Results for “Advanced Modeling and Simulation” — Page 70

DOE OSTI2023

Reducing the Flow Maldistribution in Heat Exchangers through a Novel Polymer Manifold: Numerical Evaluation

The maldistribution of working fluid is one of the issues in heat exchangers that causes a reduction in performance of not only the heat exchanger but also the entire HVAC system. One of the methods to reduce such maldistribution is to improve manifold design to evenly distribute the flow. In the present work, an advanced maldistribution reduction manifold, which was based on a preliminary maldistribution reduction manifold, was designed to further improve the flow distribution in the heat exchanger. In the design, spiral baffles are used to create vortices in the tubes to regulate the flow in each tube. The design also keeps the tubes away from the manifold inlet to avoid direct flow from the inlet. Due to the complexity, the design of the advanced maldistribution reduction manifold is for AM only, which cannot be fabricated by traditional manufacturing. To evaluate the design, a computational fluid dynamic model is developed to study flow distribution in heat exchanger manifolds. The simulation results reveal that the relative standard deviation of the tubes in the advanced maldistribution reduction design is half of the preliminary maldistribution reduction design and about 1/20 of the reference design.

42 ENGINEERING↗

DOE OSTI2016

VERA-CS Modeling and Simulation of PWR Main Steam Line Break Core Response to DNB

The Virtual Environment for Reactor Applications core simulator (VERA-CS) being developed by the Consortium for the Advanced Simulation of Light Water Reactors (CASL) includes coupled neutronics, thermal-hydraulics, and fuel temperature components with an isotopic depletion capability. The neutronics capability employed is based on MPACT, a three-dimensional (3-D) whole core transport code. The thermal-hydraulics and fuel temperature models are provided by the COBRA-TF (CTF) subchannel code. As part of the CASL development program, the VERA-CS (MPACT/CTF) code system was applied to model and simulate reactor core response with respect to departure from nucleate boiling ratio (DNBR) at the limiting time step of a postulated pressurized water reactor (PWR) main steamline break (MSLB) event initiated at the hot zero power (HZP), either with offsite power available and the reactor coolant pumps in operation (high-flow case) or without offsite power where the reactor core is cooled through natural circulation (low-flow case). The VERA-CS simulation was based on core boundary conditions from the RETRAN-02 system transient calculations and STAR-CCM+ computational fluid dynamics (CFD) core inlet distribution calculations. The evaluation indicated that the VERA-CS code system is capable of modeling and simulating quasi-steady state reactor core response under the steamline break (SLB) accident condition, the results are insensitive to uncertainties in the inlet flow distributions from the CFD simulations, and the high-flow case is more DNB limiting than the low-flow case.

CTF↗

DOE OSTI2025

Advancing Additive Manufacturing Through Artificial Intelligence–Powered, High-Throughput, Nondestructive Characterization and Process Optimization

This Cooperative Research and Development Agreement (CRADA) between Oak Ridge National Laboratory (ORNL) and ZEISS Industrial Metrology has demonstrated the transformative potential of artificial intelligence (AI)-enabled x-ray computed tomography (XCT) to accelerate the qualification and certification of additively manufactured (AM) parts. At the core of this effort is Simurgh, an AI-powered XCT reconstruction framework jointly advanced by ORNL and ZEISS that integrates computer-aided design (CAD) models, physics-based simulations, and deep learning to overcome the long-standing challenges of metal artifact correction, long scan durations, and limited flaw detectability in dense and geometrically complex components. Simurgh enables high-throughput, high-quality 3D reconstruction from sparse and fast scans, which reduces XCT acquisition times by more than an order of magnitude and simultaneously improves defect detection limits by up to fourfold compared with industry-standard approaches. This capability reduces scan costs by more than 50%, lowers labor overhead, and makes XCT characterization economically viable for routine industrial use. By enabling reliable flaw detection in minutes rather than hours, Simurgh facilitates real-time feedback loops for process parameter optimization, which was highlighted in a recent npj Computational Materials (a Nature journal) issue. In the published study, more than 100 alloy coupons were characterized within a single day. This work represents a tenfold acceleration in the development of novel AM alloys and processes compared with conventional workflows. The ZEISS collaboration has also demonstrated the scalability of Simurgh to diverse application domains, including aerospace, nuclear, automotive, and biomedical components; in these applications, ensuring structural integrity is paramount. By drastically reducing barriers to XCT adoption, this partnership has laid the foundation for digital twins and data-driven certification pipelines and directly addressed bottlenecks in qualifying new materials and designs. Together, ORNL and ZEISS have shown that Simurgh advances the state of the art in nondestructive evaluation and aligns with the broader mission of enabling Industry 4.0 manufacturing ecosystems, in which intelligent, cost-effective, rapid quality assurance is integral to accelerating innovation and ensuring safety in critical applications.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Advancing Additive Manufacturing Through Artificial Intelligence–Powered, High-Throughput, Nondestructive Characterization and Process Optimization

