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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 1,333 records · Page 74
All sourcesNASA NTRSDOE OSTI
DOE OSTI2018

HIS-TORIC: Extending core ICRF wave simulation to include realistic SOL plasmas

This paper presents a novel approach to incorporating an arbitrarily shaped edge scrape-off-layer (SOL) plasma and an ion cyclotron range of frequency (ICRF) antenna structure into existing core ICRF wave simulation models. We partition the entire computation domain into two sub-domains: a core and an edge region. Simulations in each domain are performed separately with appropriate numerical solvers. For the core, the TORIC ICRF solver [M. Brambilla, Plasma Phys. Contrl. Fusion 41, 1 (1999)] was modified to impose an essential (Dirichlet) boundary condition at its interface with the edge domain. In the edge, a finite element method (FEM) is used to solve a cold collisional plasma model. The domains are then joined together using the continuity boundary condition for the tangential electric and magnetic fields at their interfaces (Hybrid Integration of SOL to TORIC: HIS-TORIC). The model developed here was tested using an ICRH H minority heating scenario on the Alcator C-Mod tokamak [I. Hutchinson et. al., Phys. Plasmas 1, 1511 (1994)]. The simulated pattern of core wave propagation agrees well with a standard TORIC simulation. This approach opens the possibility of using a realistic diverted SOL plasma and a complicated 3D RF antenna together with a rigorous hot core plasma model, while requiring only minimal modification to existing RF codes.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2014

Aleph

Aleph is a PIC/DSMC (particle-in-cell/direct simulation Monte Carlo) software package for the simulation of low temperature plasmas. Aleph is intended to be a production quality code capable of handling complex 3D geometries. Unstructured triangular (2D) or tetrahedral (3D) meshes are used to represent simulation domains. Aleph runs either in serial on a single processor or desktop machine, or can be run in parallel using the MPI message-passing library, to enable faster performance on large problems. Aleph employs dynamic load balancing to efficiently harness thousands of processors on high performance computers and enable simulations of up to millions of mesh elements and billions of particles. Multiple decompositions of the same mesh are used: one for the particles, and one for the field solves. Electrostatic fields are computed using an unstructured mesh finite element method (FEM), and the resulting linear systems are solved using solvers from the Trilinos package (http://trilinos.org/).

Source record↗
DOE OSTI2011

Panzer

Panzer is a finite element assembly engine used for research on solving partial differential equations (PDEs). Panzer takes a physics model implemented by a user and creates and populates the linear algrbra objects, such as residuals and Jacobians, for use in implicit finite element methods. Panzer can be considered "glue code" that pulls together the capabilities of a number of open-source Trilinos packages (Epetra, Intrepid, Sacado, FEI, and Phalanx). This code provides a generic framework for describing a set of partial differential equations. Panzer provides a simple example driver that solves the undergraduate textbook partial differential equation of heat transfer in a solid (see for example, "Transport Phenomena" by Bird Stewart, and Lightfoot 1960). Panzer is intended as a tool to simplify the use of the discretization tools in Trilinos (Intrepid and Phalanx) and is meant to aid in fundamental research on discretizations. Panzer will be released open-source as a package in Trilinos under a BSD license.

Source record↗
DOE OSTI2015

Numerical Simulation of Big Area Additive Manufacturing (3D Printing) of a Full Size Car

Distortion and buildup of residual stresses are common design problems in structures manufactured using additive manufacturing techniques, popularly known as 3D printing. These problems lead to poor product quality, which often is improved by trial and error, where the sensitivity of different manufacturing configurations to product quality are experimentally determined. With the introduction of Big Area Additive Manufacturing (BAAM), where significant amount of material is deposited per unit time, trial and error philosophy reduces the economical efficiency of the process. In this work, a numerical simulation methodology based on Finite Element Method (FEM), multi-scale damage mechanics and fracture mechanics is introduced to simulate the BAAM process for determining product quality in terms of distortions, material damage and interface fracture due to manufacturing. In addition, this tool can be used to obtain the sensitivities of the manufacturing configurations with respect to product quality in an economically efficient manner compared to the trial and error philosophy. Computational tools providing a fully coupled thermo-mechanical solution of polymer additive manufacturing with chopped fiber reinforced plastics are presented.

42 ENGINEERING↗
DOE OSTI2016

Least-Squares PN Formulation of the Transport Equation Using Self-Adjoint-Angular-Flux Consistent Boundary Conditions.

