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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 1,441 records · Page 80
All sourcesNASA NTRSDOE OSTI
DOE OSTI2023

Grain Structure Evolution in Fe-6Si During Directed Energy Deposition

The purpose of this study is to explore the effect of additive manufacturing (AM) process variables on the grain structure of Fe-6Si, a soft-magnetic alloy used in electrical machine and grid applications. Samples were fabricated with laser engineered net shaping (LENS) with varying inter-pass timing and numbers of unidirectional passes. Here the results show that the grain structure was affected by both solidification and solid-state grain growth mechanisms. A model of the LENS process suggests that, although shorter inter-pass times encourage greater nucleation of new grains and therefore grain refinement during solidification, these conditions also help maintain high solid-state temperatures that allow for grain boundary motion to keep pace with the build rate. Grains formed under these conditions may span multiple layers, and the high-temperature gradient promotes directional growth. This new understanding of these microstructure evolution mechanisms will aid in using process conditions to control the competition between solidification and solid-state grain growth to create grain structures that may not be possible with conventional processing.

36 MATERIALS SCIENCE↗
DOE OSTI2016

Numerical modeling of heat-transfer and the influence of process parameters on tailoring the grain morphology of IN718 in electron beam additive manufacturing

The fabrication of 3-D parts from CAD models by additive manufacturing (AM) is a disruptive technology that is transforming the metal manufacturing industry. The correlation between solidification microstructure and mechanical properties has been well understood in the casting and welding processes over the years. This paper focuses on extending these principles to additive manufacturing to understand the transient phenomena of repeated melting and solidification during electron beam powder melting process to achieve site-specific microstructure control within a fabricated component. In this paper, we have developed a novel melt scan strategy for electron beam melting of nickel-base superalloy (Inconel 718) and also analyzed 3-D heat transfer conditions using a parallel numerical solidification code (Truchas) developed at Los Alamos National Laboratory. The spatial and temporal variations of temperature gradient (G) and growth velocity (R) at the liquid-solid interface of the melt pool were calculated as a function of electron beam parameters. By manipulating the relative number of voxels that lie in the columnar or equiaxed region, the crystallographic texture of the components can be controlled to an extent. The analysis of the parameters provided optimum processing conditions that will result in columnar to equiaxed transition (CET) during the solidification. Furthermore, the results from the numerical simulations were validated by experimental processing and characterization thereby proving the potential of additive manufacturing process to achieve site-specific crystallographic texture control within a fabricated component.

43 PARTICLE ACCELERATORS↗
DOE OSTI2016

Grain growth competition during thin-sample directional solidification of dendritic microstructures: A phase-field study

Here we present the results of a comprehensive phase-field study of columnar grain growth competition in bi-crystalline samples in two dimensions (2D) and in three dimensions (3D) for small sample thicknesses allowing a single row of dendrites to form. We focus on the selection of grain boundary (GB) orientation during directional solidification in the steady-state dendritic regime, and study its dependence upon the orientation of two competing grains. In 2D, we map the entire orientation range for both grains, performing several simulations for each configuration to account for the stochasticity of GB orientation selection and to assess the average GB behavior. We find that GB orientation selection depends strongly on whether the primary dendrite growth directions have lateral components (i.e. components perpendicular to the axis of the temperature gradient) that point in the same or opposite directions in the two grains. Here, we identify a range of grain orientations in which grain selection follows the classical description of Walton and Chalmers. We also identify conditions that favor unusual overgrowth of favorably-oriented dendrites at a converging GB. We propose a simple analytical description that reproduces the average GB orientation selection from 2D simulations within statistical fluctuations of a few degrees. In 3D, we find a similar GB orientation selection as in 2D when secondary branches grow in planes parallel and perpendicular to the sample walls. Remarkably, quasi-2D behavior is also observed even when those perpendicular sidebranching planes are rotated by a finite azimuthal angle about the primary dendrite growth axis as long as the absolute values of those azimuthal angles are equal in both grains. In contrast, when the absolute values of those azimuthal angles differ markedly, we find that unusual overgrowth events at a converging GB are promoted by a high azimuthal angle in the least-favorably-oriented grain. We also find that diverging GBs can be strongly affected by those azimuthal angles, while converging GBs exhibit a weak dependence on those angles. Finally, for diverging GBs, GB orientation is also strongly affected by the relative signs of the lateral components of the primary dendrite growth directions in both grains.

