for the simulation of flows where each phase constitutes a large structure with a relatively small total contact area between phases. Present work is also interested in this VOF method for application to air discharge into a water pool which occurs in the early operating stages of the said facilities. Our purpose is to validate the VOF method against an existing air discharge experiment of PPOOLEX by using a commercial CFD code, STAR-CCM+ version 10.04, in terms of macroscopic flow properties. Effect of turbulence is also discussed.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2026

SAVY-4000 Finite-Element Drop Test Analysis

PFE Auxiliary Systems conducted drop testing on SAVY-4000 containers to evaluate structural response under 12-foot drop conditions. In support of that effort, a finite-element modeling capability was developed to simulate drop response across multiple container sizes and impact orientations. The purpose of this work was to provide a consistent analysis framework that could support interpretation of testing, compare response trends across multiple configurations, and generate quantities of interest for later comparison with experimental data. More broadly, the analysis and testing were intended to assess whether the containers continued to perform their primary function after a 12-foot drop, namely maintaining structural integrity and containment of the contents. The modeling approach combined an implicit preload analysis with an explicit drop simulation so that each drop event began from a mechanically realistic assembled condition, including compression of the silicone O-ring. Separate models were developed for 2-quart, 5-quart, 12-quart, and 10-gallon containers. The results were evaluated in terms of strain-gauge response, collar-lid gap behavior, and accumulated plastic strain. In addition, parametric studies were performed on the 2-quart container to assess sensitivity to O-ring stiffness, friction, canister thickness, geometry tolerance, and mesh density. The simulations showed that predicted drop responses depended strongly on both container size and drop orientation. Gap metrics identified cases in which the predicted collar-lid opening exceeded the nominal O-ring cross-section threshold, while plastic strain metrics identified localized regions of elevated permanent deformation. Parametric studies showed that the predicted response was especially sensitive to the assumed O-ring stiffness and contact friction, while the geometry tolerance study produced smaller changes in the cases examined. The main value of this work was that it established a repeatable modeling and simulation workflow to support drop-test implementation, evaluate effects of future configuration changes, and understand modeling assumptions that most influenced predicted response. At the current stage, the results were viewed as preliminary model predictions rather than validated predictions. The next step would be to compare drop-test data to the model so that predictive values of the workflow could be refined and used with greater confidence to assess whether the containers maintained structural integrity and containment of the contents after a 12-foot drop.

42 ENGINEERING↗
DOE OSTI2020

A Quantum Analog Coprocessor for Correlated Electron Systems Simulation

Analog quantum simulation is an approach for studying physical systems that might otherwise be computationally intractable to simulate on classical high-performance computing (HPC) systems. The key idea behind analog quantum simulation is the realization of a physical system with a low-energy effective Hamiltonian that is the same as the low-energy effective Hamiltonian of some target system to be studied. Purpose-built nanoelectronic devices are a natural candidate for implementing the analog quantum simulation of strongly correlated materials that are otherwise challenging to study using classical HPC systems. However, realizing devices that are sufficiently large to study the properties of a non-trivial material system (e.g., those described by a Fermi-Hubbard model) will eventually require the fabrication, control, and measurement of at least 0(10) quantum dots, or other engineered quantum impurities. As a step toward large-scale analog or digital quantum simulation platforms based on nanoelectronic devices, we propose a new approach to analog quantum simulation that makes use of the large Hilbert space dimension of the electronic baths that are used to adjust the occupancy of one or a few engineered quantum impurities. This approach to analog quantum simulation allows us to study a wide array of quantum impurity models. We can further augment the computational power of such an approach by combining it with a classical computer to facilitate dynamical mean-field theory (DMFT) calculations. DMFT replaces the solution of a lattice impurity problem with the solution of a family of localized impurity problems with bath couplings that are adjusted to satisfy a self-consistency condition between the two models. In DMFT, the computationally challenging task is the high-accuracy solution of an instance of a quantum impurity model that is determined self-consistently in coordination with a mean-field calculation. We propose using one or a few engineered quantum impurities with adjustable couplings to baths to realize an analog quantum coprocessor that effects the solution of such a model through measurements of a physical quantum impurity, operating in coordination with a classical computer to achieve a self-consistent solution to a DMFT calculation. We focus on implementation details relevant to a number of technologies for which Sandia has design, fabrication, and measurement expertise. The primary technical advances outlined in this report concern the development of a supporting modeling capability. As with all analog quantum simulation platforms, the successful design and operation of individual devices depends critically on one's ability to predict the effective low-energy Hamiltonian governing its dynamics Our project has made this possible and lays the foundation for future experimental implementations.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
DOE OSTI2016