This Cooperative Research and Development Agreement (CRADA) between Oak Ridge National Laboratory (ORNL) and ZEISS Industrial Metrology has demonstrated the transformative potential of artificial intelligence (AI)-enabled x-ray computed tomography (XCT) to accelerate the qualification and certification of additively manufactured (AM) parts. At the core of this effort is Simurgh, an AI-powered XCT reconstruction framework jointly advanced by ORNL and ZEISS that integrates computer-aided design (CAD) models, physics-based simulations, and deep learning to overcome the long-standing challenges of metal artifact correction, long scan durations, and limited flaw detectability in dense and geometrically complex components. Simurgh enables high-throughput, high-quality 3D reconstruction from sparse and fast scans, which reduces XCT acquisition times by more than an order of magnitude and simultaneously improves defect detection limits by up to fourfold compared with industry-standard approaches. This capability reduces scan costs by more than 50%, lowers labor overhead, and makes XCT characterization economically viable for routine industrial use. By enabling reliable flaw detection in minutes rather than hours, Simurgh facilitates real-time feedback loops for process parameter optimization, which was highlighted in a recent npj Computational Materials (a Nature journal) issue. In the published study, more than 100 alloy coupons were characterized within a single day. This work represents a tenfold acceleration in the development of novel AM alloys and processes compared with conventional workflows. The ZEISS collaboration has also demonstrated the scalability of Simurgh to diverse application domains, including aerospace, nuclear, automotive, and biomedical components; in these applications, ensuring structural integrity is paramount. By drastically reducing barriers to XCT adoption, this partnership has laid the foundation for digital twins and data-driven certification pipelines and directly addressed bottlenecks in qualifying new materials and designs. Together, ORNL and ZEISS have shown that Simurgh advances the state of the art in nondestructive evaluation and aligns with the broader mission of enabling Industry 4.0 manufacturing ecosystems, in which intelligent, cost-effective, rapid quality assurance is integral to accelerating innovation and ensuring safety in critical applications.

36 MATERIALS SCIENCE↗

DOE OSTI2017

Pillars of the Mantle: Imaging the Interior of the Earth with Adjoint Tomography. In: PEARC17 Proceedings of the Practice and Experience in Advanced Research Computing 2017 on Sustainability, Success and Impact, Article No. 75

In this work, we investigate global seismic tomographic models obtained by spectral-element simulations of seismic wave propagation and adjoint methods. Global crustal and mantle models are obtained based on an iterative conjugate-gradient type of optimization scheme. Forward and adjoint seismic wave propagation simulations, which result in synthetic seismic data to make measurements and data sensitivity kernels to compute gradient for model updates, respectively, are performed by the SPECFEM3D_GLOBE package [1] [2] at the Oak Ridge Leadership Computing Facility (OLCF) to study the structure of the Earth at unprecedented levels. Using advances in solver techniques that run on the GPUs on Titan at the OLCF, scientists are able to perform large-scale seismic inverse modeling and imaging. Using seismic data from global and regional networks from global CMT earthquakes, scientists are using SPECFEM3D_GLOBE to understand the structure of the mantle layer of the Earth. Visualization of the generated data sets provide an effective way to understand the computed wave perturbations which define the structure of mantle in the Earth.

