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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 145 records · Page 8
All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

Enhanced MPM framework with multipatch isogeometric analysis for geotechnical applications

Achieving stable stress solutions at large strains using the Material Point Method (MPM) is challenging due to the accumulation of errors associated with geometry discretization, cell-crossing noise, and volumetric locking. Several simplified attempts exist in the literature to mitigate these errors, including higher-order frameworks. However, the stability of the MPM solution in such frameworks has been limited to simple geometries and the single-phase formulation (i.e., neglecting pore fluid). Although never explored, multipatch isogeometric analysis offers desirable qualities to simulate complex geometries while mitigating errors in the MPM. The degree of required high-order spatial integration has also never been investigated to infer a minimum limit for the stability of the stress solution in MPM. This paper presents a general-purpose numerical framework for simulating stable stresses in porous media, capturing both near incompressibility and multiphase interactions. First, the numerical framework is presented considering Non-Uniform Rational B-splines (NURBS) to perform isogeometric analysis (IGA) in MPM. Additionally, a volumetric strain smoothing algorithm is used to alleviate errors associated with volumetric locking. Second, the manifestation of cell-crossing errors is assessed via a series of problems with orders ranging from linear to cubic interpolation functions. Third, the use of NURBS is investigated and verified for problems with circular geometries. Finally, multipatch analysis is deployed to simulate plane strain and 3D penetration in soils, considering nearly incompressible elastoplastic (total stress) analysis and fully-coupled hydro-mechanical (effective stress) analysis. The stability of the solution is also analyzed for different constitutive models. From the results, it can be concluded that the framework using cubic interpolation functions with strain smoothing is the most convenient, presenting stable stress solutions for a broad range of multiphase geotechnical applications.

58 GEOSCIENCES↗
DOE OSTI2025

Local heat transfer measurement in a volumetrically heated TPMS lattice using distributed optical fiber thermal sensing

As additive manufacturing continues to reduce design constraints on heat exchange geometries, methods for high-fidelity local heat transfer measurements in nonconventional channel geometries are critical to their continued development. This study presents a novel method for measuring local heat transfer performance in volumetrically heated lattices using a distributed optical fiber temperature sensor. A diamond-type triply periodic minimal surface (TPMS) lattice, 3D-printed from a conductive polymer, was Joule heated while it was convectively cooled with air. Temperature measurements were taken at the solid–fluid interface across 14 internal locations using a single optical fiber over the Reynolds number range 800–2750. The TPMS lattice achieved up to 312% higher heat transfer coefficients compared to developing flow in a straight tube. A Nusselt number correlation was developed for the diamond TPMS, which showed good agreement with data collected for comparable geometries available in literature. In conclusion, this study presents a robust and new method for experimental measurement of the heat transfer coefficient in complex geometries and helps to understand and quantify the exceptional performance of TPMS heat transfer geometries.

TPMS↗
DOE OSTI2019

Tunable Porosity in Fused Filament 3D-Printed Blends of Intrinsically Porous Polymer and Thermoplastic Aliphatic Polyesters Polycaprolactone and Polylactic Acid

Future advances and usage of all-organic polymeric materials with permanent void spaces and high surface areas, in applications such as separations or as supports, depends heavily on the development of processing techniques to produce complex geometry objects. Here, the high free volume glassy microporous polymer PIM-1 was fabricated, as a major component in a polymer blend, into complex and customizable 3D objects by fused filament fabrication (FFF). PIM-1 was found to be compatible with polycaprolactone (PCL) and polylactic acid (PLA) and thus could be processed by extrusion into filaments with high loadings of PIM-1 (50% by mass). Ternary PCL/PLA/PIM-1 composite filaments provided an optimal balance of durability and melt flow characteristics for consistent FFF 3D printing of intricate structures. As printed, the micropores of PIM-1 were blocked and inaccessible to N2 during sorption experiments; however, the ternary composite structures displayed significant meso- and macroporosity and nanostructured phase separation. Postprinting immersion in 3-chloro-1-propanol was identified to selectively remove PCL within the composites, re-expose the characteristic micropores of PIM-1, and retain the macrostructure of the printed object. After postprinting treatments, specific surface areas by the Brunauer–Emmett–Teller method (as high as 460 m2 g–1) were found to directly correlate with the PCL content originally present. In conclusion, the extrusion-based processing methodology provides a new approach for production of intrinsically porous polymer objects in custom and complex shapes by reinforcement with thermoplastics (PCL and PLA).

