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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 1,135 records · Page 63
All sourcesNASA NTRSDOE OSTI
DOE OSTI2020

Characterization of an RF-driven argon plasma at atmospheric pressure using broadband absorption and optical emission spectroscopy

Atmospheric pressure plasmas in argon are of particular interest due to the production of highly excited and reactive species enabling numerous plasma-aided applications. In this contribution, we report on absolute optical emission and absorption spectroscopy of a radio frequency (RF) driven capacitively coupled argon glow discharge operated in a parallel-plate configuration. This enabled the study of all key parameters including electron density and temperature, gas temperature, and absolute densities of atoms in highly electronically excited states. The space and time-averaged electron density and temperature were determined from the measurement of the absolute intensity of the electron-atom bremsstrahlung in the visible range. Considering the non-Maxwellian electron energy distribution function, an electron temperature (T e ) of 2.1 eV and an electron density (n e ) of 1.1 × 10 19 m –3 were obtained. The time-averaged and spatially resolved absolute densities of atoms in the metastable (1s 5 and 1s 3 ) and resonant (1s 4 and 1s 2 ) states of argon in pure Ar and Ar/He mixture were obtained by broadband absorption spectroscopy. The 1s 5 metastable atoms had the largest density near the sheath region with a maximum value of 8 × 10 17 m –3 , while all other 1s states had densities of at most 2 × 10 17 m –3 . Here, the dominant production and loss mechanisms of these atoms were discussed, in particular, the role of radiation trapping. We conclude with a comparison of the plasma properties of the argon RF glow discharges with the more common He equivalent and highlight their differences.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2021

ADVANCED THERMAL-HYDRAULIC MODEL OF HEAT RECOVERY STEAM GENERATORS

Steam-side oxidation at elevated temperatures in heat recovery steam generators (HRSGs) can lead to overheating of local tubes, potential oxide scale exfoliation, and damage to critical equipment. Predicting the oxide growth distribution requires detailed knowledge of the distribution of tube metal temperatures. To address these challenges, a computational fluid dynamics (CFD) model of a high-pressure superheater (HPSH) was developed within the Siemens’ STAR-CCM+ CFD commercial software. The HPSH section of the steam generator was selected for modeling because of its high oxidation rates.The model development included several steps. In the first step, an oxidation model based on a parabolic oxidation relationship was implemented. The oxidation growth predicted by the model was then verified for a full-load boiler operation case. In the second step, a three-dimensional CFD model was developed to account for the thermal and flow physics involved in HRSGs. The CFD model was then verified and validated on a simplified geometry that contained six row-tubes which mimicked the tube arrangements of an HPSH section. Numerical results compared well with published experimental results. In the third step, the oxidation model was coupled to the HRSG’s CFD model, and a comparison study was performed for two cases: (a) regular finless tubes and (b) finned tubes. Preliminary results showed that the oxide thickness predicted by the case with tube fins was higher compared to that of the finless tube case, thus demonstrating the need to model the effects of the tube fins on oxide thickness.

Panicker, Nithin↗
DOE OSTI2018

Study of Morphology and Magnesium Purity, Formed by Vapor Phase Through Silicothermic Reduction

This article describes the influence of temperature profile on the morphology and impurity distributions of magnesium vapor condensation during silicothermic reduction of calcined dolomite. The formation of magnesium crystals was comprehensively analyzed by optical microscopy, scanning electron microscopy (SEM), and inductively coupled plasma (ICP). The results showed that the temperature changed the morphology and purity of condensation products in the condenser. When the temperature of the condenser zone was lower than 250 °C, the magnesium vapor condensation was fine and noncompacted. The crystal growth of magnesium occurred in the range of 250 °C and 380 °C. It was found that crystal magnesium became coarser and denser at higher temperatures. Based on the analysis of crystallized magnesium, the impurity distributions decreased at temperatures higher than those of the condenser. Furthermore, this indicates that the impurity contents with less than 0.04 pct were distributed randomly through the condenser.