Pugmire, David↗

DOE OSTI2022

Application of Monte Carlo code SHIFT for MSBR dose rate calculations

This paper presents a study that applied the Monte Carlo code SHIFT to calculate the radiological environment within a detailed Molten Salt Breeder Reactor (MSBR) model. It represents one of the first applications of the SHIFT code in stand-alone simulations for non-light water reactors to help demonstrate the code's potential uses in the design, licensing, and operation of advanced reactors. The radiological conditions of the MSBR were modeled when the reactor is at two different operation modes: normal full power and a drained state. The Forward Weighted-Consistent Adjoint Driven Importance Sampling (FW-CADIS) hybrid method in SHIFT was applied successfully to calculate the ex-core neutron and gamma dose rates for the MSBR at full power. Neutron and gamma dose rates within the drain cell were also calculated for the MSBR at the drained state by integrating the source terms obtained from an ORIGEN-S depletion calculation into the SHIFT simulation. The results indicate that in the drained state, the delayed gammas from the depleted fuel salt are the main contributors to the dose rates. (authors)

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2024

Comparing the interactions between particulate matter and cloud properties over two populated cities in Texas using WRF-Chem fine-resolution modeling

Accurate modeling of aerosol-cloud interactions is essential for reliable weather and air quality simulations, given their significant impact on precipitation patterns, cloud dynamics, and aerosol distributions. This study employed the Weather Research and Forecasting model coupled with Chemistry (WRF-Chem) to examine the impact of enhanced meteorological simulations, achieved through advanced microphysics parameterization supported by data assimilation techniques, on air quality across Texas on August 19 and 20, 2022. We tested four distinct configurations: (1) the Morrison two-moment bulk microphysics scheme, (2) Morrison's with observation nudging, (3) the Spectral Bin Microphysics (SBM), and (4) SBM with observation nudging. While the SBM scheme is known for its detailed representation of aerosol-cloud interactions, our focus was on how improvements in meteorological accuracy translate to more precise air quality simulations. Our findings demonstrated a progressive improvement in simulation accuracy, starting with the Morrison's scheme and further enhanced by adopting the SBM scheme, complemented by incorporating observation nudging. Specifically, the combination of the SBM scheme and the nudging substantially enhanced the model's ability to capture convective precipitation events, as shown by better alignment with NEXRAD radar reflectivity, with R increasing from –0.21 to 0.82, IOA from 0.10 to 0.87, and NMB decreasing from 99% to 34% in Houston. The enhanced meteorology translated into more accurate PM 2.5 concentration simulations, particularly through the more accurate representation of aerosol washout during precipitation events. In Houston, the SBM scheme with nudging improved the model's PM 2.5 simulations significantly, with NMB decreasing from –20% to 5% and IOA improving from 0.43 to 0.61. In San Antonio, improvements were also notable, with NMB improved from –27% to –22%, R increased from 0.48 to 0.82, and IOA increased from 0.66 to 0.86. Furthermore, our results underscore the crucial role of accurate meteorological simulations in refining our understanding of aerosol behaviors in relation to precipitation patterns, directly enhancing the reliability and effectiveness of air quality modeling.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2017

Transactive Systems Simulation and Valuation Platform Trial Analysis

Transactive energy systems use principles of value to coordinate responsive supply and demand in energy systems. Work continues within the Transactive Systems Program, which is funded by the U.S. Department of Energy at Pacific Northwest National Laboratory, to understand the value of, understand the theory behind, and simulate the behaviors of transactive energy systems. This report summarizes recent advances made by this program. The main capability advances include a more comprehensive valuation model, including recommended documentation that should make valuation studies of all sorts more transparent, definition of economic metrics with which transactive mechanisms can be evaluated, and multiple improvements to the time-simulation environment that is being used to evaluate transactive scenarios.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2017