In this paper, we study the Least-Squares (LS) PN form of the transport equation compatible with voids in the context of Continuous Finite Element Methods (CFEM).We first deriveweakly imposed boundary conditions which make the LS weak formulation equivalent to the Self-Adjoint Angular Flux (SAAF) variational formulation with a void treatment, in the particular case of constant cross-sections and a uniform mesh. We then implement this method in Rattlesnake with the Multiphysics Object Oriented Simulation Environment (MOOSE) framework using a spherical harmonics (PN) expansion to discretize in angle. We test our implementation using the Method of Manufactured Solutions (MMS) and find the expected convergence behavior both in angle and space. Lastly, we investigate the impact of the global non-conservation of LS by comparing the method with SAAF on a heterogeneous test problem.

Least-Squares↗
DOE OSTI2017

Formulation and Validation of an Efficient Computational Model for a Dilute, Settling Suspension Undergoing Rotational Mixing

Designing processing equipment for the mixing of settling suspensions is a challenging problem. Achieving low-cost mixing is especially difficult for the application of slowly reacting suspended solids because the cost of impeller power consumption becomes quite high due to the long reaction times (batch mode) or due to large-volume reactors (continuous mode). Further, the usual scale-up metrics for mixing, e.g., constant tip speed and constant power per volume, do not apply well for mixing of suspensions. As an alternative, computational fluid dynamics (CFD) can be useful for analyzing mixing at multiple scales and determining appropriate mixer designs and operating parameters. We developed a mixture model to describe the hydrodynamics of a settling cellulose suspension. The suspension motion is represented as a single velocity field in a computationally efficient Eulerian framework. The solids are represented by a scalar volume-fraction field that undergoes transport due to particle diffusion, settling, fluid advection, and shear stress. A settling model and a viscosity model, both functions of volume fraction, were selected to fit experimental settling and viscosity data, respectively. Simulations were performed with the open-source Nek5000 CFD program, which is based on the high-order spectral-finite-element method. Simulations were performed for the cellulose suspension undergoing mixing in a laboratory-scale vane mixer. The settled-bed heights predicted by the simulations were in semi-quantitative agreement with experimental observations. Further, the simulation results were in quantitative agreement with experimentally obtained torque and mixing-rate data, including a characteristic torque bifurcation. In future work, we plan to couple this CFD model with a reaction-kinetics model for the enzymatic digestion of cellulose, allowing us to predict enzymatic digestion performance for various mixing intensities and novel reactor designs.

09 BIOMASS FUELS↗
DOE OSTI2016

Least-Squares PN Formulation of the Transport Equation Using Self-Adjoint-Angular-Flux Consistent Boundary Conditions

In this paper, we study the Least-Squares (LS) PN form of the transport equation compatible with voids [1] in the context of Continuous Finite Element Methods (CFEM).We first deriveweakly imposed boundary conditions which make the LS weak formulation equivalent to the Self-Adjoint Angular Flux (SAAF) variational formulation with a void treatment [2], in the particular case of constant cross-sections and a uniform mesh. We then implement this method in Rattlesnake with the Multiphysics Object Oriented Simulation Environment (MOOSE) framework [3] using a spherical harmonics (PN) expansion to discretize in angle. We test our implementation using the Method of Manufactured Solutions (MMS) and find the expected convergence behavior both in angle and space. Lastly, we investigate the impact of the global non-conservation of LS by comparing the method with SAAF on a heterogeneous test problem.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2017

Performance and Reliability of Bonded Interfaces for High-Temperature Packaging

Sintered silver has proven to be a promising candidate for use as a die-attach and substrate-attach material in automotive power electronics components. It holds promise of greater reliability than lead-based and lead-free solders, especially at higher temperatures (>200 degrees C). Accurate predictive lifetime models of sintered silver need to be developed and its failure mechanisms thoroughly characterized before it can be deployed as a die-attach or substrate-attach material in wide-bandgap device-based packages. Mechanical characterization tests that result in stress-strain curves and accelerated tests that produce cycles-to-failure result will be conducted. Also, we present a finite element method (FEM) modeling methodology that can offer greater accuracy in predicting the failure of sintered silver under accelerated thermal cycling. A fracture mechanics-based approach is adopted in the FEM model, and J-integral/thermal cycle values are computed.