36 MATERIALS SCIENCE↗
DOE OSTI2017

Solid state dewetting of thin plasmonic films under focused cw-laser irradiation

Elevated temperatures and large thermal gradients are a significant source of component failure in microelectronics, and is the limiting factor in heat-assisted magnetic recording (HAMR). Here, we have investigated the effect of solid-state dewetting in Au thin films, as a function of local temperature, film thickness, and substrate adhesion. In this work, a localised temperature rise is induced in thin (≤ 50 nm) polycrystalline Au films on SiO 2 substrates via focused continuous-wave laser irradiation at 488 nm. The magnitude and distribution of the total temperature rise is measured using CCD-based thermoreflectance. This also allows a sensitive measurement of the temperature at which dewetting occurs, showing that for thin (≤ 50 nm) Au films without adhesion layers, rapid dewetting can occur at temperatures as low as 50° C. The time decay of the reflected light from the illuminating laser is used to monitor locally the dynamics of solid state dewetting. TEM diffraction analysis shows significant changes in the microstructure and crystallographic texture of the films as far as 10 µm away from the illuminated area. The use of a thin metallic adhesion layer (such as Ti or Cr) is shown to significantly improve the adhesion of the Au to the substrate and reduce the tendency towards dewetting, but does not entirely protect it from changes to the crystallographic texture.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Four-Stage Multi-Physics Simulations to Assist Temperature Sensor Design for Industrial-Scale Coal-Fired Boiler

The growth of renewable energy sources presents a pressing challenge to the operation and maintenance of existing fossil fuel power plants, given that fossil fuel remains the predominant fuel source, responsible for over 60% of electricity generation in the United States. One of the main concerns within these fossil fuel power plants is the unpredictable failure of boiler tubes, resulting in emergency maintenance with significant economic and societal consequences. A reliable high-temperature sensor is necessary for in situ monitoring of boiler tubes and the safety of fossil fuel power plants. In this study, a comprehensive four-stage multi-physics computational framework is developed to assist the design, optimization installation, and operation of the high-temperature stainless-steel and quartz coaxial cable sensor (SSQ-CCS) for coal-fired boiler applications. With the consideration of various operation conditions, we predict the distributions of flue gas temperatures within coal-fired boilers, the temperature correlation between the boiler tube and SSQ-CCS, and the safety of SSQ-CCS. With the simulation-guided sensor installation plan, the newly designed SSQ-CCSs have been employed for field testing for more than 430 days. The computational framework developed in this work can guide the future operation of coal-fired plants and other power plants for the safety prediction of boiler operations.

42 ENGINEERING↗
DOE OSTI2020

Influence of Process Parameters and Alloy Composition on Crack Mitigation in Selective Laser Melting

Microcracking and residual stresses are key limitations of laser powder bed fusion (LPBF), an additive manufacturing (AM) technique that uses a high power laser to consolidate successive layers of metal powder. For tungsten, these microcracks find their origin in the combination of a ductile-to-brittle transition (DBT) between 200°C and 400°C and high residual stresses. This work utilized in situ high speed video to capture the cracking mechanisms, and combined the experimental results with thermomechanical modeling to unveil correlations between crack network morphology and process parameter-related variables, such as the local temperature and residual stress distributions. Consequently, preheating and alloying with rare earth oxides were adopted as possible crack mitigation strategies, the efficacy of which was tested against the initial fundamental baseline results. Preheating temperatures above 500°C eliminated all cracking, though this threshold is expected to be higher when tungsten powder (higher oxygen content) is introduced. Alloying can serve as an active oxygen getter in the system, but the rare earth oxides in this work were too large to have significant contributions to crack-mitigation.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Experimental Capabilities to Support Design, Development and Demonstration of Microreactors

This work provides a summary of selected experimental capabilities being developed to support non-nuclear demonstration of microreactors under the U.S. Department of Energy’s (DOE’s) Microreactor Program. Major capabilities include the single primary heat extraction and removal emulator (SPHERE) and the microreactor agile non-nuclear experimental test bed (MAGNET). The SPHERE facility allows for controlled testing of the steady-state and transient heat rejection capabilities of a single heat pipe using electrical heaters that simulate nuclear heating. The facility is capable of monitoring axial temperature profiles along the heat pipe and surrounding test articles during startup, steady-state operation, and transients. Instrumentation includes non-contact infrared thermal imaging, surface thermocouples, spatially distributed fiber-optic temperature and strain sensors, electrical power meters, and a water-cooled, gas gap calorimeter for quantifying heat rejection from the heat pipe. The facility can be operated under both vacuum and inert-gas conditions.