Transactive Systems Simulation and Valuation Platform Trial Analysis

Transactive energy systems use principles of value to coordinate responsive supply and demand in energy systems. Work continues within the Transactive Systems Program, which is funded by the U.S. Department of Energy at Pacific Northwest National Laboratory, to understand the value of, understand the theory behind, and simulate the behaviors of transactive energy systems. This report summarizes recent advances made by this program. The main capability advances include a more comprehensive valuation model, including recommended documentation that should make valuation studies of all sorts more transparent, definition of economic metrics with which transactive mechanisms can be evaluated, and multiple improvements to the time-simulation environment that is being used to evaluate transactive scenarios.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

DOE OSTI2019

Nalu-Wind and OpenFAST: A high-fidelity modeling and simulation environment for wind energy. Milestone ECP-Q2-FY19

The goal of the ExaWind project is to enable predictive simulations of wind farms comprised of many megawatt-scale turbines situated in complex terrain. Predictive simulations will require computational fluid dynamics (CFD) simulations for which the mesh resolves the geometry of the turbines and captures the rotation and large deflections of blades. Whereas such simulations for a single turbine are arguably petascale class, multi-turbine wind farm simulations will require exascale-class resources. The primary physics codes in the ExaWind project are Nalu-Wind, which is an unstructured-grid solver for the acoustically incompressible Navier-Stokes equations, and OpenFAST, which is a whole-turbine simulation code. The Nalu-Wind model consists of the mass-continuity Poisson-type equation for pressure and a momentum equation for the velocity. For such modeling approaches, simulation times are dominated by linear-system setup and solution for the continuity and momentum systems. For the ExaWind challenge problem, the moving meshes greatly affect overall solver costs as reinitialization of matrices and recomputation of preconditioners is required at every time step. This milestone represents the culmination of several parallel development activities towards the goal of establishing a full-physics simulation capability for modeling wind turbines operating in turbulent atmospheric inflow conditions. The demonstration simulation performed in this milestone is the first step towards the "ground truth" simulation and includes the following components: neutral atmospheric boundary layer inflow conditions generated using a precursor simulation, a hybrid RANS/LES simulation of the wall-resolved turbine geometry, hybridization of the turbulence equations using a blending function approach to transition from the atmospheric scales to the blade boundary layer scales near the turbine, fluid-structure interaction (FSI) that accounts for the complete set of blade deformations (bending, twisting and pitch motion, yaw and tower displacements) by coupling to a comprehensive turbine dynamics code (OpenFAST). The use of overset mesh methodology for the simulations in this milestone presents a significant deviation from the previous efforts where a sliding mesh approach was employed to model the rotation of the turbine blades. The choice of overset meshes was motivated by the need to handle arbitrarily large deformations of the blade and to allow for blade pitching in the presence of a controller and the ease of mesh generation compared to the sliding mesh approach. FSI and the new timestep algorithm used in the simulations were developed in partnership with the A2e High-Fidelity Modeling project. The individual physics components were verified and validated (V%V) through extensive code-to-code comparisons and with experiments where possible. The detailed V&V efforts provide confidence in the final simulation where these physics models were combined together even though no detailed experimental data is available to perform validation of the final configuration. Taken together, this milestone successfully demonstrated the most advanced simulation to date that has been performed with Nalu-Wind.