30 DIRECT ENERGY CONVERSION↗
DOE OSTI2017

Thermomechanical Modeling of Sintered Silver - A Fracture Mechanics-based Approach: Extended Abstract: Preprint

Sintered silver has proven to be a promising candidate for use as a die-attach and substrate-attach material in automotive power electronics components. It holds promise of greater reliability than lead-based and lead-free solders, especially at higher temperatures (less than 200 degrees Celcius). Accurate predictive lifetime models of sintered silver need to be developed and its failure mechanisms thoroughly characterized before it can be deployed as a die-attach or substrate-attach material in wide-bandgap device-based packages. We present a finite element method (FEM) modeling methodology that can offer greater accuracy in predicting the failure of sintered silver under accelerated thermal cycling. A fracture mechanics-based approach is adopted in the FEM model, and J-integral/thermal cycle values are computed. In this paper, we outline the procedures for obtaining the J-integral/thermal cycle values in a computational model and report on the possible advantage of using these values as modeling parameters in a predictive lifetime model.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2017

Process Modeling and Validation for Metal Big Area Additive Manufacturing

Metal Big Area Additive Manufacturing (mBAAM) is a new additive manufacturing (AM) technology based on the metal arc welding. A continuously fed metal wire is melted by an electric arc that forms between the wire and the substrate, and deposited in the form of a bead of molten metal along the predetermined path. Objects are manufactured one layer at a time starting from the base plate. The final properties of the manufactured object are dependent on its geometry and the metal deposition path, in addition to depending on the basic welding process parameters. Computational modeling can be used to accelerate the development of the mBAAM technology as well as a design and optimization tool for the actual manufacturing process. We have developed a finite element method simulation framework for mBAAM using the new features of software ABAQUS. The computational simulation of material deposition with heat transfer is performed first, followed by the structural analysis based on the temperature history for predicting the final deformation and stress state. In this formulation, we assume that two physics phenomena are coupled in only one direction, i.e. the temperatures are driving the deformation and internal stresses, but their feedback on the temperatures is negligible. The experiment instrumentation (measurement types, sensor types, sensor locations, sensor placements, measurement intervals) and the measurements are presented. The temperatures and distortions from the simulations show good correlation with experimental measurements. Ongoing modeling work is also briefly discussed.

Simunovic, Srdjan↗
DOE OSTI2017

Load-Direction-Derived Support Structures for Wind Turbines: A Lattice Tower Concept and Preparations for Future Certifications: Preprint

The call for more cost-effective and environmentally friendly tower concepts is motivated by tower costs [1] and tower CO2-emission contributions [2], which are high relative to the whole wind turbine system. The proposed rotatable tower concept with yaw bearing at the bottom instead of the top of the tower will provide beneficial economic and environmental impacts to the turbine system. This wind alignment capability indicates a load-direction-derived tower design. By combining this approach with a lattice concept, large material and cost savings for the tower can be achieved. This paper presents a way to analyze and verify the proposed design through aero-servo-elastic simulations, which make future certifications of rotatable tower concepts viable. For this reason, the state-of-the-art, open-source lattice-tower finite-element-method (FEM) module SubDyn [10], developed by the National Renewable Energy Laboratory, has been modified to account for arbitrary member cross-sections. Required changes in the beam element stiffness and mass matrix formulation took place according to an energy method [13]. All validated adaptions will be usable within the aero-servo-elastic simulation framework FAST and are also beneficial for other nonrotatable lattice structures.

17 WIND ENERGY↗
DOE OSTI2015

Guaranteed Quality Conformal Mesh Decomposition.

Interface-conforming elements generated by the conformal decomposition finite element method can have arbitrarily poor quality due to the arbitrary intersection of the base triangular or tetrahedral mesh with material interfaces. This can have severe consequences for both the solvability of linear systems and for the interpolation error of fields represented on these meshes. The present work demonstrates that snapping the base mesh nodes to the interface whenever the interface cuts close to a node results in conforming meshes of good quality. Theoretical limits on the snapping tolerance are derived, and even conservative tolerance choices result in limiting the stiffness matrix condition number to within a small multiple of that of the base mesh. Interpolation errors are also well controlled in the norms of interest. In 3D, use of node-to-interface snapping also permits a simpler and more robust vertex ID-based element decomposition algorithm to be used with no serious detriment to mesh quality.