36 MATERIALS SCIENCE↗
DOE OSTI2022

Hardware-Accelerated Ray Tracing of CAD-Based Geometry for Monte Carlo Radiation Transport

Monte Carlo radiation transport (MCRT) methods have been used to simulate radiation environments for many decades by tracking individual particles through a model to accumulate statistical information. MCRT geometry is historically formed using the constructive solid geometry (CSG). Recently, significant work has been performed to support simulations using computer-aided design (CAD)-based tessellated surfaces to support highly complex geometries. Ray tracing acceleration data structures from the rendering and visualization community are applied to accelerate particle tracking in CAD-based models. Despite these efforts, CSG representations provide the superior performance in surface intersection operations during particle flight. Concurrently, pseudo Monte Carlo methods have become prevalent in rendering applications to support more realistic models for scattering media, motivating innovations that are advantageous for MCRT simulations. Finally, the authors’ work extends these innovations by employing Intel’s Embree ray tracing kernel within a geometry toolkit for Monte Carlo to improve the simulation performance using CAD-based models by factors of 1.5 to 2.

42 ENGINEERING↗
DOE OSTI2025

Residual stress distribution in an additively manufactured complex structure by neutron diffraction measurement

Residual stress in an aerodynamically shaped Ni-based superalloy airfoil fabricated by laser powder bed fusion was measured by neutron diffraction. The experiment was conducted by considering the complex shape, implementing computer aided experiment planning, and automatic alignment at each rapid measurement. The 3-dimensional (3D) residual stress distribution in the airfoil is presented in this work, which lacks symmetry due to the complex geometry of the airfoil. In conclusion, the results provide theoretical thermal processing models a complete residual stress dataset of simulation validation on 3D shape complex structure.

Residual stress↗
DOE OSTI2023

Embedding thermocouples in SS316 with laser powder bed fusion

Recent advances in manufacturing technologies have enabled the fabrication of complex geometries for a wide range of applications, including the energy, aerospace, and civil sectors. The ability to integrate sensors at critical locations within these complex components during the manufacturing process could benefit process monitoring and control by reducing reliance on models to relate surface measurements to internal phenomena. This study investigated embedding thermocouples in a SS316 matrix using laser powder bed fusion. Under optimal processing conditions, embedded thermocouples were characterized post-building, finding good bonding to the matrix with no melt pool penetration to the sensing elements. Futher, the embedded thermocouple performed similarly to an identical non-embedded thermocouple during thermal testing to 500 °C with only a slight difference in response time, which was attributed to the differences in mass and the associated thermal time constants.

image analysis↗
DOE OSTI2020

Fourier Analysis-Based Evolutionary Multi-Objective Multiphysics Optimization of Liquid-Cooled Heat Sinks

Optimal heat dissipation in power modules can significantly increase their power density. Removing the generated heat is critical for capturing the benefits of advanced semiconductor materials and improving the reliability of the device operation. This article proposes a design optimization method for liquid-cooled heat sinks that use a Fourier analysis-based tool and an evolutionary optimization algorithm to optimize the heat sink geometry for specified objectives. The optimized heat sink geometry is then compared with state-of-the-art solutions in literature based on finite element analysis of different designs. The proposed methodology can develop complex geometries that outperform the conventional heat sink geometries.

Sahu, Raj↗
DOE OSTI2020

Example Evaluation of a Representative Heat Pipe Test Article Design for Structural Acceptability using ASME Design Rules

This report describes a design analysis of a test article mimicking a core block of a heat-pipe mi-croreactor using the ASME Boiler & Pressure Vessel Code Section III, Division 5, Subsection HB, Subpart B rules. These rules cover the design and construction of elevated temperature nu-clear reactor structural components, like the core block of a heat-pipe microreactor emulated by the test article. The purposes of the report are to: (1) provide a step-by-step example of applying the ASME rules to a reasonable core block geometry and corresponding loading conditions, (2) to provide design feedback on the test article, and (3) to evaluate the ASME rules for use in the design of complex heat-pipe microreactor components. The test article design has a relatively short ASME design life, limited by high thermal stresses. The current ASME rules are adequate for evaluating the core block component designs, though they could be optimized to increase the design efficiency and reduce the amount of designer/analyst time required to execute the design process. The report covers both the current, 2019 edition ASME rules and modified, currently unapproved, rules designed to improve the design process for components with complex geometries and high secondary stresses, like the core block test article.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2025

Modeling Electrodeposition in 3D Porous Architectures for Solid-State Li-Metal Batteries

Li-metal storage in three-dimensional (3D) electrodes is considered a potential dendrite-mitigation strategy. The large surface area and high porosity of these electrodes result in reduced local Li-plating current densities. The porous topology provides a scaffold for Li-deposition and stripping, maintaining both mechanical integrity and Li accessibility. The goal of this study is to understand how characteristics, such as geometry and material properties, affect the current distribution and deposition pattern. To this end, we developed a computational method to track material growth driven by electrodeposition within a complex geometry. This method ensures that the finite-element discretization remains conforming to the moving boundary while preserving an adequate mesh quality, and thus maintains solution accuracy. Using this new computational tool, we analyze the conditions under which porous anode architectures effectively expand the surface area of the charge-transfer interface, and self-regulate current density and dendrite growth.