42 ENGINEERING↗
DOE OSTI2025

Development and Validation of MALAMUTE model for Electric Field Assisted Sintering of Structural Materials

Fusion power plant designs feature extreme material performance requirements for structural material candidates. In addition to conventional alloys, more advanced composites and oxide dispersion strengthened (ODS) alloys are being explored, however, achieving the desired microstructures to maximize performance using traditional manufacturing methods can be challenging. The advanced manufacturing (AM) electric field-assisted sintering (EFAS) technique offers improved control over the final microstructure through higher heating and cooling rates and moderate pressures. Modeling and simulation tools show promise in elucidating the process-structure-property-performance (PSPP) correlation for AM-produced parts, including the EFAS process. An inherently multiscale process, the EFAS technique aligns well with the multiscale modeling capability of the open-source Multiphysics Object-Oriented Simulation Environment (MOOSE)[cite]. We present here an electro-thermo-mechanical approach to modeling the EFAS process using the MOOSE Application Library for Advanced Manufacturing UTilitiEs (MALAMUTE) code. Prediction of the field and gradient distributions across the EFAS tooling is required to accurately describe the conditions for the lower-scale microstructural evolution models. In this work we present the MALAMUTE model developed to predict the electrical potential, temperature, and mechanical stress distribution across the EFAS graphite tooling and part at the larger engineering-scale. Validation of the MALAMUTE engineering-scale model is completed using data from experimental densification and pre-densified runs of iron powder via EFAS at 1000oC. These runs were conducted using a Thermal Technology DCS-5 EFAS system. Data collected during the experiment runs include the direct current (DC) supplied to the graphite tooling, the temperature of the graphite tooling as measured with a pyrometer, and the force applied to the top of the graphite tooling stack, and the data were recorded every 10 seconds. Our validation approach used the current and force data from the EFAS run as boundary condition inputs to the MAMALUTE simulation; the temperature data were used to evaluate the MALAMUTE EFAS model prediction. Results of the MALAMUTE simulations are employed to connect the external pyrometer temperature measurement to the temperature profile across the part undergoing consolidation. We investigate the impact of material property variation and mesh deformation on the temperature profile as predicted by MALAMUTE. We conclude by highlighting projects where the MALAMUTE EFAS modeling and simulation capabilities will be used to assist experimental design.

36 - MATERIALS SCIENCE↗
DOE OSTI2022

Preliminary Observations on the Hydrogen Redistribution Feedback in YH-Moderated Monolithic Microreactors.

Nuclear microreactors promise to open new markets for nuclear industry. This is due to their potential competitive cost in non-traditional market segments, e.g., mines, forward military basis, extraterrestrial surfaces and remote areas, and inherently safe characteristics that make them deployable where other power sources are not available or difficult to exploit. Transition metal dihydrides have been considered among the most promising candidates for moderating nuclear microreactors. In particular, yttrium hydride (YH\textsubscript{x}) has been selected for high temperature applications due to its high thermal stability and relatively high hydrogen retention at temperatures exceeding $870^\circ C$. One of the main issues associated with the use of hydrides is that, when exposed to temperature, stress, or concentration gradients, the hydrogen contained in the metallic matrix tends to redistribute and leak from the moderating elements, potentially leading to reactivity losses and power swings. The purpose of this paper is to gain a better physical understanding of the neutronic feedback associated with the hydrogen redistribution in YH\textsubscript{x}, by using Griffin and Bison. This feedback is inherently multiphysics, since the hydrogen distribution is strongly dependent on the moderator temperature spatial distribution. In particular, we want to understand the sign (+/-) of the neutronic feedback, its order of magnitude, and its underlying physical causes.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2018

Multiphase Model of Semisolid Slurry Generation and Isothermal Holding During Cooling Slope Rheoprocessing of A356 Al Alloy