42 ENGINEERING↗
DOE OSTI2017

A finite element/level set model of polyurethane foam expansion and polymerization

Polyurethane foams are used widely for encapsulation and structural purposes because they are inexpensive, straightforward to process, amenable to a wide range of density variations (1 lb/ft3 - 50 lb/ft3), and able to fill complex molds quickly and effectively. Computational model of the filling and curing process are needed to reduce defects such as voids, out-of-specification density, density gradients, foam decomposition from high temperatures due to exotherms, and incomplete filling. This paper details the development of a computational fluid dynamics model of a moderate density PMDI structural foam, PMDI-10. PMDI is an isocyanate-based polyurethane foam, which is chemically blown with water. The polyol reacts with isocyanate to produces the polymer. PMDI- 10 is catalyzed giving it a short pot life: it foams and polymerizes to a solid within 5 minutes during normal processing. To achieve a higher density, the foam is over-packed to twice or more of its free rise density of 10 lb/ft3. The goal for modeling is to represent the expansion, filling of molds, and the polymerization of the foam. This will be used to reduce defects, optimize the mold design, troubleshoot the processed, and predict the final foam properties. A homogenized continuum model foaming and curing was developed based on reaction kinetics, documented in a recent paper; it uses a simplified mathematical formalism that decouples these two reactions. The chemo-rheology of PMDI is measured experimentally and fit to a generalized- Newtonian viscosity model that is dependent on the extent of cure, gas fraction, and temperature. The conservation equations, including the equations of motion, an energy balance, and three rate equations are solved via a stabilized finite element method. The equations are combined with a level set method to determine the location of the foam-gas interface as it evolves to fill the mold. Understanding the thermal history and loads on the foam due to exothermicity and oven curing is very important to the results, since the kinetics, viscosity, and other material properties are all sensitive to temperature. Results from the model are compared to experimental flow visualization data and post-test X-ray computed tomography (CT) data for the density. Several geometries are investigated including two configurations of a mock structural part and a bar geometry to specifically test the density model. We have found that the model predicts both average density and filling profiles well. However, it under predicts density gradients, especially in the gravity direction. Further model improvements are also discussed for future work.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Flow Behavior of Particulate Pine Forest Residues and Corn Stover: A Comparison of Experiments and Simulations

Feeding and handling problems have been recognized as a major contributor to low production of renewable cellulosic ethanol in the US, which achieved only 7% of nameplate capacity in 2016. In this work we compare the flow behavior of pine forest residues and corn stover at various particle sizes and moisture contents in instrumented pilot-scale hopper tests and instrumented shear testers to continuum finite element method (FEM) and discrete element method (DEM) models. The shear testers include a Schulze ring shear tester, a custom large Peschl-style tester, and a modified Johanson direct shear tester. In addition to measurements of normal force and torque, the shear testers are also instrumented with arrays of pressure transducers. Modeling approaches include a Drucker-Prager model, a micropolar hypoelasticity model, and DEM simulations employing non-spherical, deformable particles. Results from physical experiments indicate that continuum elastoplastic models, such as Drucker-Prager models, do not account for the full complexity of biomass flow, and that more advanced rheological models are better able to predict nuances of the flow behavior, especially the compressive stress field.

09 BIOMASS FUELS↗
DOE OSTI2019

FEAA90: Physics-based Creep Simulation of Thick Section Welds in High Temperature and Pressure Applications

Welded microstructures of ?’-strengthened, nickel-based alloy, 740H, contain significant microstructural heterogeneities that can have a strong influence on the dislocation dynamics, resulting in very different creep behavior compared to the base metal. Crystal plasticity-based finite element method (CPFEM) has been widely used to incorporate the effect of microstructural heterogeneities on deformation at the polycrystalline scale and is being utilized in this work to model the creep behavior of 740H GTA welds. Current model development is focused on secondary creep considering dislocation climb, glide, and, anti-phase boundary shearing or Orowan looping. A dislocation-density based CPFEM model addressing these mechanisms is currently being implemented in the Multi-Physics Object Oriented Simulation Environment (MOOSE: mooseframework.org) software that provides the ability to solve problems involving multiple physics concurrently and implicitly. Short term creep tests at 700-800°C of cross weld and all-weld metal samples from GTA welds in Alloy 740 will be used to determine input parameters for the model. Long term creep tests at 750°C on Alloy 740H GTA welds will be used to validate the results of modeling and simulation. The model will also be applied to welds with microstructures that develop during hybrid laser arc welding (HLAW) of Alloy 740H to evaluate the effect of weld microstructure on of the validity of the model.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2019

Separate-Effects Validation Experiments for Models of Fracture in Ceramic Nuclear Fuel