17 WIND ENERGY↗

DOE OSTI2018

Interface Tracking Investigation of Geometric Effects on the Bubbly Flow in PWR Subchannels

We report that absorbing heat from the fuel rod surface, water as coolant can undergo subcooled boiling within a pressurized water reactor (PWR) fuel rod bundle. Because of the buoyancy effect, the vapor bubbles generated will then rise along and interact with the subchannel geometries. Reliable prediction of bubble behavior is of immense importance to ensure safe and stable reactor operation. However, given a complex engineering system like a nuclear reactor, it is very challenging (if not impossible) to conduct high-resolution measurements to study bubbly flows under reactor operation conditions. The lack of a fundamental two-phase-flow database is hindering the development of accurate two-phase-flow models required in more advanced reactor designs. In response to this challenge, first-principles–based numerical simulations are emerging as an attractive alternative to produce a complementary data source along with experiments. Leveraged by the unprecedented computing power offered by state-of-the-art supercomputers, direct numerical simulation (DNS), coupled with interface tracking methods, is becoming a practical tool to investigate some of the most challenging engineering flow problems. In the presented research, turbulent bubbly flow is simulated via DNS in single PWR subchannel geometries with auxiliary structures (e.g., supporting spacer grid and mixing vanes). The geometric effects these structures exert on the bubbly flow are studied with both a conventional time-averaging approach and a novel dynamic bubble tracking method. Lastly, the new insights obtained will help inform better two-phase models that can contribute to safer and more efficient nuclear reactor systems.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2016

Advanced 3D Characterization and Reconstruction of Reactor Materials FY16 Final Report

A coordinated effort to link advanced materials characterization methods and computational modeling approaches is critical to future success for understanding and predicting the behavior of reactor materials that operate at extreme conditions. The difficulty and expense of working with nuclear materials have inhibited the use of modern characterization techniques on this class of materials. Likewise, mesoscale simulation efforts have been impeded due to insufficient experimental data necessary for initialization and validation of the computer models. The objective of this research is to develop methods to integrate advanced materials characterization techniques developed for reactor materials with state-of-the-art mesoscale modeling and simulation tools. Research to develop broad-ion beam sample preparation, high-resolution electron backscatter diffraction, and digital microstructure reconstruction techniques; and methods for integration of these techniques into mesoscale modeling tools are detailed. Results for both irradiated and un-irradiated reactor materials are presented for FY14 - FY16 and final remarks are provided.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2024

Advanced Sensor Deployment for Distribution System State Estimation and Fault Identification

Distribution systems are currently facing steep operational challenges as a result of the rapidly increasing integration of renewables and other distributed energy resources (DERs) at both the primary and secondary circuit levels. Distribution utilities and system operators have traditionally had some visibility of their primary circuits using low-frequency supervisory control and data acquisition systems, and they have had very poor if not zero visibility of the secondary circuits where the presence of DERs is constantly increasing. Therefore, this paper presents simulation studies to demonstrate the benefits of an advanced, high-fidelity sensor technology, called as the Meta-Alert System (MAS), developed by Electrical Grid Monitoring, Ltd. (EGM), on the distribution grid. First, a reliable model of the EGM sensors is developed, and then two use cases, distribution system state estimation (DSSE) and fault identification are simulated to evaluate the performance of the MAS technology. Simulation results on the Electric Power Research Institute J1 feeder demonstrate that the MAS can effectively participate in system-level DSSE programs and can detect and locate faults faster than traditional distribution protection schemes.

distribution system↗

DOE OSTI2022

An Interactive Visualization Tool for Large-Scale Building Stock Modeling: Preprint

Recent advancements in data science and high-performance computing are making it easier to run millions of building simulations, but meaningful visualization of such large datasets remains a challenge. This paper presents a new tool developed to view the results of large-scale OpenStudio simulations of national, regional, or local building stocks. The tool processes millions of simulations to calculate measure savings, utility bills, carbon emissions, primary energy, and cost-effectiveness metrics at a high geographic resolution. Interactive visualizations of the building characteristics, consumption, and measure savings data include proportional symbol maps and histogram plots and can be filtered by any building characteristic.