36 MATERIALS SCIENCE↗
DOE OSTI2017

Building blocks for a digital twin of additive manufacturing

Properties and serviceability of additively manufactured components are affected by their geometry, microstructure and defects. These important attributes are now optimized by trial and error because the essential process variables cannot currently be selected from scientific principles. A recourse is to build and rigorously validate a digital twin of the additive manufacturing process that can provide accurate predictions of the spatial and temporal variations of metallurgical parameters that affect the structure and properties of components. Key building blocks of a computationally efficient first-generation digital twin of laser-based directed energy deposition additive manufacturing utilize a transient, three-dimensional model that calculates temperature and velocity fields, cooling rates, solidification parameters and deposit geometry. The measured profiles of stainless steel 316L and Alloy 800H deposits as well as the secondary dendrite arm spacing (SDAS) and Vickers hardness measurements are used to validate the proposed digital twin. The predicted cooling rates, temperature gradients, solidification rates, SDAS and micro-hardness values are shown to be more accurate than those obtained from a commonly used heat conduction calculation. Finally, these metallurgical building blocks serve as a phenomenological framework for the development of a digital twin that will make the expanding knowledge base of additive manufacturing usable in a practical way for all scientists and engineers.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Multiscale investigation of thermomechanical and compositional developments in Ni alloy 718 under laser processing

Laser processing has been widely employed in various applications due to its exceptional spatial resolution. However, the rapid temperature gradients generated in localized areas present significant challenges for experimental characterization using conventional instruments. To characterize Ni alloy 718 during laser processing, we employed in-situ synchrotron X-ray diffraction with a high-speed detector, a method particularly well-suited for probing processes with high temporal and spatial resolution. Through a series of in-situ experiments, we investigated the local variations in the evolution of microstructures and thermomechanical behaviors within a keyhole mode melt pool. The in situ macroscopic thermomechanical behaviors were quantified using an empirical model derived from diffraction patterns, with experimental results showing reasonable agreement with finite element analysis. Various laser parameters were tested to assess their influences on the residual strains in the melt pools. The results revealed that the residual strain in the keyhole mode melt pool is relatively insensitive to variations in the parameters and is smaller than that in the melt pool created under conduction mode laser scanning. Additionally, we analyzed the shapes of individual diffraction spots, providing insights into the plastic behaviors and compositional developments in the resolidified alloy. The analysis confirmed that compositional variations in a dendritic microstructure manifest as asymmetric broadening of the diffraction spots.

Ni alloy 718↗
DOE OSTI2020

Multi-scale microstructural investigation of a laser 3D printed Ni-based superalloy

The heterogeneous microstructure of a laser 3D printed Ni-based superalloy was examined at multiple length scales. The sub-millimeter-sized columnar crystal grains are composed of micron-sized cellular colonies. The crystal grains grow in epitaxy with the substrate under the large temperature gradient and high cooling rate. The cell boundaries, decorated with γ/γ' eutectics, μ-phase precipitates and high density of dislocations, show enrichment of γ' forming elements and low-angle misorientations. Dislocations trapped in the intra-cellular regions are characterized as statistically stored dislocations with no detectable contribution to lattice curvature, and are the results of the interaction between dislocations and γ' precipitates.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Hydro-mechanical behavior of heated bentonite buffer for geologic disposal of high-level radioactive waste: A bench-scale X-ray computed tomography investigation

The behavior of heated bentonite buffer is critical for the security and long-term performance of a geological repository for high-level radioactive waste (HLW). While laboratory column experiments have been conducted to investigate compacted bentonite and coupled THMC (thermal-hydro-mechanical and chemical) processes for a moderate temperature range of up to 100 °C, data for a higher temperature range are limited. Understanding bentonite behavior and coupled THMC processes under higher temperatures (e.g., up to 200 °C) could allow for a more economic repository design and would expand the data and knowledge base for more reliable modeling. In this study, a bench-scale experiment was conducted in a compacted bentonite column experiencing both heating up to 200 °C in the center and hydration from a sand-clay boundary surrounding the column. During the experiment run for 1.5 years, frequent X-ray computed tomography (CT) scanning of bentonite provided insights into the spatiotemporal evolution of (1) hydration/dehydration, (2) clay swelling/shrinkage, (3) displacement, and (4) mineral precipitation. After the experiment, a comprehensive post-dismantling characterization of bentonite samples was conducted. Results showed that the bentonite hydration was axi-symmetrical despite the initial heterogeneity due to packing, confirming the ability of bentonite to seal fast flow/transport paths. Further, compared to a non-heated control experiment, the heated column showed greater CT density variations along the radial distance, indicating that homogenization of bentonite might be more difficult if a temperature gradient is maintained in the repository. Precipitation of an anhydrite layer occurred in the inner hot zone, pointing to potential concerns about salt precipitation causing canister corrosion. Ultimately, the experiments provided a high-resolution window into the strongly dynamic and coupled behavior of bentonite exposed to heating, hydration and swelling, which will be valuable for improving modeling of coupled processes, especially for the early state of a HLW repository.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2015