3D electrode architectures↗
DOE OSTI2015

Laser size reduction of contaminated Magnox Pond skips - 15166

The Magnox Pond Program Team at Hinkley Point A Power Station have successfully demonstrated the use of an automated Computer Numeric Controlled (CNC) dry milling process to efficiently decontaminate radioactive pond skips that were once used to store and transport Magnox spent fuel assemblies between reactor sites and Sellafield for reprocessing. This decontamination process has ensured ILW skips meet metal melt recycling criteria, and even Out of Scope levels, while at the same time producing dry swarf that is easily disposed of as ILW. However, the dry milling method requires the skips to be size reduced to a very simple flat geometry to simplify the milling operation. Several size reduction techniques (mechanical and thermal) have been evaluated. Based on the advantages of remote handling, high cutting speed, flexibility with complex geometries, reduced secondary waste production and significantly reduced worker exposure, robotically operated fibre delivered laser cutting was chosen. This paper describes the development, installation and operation of an automated laser cutting system commissioned at Hinkley Point A to size reduce contaminated skips in to five flat sections. It was demonstrated that a complete skip can be remotely size reduced in less than 60 minutes. This successful demonstration, coupled with CNC milling, has the potential to save an estimated British Pounds 30 million across the Magnox sites alone, with much higher saving potentials for skips stored at Sellafield, enabling this new size reduction process to meet cost reduction objectives of the UK's Nuclear Decommissioning Authority. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2019

An Agile Design-to-Simulation Workflow Using a New Conforming Moving Least Squares Method

This report summarizes the accomplishments and challenges of a two year LDRD effort focused on improving design-to-simulation agility. The central bottleneck in most solid mechanics simulations is the process of taking CAD geometry and creating a discretization of suitable quality, i.e., the "meshing" effort. This report revisits meshfree methods and documents some key advancements that allow their use on problems with complex geometries, low quality meshes, nearly incompressible materials or that involve fracture. The resulting capability was demonstrated to be an effective part of an agile simulation process by enabling rapid discretization techniques without increasing the time to obtain a solution of a given accuracy. The first enhancement addressed boundary-related challenges associated with meshfree methods. When using point clouds and Euclidean metrics to construct approximation spaces, the boundary information is lost, which results in low accuracy solutions for non-convex geometries and mate rial interfaces. This also complicates the application of essential boundary conditions. The solution involved the development of conforming window functions which use graph and boundary information to directly incorporate boundaries into the approximation space.

42 ENGINEERING↗
DOE OSTI2022

Status of Additive Manufacturing Capabilities for Processing Refractory Alloys Under the Mo-99 Program

The enriched 100 Mo target, denoted as aMo, that Northstar Medical Radioisotopes is developing to produce 99 Mo from an accelerator-based method is a disk-type geometry with a 0.5–0.715 mm thickness and a 29 mm outer diameter. A press and sinter method was adopted to fabricate these samples from aMo powder feedstock. Inherent porosity from the press and sinter method makes the disks more easily dissolvable during 99 Mo postprocessing. However, the disk-type geometry will be subject to thermal stresses due to temperature variations once the geometry is in line with the accelerated electron beam, causing warping and possible failure. Additive manufacturing (AM) processes such as laser powder bed fusion (LPBF) enable the manufacturing of custom, complex geometries that may otherwise be difficult to produce with more conventional methods (e.g., press and sinter approach). Therefore, the National Nuclear Security Administration’s Molybdenum-99 Program invested in developing an AM facility dedicated to processing and printing refractory powders. This report details the LPBF process, how irregular refractory powder can be prepared for LPBF, and the equipment that is available to support the program.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Nb₃Sn Coating of Twin Axis Cavity for SRF Applications

The twin axis cavity with two identical accelerating beams has been proposed for energy recovery linac (ERL) applications. Nb₃Sn is a superconducting material with a higher critical temperature and a higher critical field as compared to Nb, which promises a lower operating cost due to higher quality factors. Two niobium twin axis cavities were fabricated at JLab and were proposed to be coated with Nb₃Sn. Due to their more complex geometry, the typical coating process used for basic elliptical cavi-ties needs to be improved to coat these cavities. This development advances the current coating system at JLab for coating complex cavities. Two twin axis cavities were coated recently for the first time. This contribution dis-cusses initial results from coating of twin axis cavities, RF testing and witness sample analysis with an overview of the current challenges towards high performance Nb₃Sn coated twin axis cavities.