big data↗

DOE OSTI2017

Chapter 11: Simulating Biomass Fast Pyrolysis at the Single Particle Scale

Simulating fast pyrolysis at the scale of single particles allows for the investigation of the impacts of feedstock-specific parameters such as particle size, shape, and species of origin. For this reason particle-scale modeling has emerged as an important tool for understanding how variations in feedstock properties affect the outcomes of pyrolysis processes. The origins of feedstock properties are largely dictated by the composition and hierarchical structure of biomass, from the microstructural porosity to the external morphology of milled particles. These properties may be accounted for in simulations of fast pyrolysis by several different computational approaches depending on the level of structural and chemical complexity included in the model. The predictive utility of particle-scale simulations of fast pyrolysis can still be enhanced substantially by advancements in several areas. Most notably, considerable progress would be facilitated by the development of pyrolysis kinetic schemes that are decoupled from transport phenomena, predict product evolution from whole-biomass with increased chemical speciation, and are still tractable with present-day computational resources.

09 BIOMASS FUELS↗

DOE OSTI2024

Transformer-powered surrogates close the ICF simulation-experiment gap with extremely limited data

Abstract Recent advances in machine learning, specifically transformer architecture, have led to significant advancements in commercial domains. These powerful models have demonstrated superior capability to learn complex relationships and often generalize better to new data and problems. This paper presents a novel transformer-powered approach for enhancing prediction accuracy in multi-modal output scenarios, where sparse experimental data is supplemented with simulation data. The proposed approach integrates transformer-based architecture with a novel graph-based hyper-parameter optimization technique. The resulting system not only effectively reduces simulation bias, but also achieves superior prediction accuracy compared to the prior method. We demonstrate the efficacy of our approach on inertial confinement fusion experiments, where only 10 shots of real-world data are available, as well as synthetic versions of these experiments.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2018

Global Sensitivity Analysis and Estimation of Model Error, Toward Uncertainty Quantification in Scramjet Computations

The development of scramjet engines is an important research area for advancing hypersonic and orbital flights. Progress toward optimal engine designs requires accurate flow simulations together with uncertainty quantification. However, performing uncertainty quantification for scramjet simulations is challenging due to the large number of uncertain parameters involved and the high computational cost of flow simulations. These difficulties are addressed in this paper by developing practical uncertainty quantification algorithms and computational methods, and deploying them in the current study to large-eddy simulations of a jet in crossflow inside a simplified HIFiRE Direct Connect Rig scramjet combustor. First, global sensitivity analysis is conducted to identify influential uncertain input parameters, which can help reduce the system’s stochastic dimension. Second, because models of different fidelity are used in the overall uncertainty quantification assessment, a framework for quantifying and propagating the uncertainty due to model error is presented. In conclusion, these methods are demonstrated on a nonreacting jet-in-crossflow test problem in a simplified scramjet geometry, with parameter space up to 24 dimensions, using static and dynamic treatments of the turbulence subgrid model, and with two-dimensional and three-dimensional geometries.

33 ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2026

Enhanced climate reproducibility testing with false discovery rate correction

Simulating the Earth's climate is an important and complex problem, thus climate models are similarly complex, comprised of millions of lines of code. In order to appropriately utilize the latest computational and software infrastructure advancements in Earth system models running on modern hybrid computing architectures to improve their performance, precision, accuracy, or all three; it is important to ensure that model simulations are repeatable and robust. This introduces the need for establishing statistical or non-bit-for-bit reproducibility, since bit-for-bit reproducibility may not always be achievable. Here, we propose a short-simulation ensemble-based test for an atmosphere model to evaluate the null hypothesis that modified model results are statistically equivalent to that of the original model. We implement this test in version 2 of the US Department of Energy's Energy Exascale Earth System Model (E3SM). The test evaluates a standard set of output variables across the two simulation ensembles and uses a false discovery rate correction to account for multiple testing. The false positive rates of the test are examined using re-sampling techniques on large simulation ensembles and are found to be lower than the currently implemented bootstrapping-based testing approach in E3SM. We also evaluate the statistical power of the test using perturbed simulation ensemble suites, each with a progressively larger magnitude of change to a tuning parameter. The new test is generally found to exhibit more statistical power than the current approach, being able to detect smaller changes in parameter values with higher confidence.

Kelleher, Michael E. [Oak Ridge National Laborator↗