Numerical investigation of spontaneous flame propagation under RCCI conditions

This paper presents results from one and two-dimensional direct numerical simulations under Reactivity Controlled Compression Ignition (RCCI) conditions of a primary reference fuel (PRF) mixture consisting of n-heptane and iso-octane. RCCI uses in-cylinder blending of two fuels with different autoignition characteristics to control combustion phasing and the rate of heat release. These simulations employ an improved model of compression heating through mass source/sink terms developed in a previous work by Bhagatwala et al. (2014), which incorporates feedback from the flow to follow a predetermined experimental pressure trace. Two-dimensional simulations explored parametric variations with respect to temperature stratification, pressure profiles and n-heptane concentration. Furthermore, statistics derived from analysis of diffusion/reaction balances locally normal to the flame surface were used to elucidate combustion characteristics for the different cases. Both deflagration and spontaneous ignition fronts were observed to co-exist, however it was found that higher n-heptane concentration provided a greater degree of flame propagation, whereas lower n-heptane concentration (higher fraction of iso-octane) resulted in more spontaneous ignition fronts. A significant finding was that simulations initialized with a uniform initial temperature and a stratified n-heptane concentration field, resulted in a large fraction of combustion occurring through flame propagation. The proportion of spontaneous ignition fronts increased at higher pressures due to shorter ignition delay when other factors were held constant. For the same pressure and fuel concentration, the contribution of flame propagation to the overall combustion was found to depend on the level of thermal stratification, with higher initial temperature gradients resulting in more deflagration and lower gradients generating more ignition fronts. Statistics of ignition delay are computed to assess the Zel’dovich (1980) theory for the mode of combustion propagation based on ignition delay gradients.

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

5 kHz thermometry in a swirl-stabilized gas turbine model combustor using chirped probe pulse femtosecond CARS. Part 2. Analysis of swirl flame dynamics

We have performed a detailed analysis of the temperature field in a turbulent swirl flame operating with a self-excited thermo-acoustic instability. The temperature field was measured using 5 kHz chirped-probe-pulse (CPP) femtosecond (fs) coherent anti-Stokes Raman scattering (CARS). The measurements are described in detail in the part 1 companion article. In this paper, part 2, a detailed analysis of the time-resolved temperature measurements and simultaneous pressure measurements is performed to provide insight into the dynamics and structure of the swirl-stabilized flame. Here this work is the first to capture the dynamics of the flame, flow, and coupled flow-flame processes using high-fidelity, spatially- and temporally-resolved thermometry in a flame of practical relevance. The time-averaged contour plot of the temperature field indicates that the flame is very flat and stabilizes approximately 10 mm downstream of the burner face. In this region, there are very significant temperature fluctuations indicating a very high level of unsteadiness. The temperature probability distribution functions (PDFs) are clearly bimodal in this region near the injector face. A Fourier analysis of the temperature time series revealed multiple coherent oscillatory modes. The strongest oscillation was found to be coherent and in-phase with an acoustic resonance at 314 Hz, as expected from the Rayleigh criteria for the unstable flame. An analysis of the phase-conditioned average temperature fields clearly shows an axial pumping of low-temperature reactants, which are consumed after a convective delay and result in a spike in the global heat-release rate. Continued analysis also revealed a 438 Hz oscillation that was found to correspond with the dynamics of convective transport by a helical precessing vortex core (PVC). The structure of the PVC, and its interaction with the flame, were studied based on the presence of this characteristic frequency in the power spectral densities computed throughout the flow. The precision and time-resolution of the CPP fsCARS measurements was also sufficient to enable computation of the integral time-scales as well as the PDFs of the temporal temperature gradients. A sample of state space trajectories were used to provide insight into the nature of coupling between the narrowband acoustic resonance and the broadband spectrum of turbulent flame processes.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2020

Multidimensional simulations of Mckenna-driven flow tube configuration: Investigating non-ideality in NO x formation flow tube experiments