In the present paper, we present an experimentally validated 3D multiphase and multiscale solidification model to understand the transport processes involved during slurry generation with a cooling slope. In this process, superheated liquid alloy is poured at the top of the cooling slope and allowed to flow along the slope under the influence of gravity. As the melt flows down the slope, it progressively loses its superheat, starts solidifying at the melt/slope interface with formation of solid crystals, and eventually exits the slope as semisolid slurry. In the present simulation, the three phases considered are the parent melt as the primary phase, and the solid grains and air as secondary phases. The air phase forms a definable air/liquid melt interface as the free surface. After exiting the slope, the slurry fills an isothermal holding bath maintained at the slope exit temperature, which promotes further globularization of microstructure. The outcomes of the present model include prediction of volume fractions of the three different phases considered, grain evolution, grain growth, size, sphericity and distribution of solid grains, temperature field, velocity field, macrosegregation and microsegregation. In addition, the model is found to be capable of making predictions of morphological evolution of primary grains at the onset of isothermal coarsening. The results obtained from the present simulations are validated by performing quantitative image analysis of micrographs of the rapidly oil-quenched semisolid slurry samples, collected from strategic locations along the slope and from the isothermal slurry holding bath.

36 MATERIALS SCIENCE↗
DOE OSTI2015

Modeling of dissociation and energy transfer in shock-heated nitrogen flows

This work addresses the modeling of dissociation and energy transfer processes in shock heated nitrogen flows by means of the maximum entropy linear model and a newly proposed hybrid bin vibrational collisional model. Both models aim at overcoming two of the main limitations of the state of the art non-equilibrium models: (i) the assumption of equilibrium between rotational and translational energy modes of the molecules and (ii) the reliance on the quasi-steady-state distribution for the description of the population of the internal levels. The formulation of the coarse-grained models is based on grouping the energy levels into bins, where the population is assumed to follow a Maxwell-Boltzmann distribution at its own temperature. Different grouping strategies are investigated. Following the maximum entropy principle, the governing equations are obtained by taking the zeroth and first-order moments of the rovibrational master equations. The accuracy of the proposed models is tested against the rovibrational master equation solution for both flow quantities and population distributions. Calculations performed for free-stream velocities ranging from 5 km/s to 10 km/s demonstrate that dissociation can be accurately predicted by using only 2-3 bins. It is also shown that a multi-temperature approach leads to an under-prediction of dissociation, due to the inability of the former to account for the faster excitation of high-lying vibrational states.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
DOE OSTI2024

Analysis of thermal and mechanical properties with inventory level of the molten salt storage tank in central receiver concentrating solar power plants

Molten salt thermal energy storage (TES) tanks ensure steady power output of concentrating solar power (CSP) plants; however, recent tank failures have highlighted the need for further analysis. Current studies primarily focus on analyzing the molten salt flow, heat transfer, and thermal efficiency. Additionally, research on the latest tank structures is limited and lacks newest experimental validation. This study measures temperature and molten salt inventory levels in the high-temperature tank at a 50 MW central receiver CSP plant, connected to the power grid in 2019. A multi-physics model was developed to evaluate thermal and mechanical properties of TES tanks by combining computational fluid dynamics and finite element modeling using real plant data. Heat loss, temperature, displacement, and stress distribution of the tank at different inventory levels were investigated. Results show that ambient air velocity near the tank roof reaches 2.14 m/s, much higher than 0.2 m/s near the wall. The temperatures of inventory fluid and tank are close, varying slightly at different levels due to thermal conduction and radiation. Because the heat loss strongly depends on temperature, the total tank loss remains nearly constant across inventory levels. Larger temperature gradients and thermal stresses are primarily localized along the tank floor edge and the air-salt interface. Notably, the maximum thermal stress at the tank edge is three times higher than that at the interface. The magnitude of total stress changes by less than 5 MPa with and without thermal load, indicating that high temperatures exert only a minor impact on tank stress. In contrast, thermal load significantly affects tank deformation, particularly at the roof edge, where values exceed 150 mm. Despite the large variation in molten salt levels, tank wall temperatures and displacements present a minor change, suggesting a weak correlation with inventory levels. In conclusion, the findings obtained in this study provide important insights on the TES tank that could be used to optimize tank design and operation strategies.