SU-F-T-672: A Novel Kernel-Based Dose Engine for KeV Photon Beams

Purpose: Mimicking state-of-the-art patient radiotherapy with high precision irradiators for small animals allows advanced dose-effect studies and radiobiological investigations. One example is the implementation of pre-clinical IMRT-like irradiations, which requires the development of inverse planning for keV photon beams. As a first step, we present a novel kernel-based dose calculation engine for keV x-rays with explicit consideration of energy and material dependencies. Methods: We follow a superposition-convolution approach adapted to keV x-rays, based on previously published work on micro-beam therapy. In small animal radiotherapy, we assume local energy deposition at the photon interaction point, since the electron ranges in tissue are of the same order of magnitude as the voxel size. This allows us to use photon-only kernel sets generated by MC simulations, which are pre-calculated for six energy windows and ten base materials. We validate our stand-alone dose engine against Geant4 MC simulations for various beam configurations in water, slab phantoms with bone and lung inserts, and on a mouse CT with (0.275mm)3 voxels. Results: We observe good agreement for all cases. For field sizes of 1mm{sup 2} to 1cm{sup 2} in water, the depth dose curves agree within 1% (mean), with the largest deviations in the first voxel (4%) and at depths>5cm (<2.5%). The out-of-field doses at 1cm depth agree within 8% (mean) for all but the smallest field size. In slab geometries, the mean agreement was within 3%, with maximum deviations of 8% at water-bone interfaces. The γ-index (1mm/1%) passing rate for a single-field mouse irradiation is 71%. Conclusion: The presented dose engine yields an accurate representation of keV-photon doses suitable for inverse treatment planning for IMRT. It has the potential to become a significantly faster yet sufficiently accurate alternative to full MC simulations. Further investigations will focus on energy sampling as well as calculation times. Research at ICR is also supported by Cancer Research UK under Programme C33589/A19727 and NHS funding to the NIHR Biomedical Research Centre at RMH and ICR. MFF is supported by Cancer Research UK under Programme C33589/A19908.

43 PARTICLE ACCELERATORS↗
DOE OSTI2017

Turbulent Flow Simulation at the Exascale: Opportunities and Challenges Workshop: August 4-5, 2015, Washington, D.C.

This report details the impact exascale will bring to turbulent-flow simulations in applied science and technology. The need for accurate simulation of turbulent flows is evident across the DOE applied-science and engineering portfolios, including combustion, plasma physics, nuclear-reactor physics, wind energy, and atmospheric science. The workshop brought together experts in turbulent-flow simulation, computational mathematics, and high-performance computing. Building upon previous ASCR workshops on exascale computing, participants defined a research agenda and path forward that will enable scientists and engineers to continually leverage, engage, and direct advances in computational systems on the path to exascale computing.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2021

Large-Eddy Simulation of Laser-Ignited Direct Injection Gasoline Spray for Emission Control

Large-Eddy Simulations (LES) of a gasoline spray, where the mixture was ignited rapidly during or after injection, were performed in comparison to a previous experimental study with quantitative flame motion and soot formation data [SAE 2020-01-0291] and an accompanying Reynolds-Averaged Navier–Stokes (RANS) simulation at the same conditions. The present study reveals major shortcomings in common RANS combustion modeling practices that are significantly improved using LES at the conditions of the study, specifically for the phenomenon of rapid ignition in the highly turbulent, stratified mixture. At different ignition timings, benchmarks for the study include spray mixing and evaporation, flame propagation after ignition, and soot formation in rich mixtures. A comparison of the simulations and the experiments showed that the LES with Dynamic Structure turbulence were able to capture correctly the liquid penetration length, and to some extent, spray collapse demonstrated in the experiments. For early and intermediate ignition timings, the LES showed excellent agreement to the measurements in terms of flame structure, extent of flame penetration, and heat-release rate. However, RANS simulations (employing the common G-equation or well-stirred reactor) showed much too rapid flame spread and heat release, with connections to the predicted turbulent kinetic energy. With confidence in the LES for predicted mixture and flame motion, the predicted soot formation/oxidation was also compared to the experiments. The soot location was well captured in the LES, but the soot mass was largely underestimated using the empirical Hiroyasu model. An analysis of the predicted fuel–air mixture was used to explain different flame propagation speeds and soot production tendencies when varying ignition timing.