A number of advances have recently been made in modeling fracture initiation and propagation in ceramic light water reactor (LWR) fuel. These include the use of techniques such as peridynamics, the extended finite element method (XFEM), the discrete element method (DEM), and phase field fracture. Improved predictions of fracture in LWR fuel can benefit fuel performance simulations in a number of ways, with important implications for radial relocation, pellet-cladding mechanical interactions, and fragmentation during accident conditions. Although these modeling approaches appear promising, to-date most of their applications have been to fresh fuel. A major limitation in applying these approaches with confidence to a wider variety of conditions, such as fragmentation of high-burnup fuel, is that there is very limited data that can be directly used to validate the results of these fracture models. While fracture patterns are available from cross-sections of numerous irradiated fuel rods, the fuel rods have typically been subjected to complex irradiation histories. To validate models of fracture propagation, focused experiments that give snapshots of the initiation and propagation of fracture under well characterized prototypical reactor conditions are needed. Under a multi-institutional U.S. Department of Energy Integrated Research Project (IRP), three separate-effects validation experiments are underway to provide information on the propagation of cracks in LWR fuel under controlled conditions. The primary challenge in developing such an experiment is in providing conditions that result in a radial temperature distribution that is prototypical of LWR in-reactor conditions. Two out-of-reactor experiments are being planned that employ very different approaches to achieve such a temperature distribution. The first of these achieves this by employing a combination of inductive and resistive electrical heating to generate volumetric heating. The second experiment involves slowly heating a pellet in a metal rod to a high temperature, and then quenching that rod in a cold bath. The quenching process generates a temperature profile approximating that in an LWR fuel rod for a moment, but has a very different temperature history from the LWR. Finally, an experiment is being planned for the Idaho National Laboratory TREAT reactor that will use nuclear fission as a heat source, and which will employ a metal heat sink to replicate the thermal conditions provided by coolant in an LWR. These experiments all have their advantages and drawbacks, with varying levels of ability to reproduce actual LWR conditions and varying ability to use instruments to monitor quantities of interest over the course of the experiment that can be used to validate fracture models. For that reason, these different experimental approaches are complimentary to each other, and the combined results are expected to significantly improve confidence in the ability of computational models to simulate fracture in ceramic nuclear fuel.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2020

Improvements to the Modeling of the TREAT Reactor and Experiments

This paper summarizes the latest improvements and lessons learned from the modeling and simulation of the transient test reactor at Idaho National Laboratory using the MAM- MOTH reactor physics application. MAMMOTH is a MOOSE-based, Finite Element Method application that specializes in the analysis of the spatial dynamics behavior of nuclear reactors. Since early 2018 several transient tests have been conducted at TREAT, thus providing the opportunity to apply and benchmark modern modeling and simulation tools. MAMMOTH was used to provide predictions of the power coupling factor between the core and the experiment for various experiments. Even though the power coupling factor predictions agree very well with the experimental data, within the bounds of the experimental uncertainty, one shortcoming was the underprediction of the total energy deposited in the core and in the experiment. Determination of the sources for this discrepancy are ongoing, but several key problems have been identified and resolved, thus providing valuable insights for future research. This paper discusses several of these lessons learned. First, the heat capacity data for the TREAT fuel has some significant problems due to limitations of the measurement techniques used circa 1960s. The sensitivity of the peak power and the total energy deposition to various representations of the heat capacity is approximately 5%. Second, the effects of the biological shield and thermal column on the modeling of the core are non-negligible, since they affect the mean generation time and the effective reflection of neutrons back into the core, which is suspected to be important during the core heat up. Matching the reactor period resolves the fact that the reduced spatial domain used in the MAMMOTH model underpredicts the mean generation time. The neutron reflection from these regions is marginally improved with the use of an albedo boundary condition. Third, modeling of the control rod movement with a multi-scheme method is introduced and its current limitations are exposed. Fourth, we explore the effects of using a homogenized model with Superhomogenization equivalence and how that differs from fully heterogeneous simulations. Finally, the energy condensation effects for this graphite core are significant. Solutions with 10 and 26 energy groups show the benefits of using a finer coarse group structure.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2021

An IIPG-Based Finite Element Framework in MOOSE for Modeling Fiber Reinforced Composite Failure Governed by Extrinsic Cohesive Laws

Many material and structure failures are initiated at the interface between two distinctive materials, such as the debonding of interfaces of matrix/fiber of composites or bulk matrix/inclusion in metals at micro-scales. Accurate and robust modeling of these interface failures is critical to the design of novel material and structure with improved functionality. This paper presents a robust implementation of a discontinuous Galerkin finite element method in MOOSE based on the Incomplete Interior Penalty Galerkin scheme for modeling material interface behavior. This DG-based interface method naturally accommodates important extrinsic cohesive zone material models and is capable of modeling the failures of material interfaces across which material properties are highly distinctive. We demonstrate a good performance of the proposed method using single fiber and multiple fiber debonding problems.

97 MATHEMATICS AND COMPUTING↗