14 SOLAR ENERGY↗
DOE OSTI2023

Toward High Conversion Efficiency of Thermoelectric Modules through Synergistical Optimization of Layered Materials

Abstract Waste‐heat electricity generation using high‐efficiency solid‐state conversion technology can significantly decrease dependence on fossil fuels. Here, a synergistical optimization of layered half‐Heusler (hH) materials and module to improve thermoelectric conversion efficiency is reported. This is realized by manufacturing multiple thermoelectric materials with major compositional variations and temperature‐gradient‐coupled carrier distribution by one‐step spark plasma sintering. This strategy provides a solution to overcome the intrinsic concomitants of the conventional segmented architecture that only considers the matching of the figure of merit ( zT ) with the temperature gradient. The current design is dedicated to temperature‐gradient‐coupled resistivity and compatibility matching, optimum zT matching, and reducing contact resistance sources. By enhancing the quality factor of the materials by Sb‐vapor‐pressure‐induced annealing, a superior zT of 1.47 at 973 K is achieved for (Nb, Hf)FeSb hH alloys. Along with the low‐temperature high‐ zT hH alloys of (Nb, Ta, Ti, V)FeSb, the single stage layered hH modules are developed with efficiencies of ≈15.2% and ≈13.5% for the single‐leg and unicouple thermoelectric modules, respectively, under Δ T of 670 K. Therefore, this work has a transformative impact on the design and development of next‐generation thermoelectric generators for any thermoelectric material families.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2021

Universal Bound to the Amplitude of the Vortex Nernst Signal in Superconductors

A liquid of superconducting vortices generates a transverse thermoelectric response. This Nernst signal has a tail deep in the normal state due to superconducting fluctuations. Here, we present a study of the Nernst effect in two-dimensional heterostructures of Nb-doped strontium titanate (STO) and in amorphous MoGe. Additionally, the Nernst signal generated by ephemeral Cooper pairs above the critical temperature has the magnitude expected by theory in STO. On the other hand, the peak amplitude of the vortex Nernst signal below Tc is comparable in both and in numerous other superconductors despite the large distribution of the critical temperature and the critical magnetic fields. In four superconductors belonging to different families, the maximum Nernst signal corresponds to an entropy per vortex per layer of ≈kBln 2 .

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2017

Beyond the classical kinetic model for chronic graphite oxidation by moisture in high temperature gas-cooled reactors

Four grades of nuclear graphite with various microstructures were subjected to accelerated oxidation tests in helium with traces of moisture and hydrogen in order to evaluate the effects of chronic oxidation on graphite components in high temperature gas cooled reactors. Kinetic analysis showed that the Langmuir-Hinshelwood (LH) model cannot consistently reproduce all results. In particular, at high temperatures and water partial pressures oxidation was always faster than the LH model predicts, with stronger deviations for superfine grain graphite than for medium grain grades. It was also found empirically that the apparent reaction order for water has a sigmoid-type variation with temperature which follows the integral Boltzmann distribution function. This suggests that the apparent activation with temperature of graphite reactive sites that causes deviations from the LH model is rooted in specific structural and electronic properties of surface sites on graphite. A semi-global kinetic model was proposed, whereby the classical LH model was modified with a temperature-dependent reaction order for water. The new Boltzmann-enhanced model (BLH) was shown to consistently predict experimental oxidation rates over large ranges of temperature (800-1100 oC) and partial pressures of water (3-1200 Pa) and hydrogen (0-300 Pa), not only for the four grades of graphite but also for the historic grade H-451. The BLH model offers as more reliable input for modeling the chemical environment effects during the life-time operation of new grades of graphite in advanced nuclear reactors operating at high and very high temperatures.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2016

Ceria nanoclusters on graphene/Ru(0001): A new model catalyst system

The growth of ceria nanoclusters on single-layer graphene on Ru(0001) has been examined, with a view towards fabricating a stable system for model catalysis studies. The surface morphology and cluster distribution as a function of oxide coverage and substrate temperature has been monitored by scanning tunneling microscopy (STM), whereas the chemical composition of the cluster deposits has been determined by Auger electron spectroscopy (AES). The ceria nanoparticles are of the CeO2(111)-type and are anchored at the intrinsic defects of the graphene surface, resulting in a variation of the cluster densities across the macroscopic sample surface. The ceria clusters on graphene display a remarkable stability against reduction in ultrahigh vacuum up to 900 K, but some sintering of clusters is observed for temperatures >450 K. The evolution of the cluster size distribution suggests that the sintering proceeds via a Smoluchowski ripening mechanism, i.e. diffusion and aggregation of entire clusters.

Ceria, CeO2, nanoclusters, graphene, Ru(0001), Smo↗