43 PARTICLE ACCELERATORS↗
DOE OSTI2016

Numerical studies of nonlinear ultrasonic guided waves in uniform waveguides with arbitrary cross sections

Nonlinear guided waves have been investigated widely in simple geometries, such as plates, pipe and shells, where analytical solutions have been developed. This paper extends the application of nonlinear guided waves to waveguides with arbitrary cross sections. The criteria for the existence of nonlinear guided waves were summarized based on the finite deformation theory and nonlinear material properties. Numerical models were developed for the analysis of nonlinear guided waves in complex geometries, including nonlinear Semi-Analytical Finite Element (SAFE) method to identify internal resonant modes in complex waveguides, and Finite Element (FE) models to simulate the nonlinear wave propagation at resonant frequencies. Two examples, an aluminum plate and a steel rectangular bar, were studied using the proposed numerical model, demonstrating the existence of nonlinear guided waves in such structures and the energy transfer from primary to secondary modes.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2024

Performance Analysis of an Optimization Algorithm for Metamaterial Design on the Integrated High-Performance Computing and Quantum Systems

Optimizing metamaterials with complex geometries is a big challenge. Although an active learning algorithm, combining machine learning (ML), quantum computing, and optical simulation, has emerged as an efficient optimization tool, it still faces difficulties in optimizing complex structures that have potentially high performance. In this work, we comprehensively analyze the performance of an optimization algorithm for metamaterial design on the integrated HPC and quantum systems. We demonstrate significant time advantages through message-passing interface (MPI) parallelization on the high-performance computing (HPC) system showing approximately 54% faster ML tasks and 67 times faster optical simulation against serial workloads. Furthermore, we analyze the performance of a quantum algorithm designed for optimization, which runs with various quantum simulators on a local computer or HPC-quantum system. Results showcase ~24 times speedup when executing the optimization algorithm on the HPC-quantum hybrid system. This study paves a way to optimize complex metamaterials using the integrated HPC-quantum system.

Kim, Seongmin↗
DOE OSTI2018

Formulation and computation of dynamic, interface-compatible Whitney complexes in three dimensions

A discrete De Rham complex enables compatible, structure-preserving discretizations for a broad range of partial differential equations problems. Such discretizations can correctly reproduce the physics of interface problems, provided the grid conforms to the interface. However, large deformations, complex geometries, and evolving interfaces makes generation of such grids difficult. We develop and demonstrate two formally equivalent approaches that, for a given background mesh, dynamically construct an interface-conforming discrete De Rham complex. Both approaches start by dividing cut elements into interface-conforming subelements but differ in how they build the finite element basis on these subelements. The first approach discards the existing non-conforming basis of the parent element and replaces it by a dynamic set of degrees of freedom of the same kind. The second approach defines the interface-conforming degrees of freedom on the subelements as superpositions of the basis functions of the parent element. These approaches generalize the Conformal Decomposition Finite Element Method (CDFEM) and the extended finite element method with algebraic constraints (XFEM-AC), respectively, across the De Rham complex.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
DOE OSTI2024

Multi-Physics Topology Optimization for Dual Flow Heat Exchangers

Current heat exchanger (HX) designs are subjected to strict constraints pertaining to their manufacturability through conventional lengthy and expensive processes consisting of subtractive, forming and brazing processes. Therefore, existing HXs are typically restricted to the classical and rather simple geometries, such as plate-fin or shell-tube geometries, with lower efficiency and larger size. To increase HX efficiencies, novel designs are needed. Recent advances in topology optimization (TO) and additive manufacturing (AM) offer significant flexibility in design and fabrication of complex geometries, with potentially superior thermo-mechanical performance and high-power density. On the other hand, there is no commercially available software tool that addresses the combined coupling of structural, fluid dynamics, and thermal with multiple materials (hot and cold streams, solid, and void space) in TO of HXs. The goal of this project is to develop a multi-physics multi-phase TO approach to enhance the performance of HXs. The optimized design will be additively manufactured and tested in a physical environment to quantify its performance.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2024

Comments on the double cone wormhole

In this paper we revisit the double cone wormhole introduced by Saad, Shenker and Stanford (SSS), which was shown to reproduce the ramp in the spectral form factor. As a first approximation we can say that this solution computes Tr[e –iKT ], a trace of the “evolution” operator that generates Schwarzschild time translations on the two sided wormhole geometry. This point of view leads to a simple way to compute the normalization factor of the wormhole. When we have bulk matter fields, SSS suggested using a modified evolution K ~ which involves a slightly complex geometry, so that we are really computing Tr[e –iK ~ T ]. We argue that, for general black holes, the spectrum of K ~ is given by quasinormal mode frequencies. We explain that this reproduces various features that were previously predicted from the spectral form factor on hydrodynamics grounds. We also give a general algebraic construction of the modified boost in terms of operators constructed from half sided modular inclusions. For the special case of JT gravity, we work out the backreaction of matter on the geometry of the double cone and find that it deforms the geometry in an undesirable direction. We finally give some comments on the possible physical interpretation of K ~ .

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