42 ENGINEERING↗
DOE OSTI2021

Cabin Thermal Management Analysis for SuperTruck II Next-Generation Hybrid Electric Truck Design

In this article, we present a multistage, coupled thermal management simulation approach, informed by physical testing where available, to aid design decisions for PACCAR's SuperTruck II hybrid truck cabin concept. Focus areas include cabin insulation, battery sizing, and sleeper curtain position, as well as heating, ventilating, and air-conditioning (HVAC) component and accessory configurations, to maintain or improve thermal comfort while saving energy. The authors analyzed weather data and determined the national vehicle miles traveled weighted temperature and solar conditions for long-haul trucks. Example weather day profiles were selected to approximate the 5th and 95th percentile weighted conditions. A daylong drive cycle was developed to impose appropriate external wind conditions during rest and driving periods. Using the National Renewable Energy Laboratory's vehicle HVAC modeling and simulation tool VTCab, HVAC load design trade-off studies for the new truck geometry concept were completed. Parameters analyzed included effects of paint color, insulation, glass transmissivity, and curtain location. Simulation results helped with early design material selections for efficient cabin climate control. A detailed three-dimensional computer-aided engineering (CAE), computational fluid dynamics (CFD), radiation, and human physiology co-simulation, referred to in this article as CAE Thermal-CFD, was used to evaluate thermal comfort and energy impacts of diffuser configurations and air supply settings in driving and hoteling modes. Analysis revealed that it is more difficult to heat the cabin in hoteling mode during the winter than to cool the space in the summer. This seasonal load profile drives the requirement of additional energy storage for heating comfort. To determine the battery capacity requirement, multiday HVAC operation drive cycle simulations were then completed, showing that a 15-kWh battery would be required for HVAC operation during hoteling. Results helped reduce cabin thermal loads, determine component sizing requirements, and improve occupant comfort to save fuel and contribute to the economic viability of the hybrid system.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2018

Multifamily Tool for Energy Audits (MulTEA) Engineering Manual (Version 1)

The Multifamily Tool for Energy Audits (MulTEA) is an energy audit tool designed to provide auditors with an improved energy simulation tool for multifamily buildings and an improved tool for identifying cost-effective energy-efficiency retrofit measures for multifamily buildings. MulTEA is designed specifically to help states and local weatherization agencies implement the Department of Energy (DOE) Weatherization Assistance Program. MulTEA was developed jointly by the Oak Ridge National Laboratory (ORNL) and the Lawrence Berkeley National Laboratory (LBNL). MulTEA is part of ORNL’s web-based Weatherization Assistant suite of audit tools (https://weatherization.ornl.gov/softwaredescription/). The energy calculation engine including the DOE- 2 simulation model and supplementary calculation modules is shared by MulTEA and LBNL’s Home Energy Saver pro (HESpro) (http://hespro.lbl.gov/pro/). On the ORNL side, the energy calculation engine is coupled with a user interface and output reporting capabilities based on Weatherization Assistance Program regulations and guidelines pertinent to MulTEA. On the LBNL side, the same engine will be used in HESpro to expand it to handle multifamily buildings. MulTEA is designed to address small and large multifamily buildings with decentralized and centralized heating, ventilation, and air-conditioning (HVAC) and domestic hot water (DHW) systems. Version 1 of MulTEA addresses small multifamily buildings with decentralized HVAC systems, and decentralized or centralized DHW systems. The capability to model large buildings and centralized HVAC systems will be incorporated in Version 2.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2020

Collaborative investigation of the internal flow and near-nozzle flow of an eight-hole gasoline injector (Engine Combustion Network Spray G)

The internal details of fuel injectors have a profound impact on the emissions from gasoline direct injection engines. However, the impact of injector design features is not currently understood, due to the difficulty in observing and modeling internal injector flows. Gasoline direct injection flows involve moving geometry, flash boiling, and high levels of turbulent two-phase mixing. In order to better simulate these injectors, five different modeling approaches have been employed to study the engine combustion network Spray G injector. Here these simulation results have been compared to experimental measurements obtained, among other techniques, with X-ray diagnostics, allowing the predictions to be evaluated and critiqued. The ability of the models to predict mass flow rate through the injector is confirmed, but other features of the predictions vary in their accuracy. The prediction of plume width and fuel mass distribution varies widely, with volume-of-fluid tending to overly concentrate the fuel. All the simulations, however, seem to struggle with predicting fuel dispersion and by inference, jet velocity. This shortcoming of the predictions suggests a need to improve Eulerian modeling of dense fuel jets.

ECN↗
DOE OSTI2017

An Unsteady State Gas Transport Model in Matrix Laboratory (MATLAB) for PWR Gas Management

Reactor Coolant System (RCS) hydrogen gas management can be a challenge at Pressurized Water Reactors (PWRs) during shutdown, startup, and steady state operation. Poor hydrogen control can result in higher general corrosion rates for RCS components and increases in critical path time for shutdown or startup. Also, performance indicator penalties may be accrued by entry into Electric Power Research Institute (EPRI) Action Level conditions or by accrual of Chemistry Effectiveness Index (CEI) penalties established by the Institute of Nuclear Power Operations (INPO). Furthermore, poor hydrogen control may increase industrial safety risk due to the creation of an explosive environment. Part of the hydrogen management difficulty arises from the interaction of several phenomena that require complex simulations to fully understand. While hydrogen gas transport models have been developed, the application of these models is limited by the computational intensity required to accurately model the dynamism inherent in plant shutdown or startup. Subsequently, a gas transport model is developed in a suitable computational program to meet these needs and provide input to an optimized RCS hydrogen management strategy for all operational modes. The gas transport model is used to model RCS hydrogen behavior for an example PWR during an End of Cycle (EOC) Forced Outage (FO) startup, a refueling outage (RFO) shutdown, and during nominal steady state operation. The computational software selected is Matrix Laboratory (MATLAB{sup R})

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2018

Performance Assessment of a Photonic Radiative Cooling System for Office Buildings

Spectrally selective materials show high technical potential for use as radiative cooling heat exchangers for buildings. Recent work by Stanford University has applied a photonic approach to tailor the optical properties of a coating material. In a prototype test, a radiative cooler based on that photonic material has demonstrated the ability to maintain radiator surfaces at below-ambient temperatures in the presence of intense, direct sunlight. This paper presents the simulation and parametric analysis of photonic radiative cooling system that integrates the use of the photonic radiative cooler and radiant floor cooling via the whole energy simulation program EnergyPlus. The simulation was made for a medium office building with three floors and a total floor area of 5,000 m2. Three key design parameters including the storage tank size, the radiator area, and the number of floors are expected to have a large impact on system performance were investigated in this paper. The results show that the percentage of cooling electricity savings from the photonic radiative cooling system relative to a reference variable-air-volume system has a linear relationship with the radiator area, and a quadratic correlation with both tank size and the number of floors. The findings from this parametric analysis are valuable to understand how component sizing affects system performance.

Wang, Weimin↗
DOE OSTI2020

Thermal characterization of the build chamber in electron beam melting

Electron beam powder bed fusion, commonly termed electron beam melting (EBM), offers great versatility in multiple-part processes and can produce high quality as-built components due to low residual stresses. The EBM process is complex and requires careful thermal management, including uniform and consistent preheating of the powder bed, in order to ensure quality and consistency of the product. However, most of the simulations in the literature focus on the selective melting stage of the process. As of today, optimal conditions for initial pre-heating temperatures are only available for specific materials. Thus, in order to extend the EBM technology to other desired build materials, a much better understanding of the pre-heating stages is required. In this work, numerical and experimental approaches are combined in order to investigate the effects and sensitivities of heat removal from the build plate during EBM pre-heating stages. For this purpose, a carefully reconstructed numerical model of the build chamber of an ARCAM Q20 + machine is developed. It includes all main parts of the chamber and all relevant heat transfer mechanisms, whereas special attention is paid to radiation heat exchange between various bodies. In order to validate the model, dedicated experiments are performed, in which a system of thermocouples is installed in the build chamber, allowing direct measurement of the local temperatures of the start-plate and heat shields. A good agreement between the simulation and experimental findings is achieved, leading to a better understanding of the thermal processes characteristic to the pre-heating stages. This basic analysis is followed by a representative pre-heating case, where a powder bed is also considered. The energy required to obtain the desired pre-heating temperatures is evaluated, and the role of the powder bed in heat transfer within the chamber is assessed. The pre-heating stage, simulated in the present work, is supposed to create proper conditions for sintering and consequent melting of the powder, which are highly dependent on the local temperatures and heat transfer features. Thus, the findings of the reported work present a step towards a better understanding of the thermal processes that characterize EBM. The reported model can be further used to provide realistic boundary condition inputs for other meso- or macro-scale models as a function of time and geometry. The model can serve also for verification of machine settings, i.e., jump-safe and melt-safe ones which actually provide desired preheat, and for development of settings for new powders.

36 MATERIALS SCIENCE↗