Multidimensional simulations have been conducted to simulate atmospheric pressure, flat-flame/McKenna-burner-driven-flow tube experiments targeted to obtain NO x speciation data for predicting/analyzing syngas combustion emissions. In a prior work, we demonstrated the impacts of multidimensional transport on post flame region prediction departures from those assuming unidimensional flow/transport conditions. In this work, we develop and utilize a multidimensional laminar reacting flow solver to simulate the fully coupled flame and post flame regions to further elucidate the impacts of the earlier unidimensional modeling assumptions on interpreting post flame NO x experimental data. The model is used to simulate a lean, premixed syngas/air flame and its associated post flame regions within a cylindrical flow-tube-like arrangement. The combustion process takes place under atmospheric condition with trace amount of NO x seeding fed into the inlet gas stream. The spatial evolution of NO x species (NO and NO 2 ) in the flame and in the post-combustion zone suggests two distinct regions: 1) a region encompassing the flame structure itself; and 2) a post flame region in which the temperature decays due to both axial and radial transport processes. The predictions show that for the conditions studied, a pulsatile flow field exists due to the formation of an expanding and contracting recirculation zone in the outer periphery of the flow tube. By resolving the nature of the flow, the resulting time-averaged temperature and species concentrations show improved agreement with existing experimental measurements. The flow-field interaction results in radial inhomogeneities in the NO 2 profiles with the maximum concentration offset from the flow centerline. The location of the peak in NO 2 is coupled with radial temperature gradients from wall cooling effects and their significant influence on NO/NO 2 interconversion kinetics, producing notable NO 2 accumulation in regions near the wall. Geometrical configurations capable of suppressing/minimizing the pulsatile nature are also investigated and the results are compared. Other experimental configurations could be considered in parametric simulations to determine the optimal configuration that would minimize non-idealities in the observations. The work shows the value in performing such computations in advance of settling on a particular design for flow tube/flow reactor experiments.

42 ENGINEERING↗
DOE OSTI2024

Large eddy simulation of lean blow-off in swirl-stabilized flame with the subgrid dissipation concept

The lean blow-off mechanism of the premixed swirl flame is numerically investigated by large eddy simulation (LES) with the subgrid dissipation concept (SDC) combustion model. Three simulated cases cover stable, near blow-off, and transient conditions. Compared with the experiment, the LES-SDC approach captures the flow and combustion features for stable and near blow-off conditions. More importantly, the predictions of the blowoff procedure and duration agree satisfactorily with the experiment, indicating that the LES-SDC approach is a promising tool for predicting strong, unsteady turbulent combustion processes. Further, the numerical results are used to investigate the blow-off mechanism. Two stages in the blow-off procedure are specified. The first is the necking and extinction of the downstream flame surface, and the second is the shrinking of the upstream flame surface. The blow-off mechanism is well explained by the theory of stretched flame extinction. At the end of the recirculation zone, the large negative radial velocity pushes the flame to the central line. The combustion process here can be abstracted as the stretched counter-flame of the reactant-reactant configuration. The excessive flame stretch dominates the flame extinction and triggers the blow-off event. The upstream flame resists the intense stretch with the help of hot product recirculation, and the combustion here can be idealized as the counter-flame of the reactant-product configuration. The alignment of the temperature gradient and flow velocity, together with the excessive stretch, clearly indicates the tendency of flame local extinction. A Damköhler number-based blow-off criterion is raised from the mean flow strain rate and laminar flame bulk extinction strain rate.

42 ENGINEERING↗
DOE OSTI2022

Qualitative and quantitative analysis of neutron irradiation effects in SiC/SiC composites using X-ray computed tomography

Silicon carbide fiber-reinforced silicon carbide matrix (SiC/SiC) composites are candidate materials for cladding of light water reactor (LWR) fuels. Loss of fission product gas retention due to the formation of microcrack networks is considered a potential failure mechanism for SiC/SiC-cladded fuels. In this work, a variety of SiC/SiC composite tubes were irradiated with and without an LWR-relevant radial heat flux in the High Flux Isotope Reactor, followed by detailed characterization with X-ray computed tomography (XCT). This first set of XCT data for neutron-irradiated samples confirmed that the internal stresses arising from a combination of temperature gradients and irradiation-induced swelling act as the primary driver for cracking. Consequently, while the observed cracking patterns varied depending on the tube architectures, the sharp edges of relatively large pores were found to be the common stress concentrator. These findings are useful to help improve the design and manufacturing of SiC/SiC fuel claddings for reduced failure probability.

42 ENGINEERING↗
DOE OSTI2022

Machine learning in nuclear materials research

Nuclear materials are often demanded to function for extended time in extreme environments, including high radiation fluxes with associated transmutations, high temperature and temperature gradients, mechanical stresses, and corrosive coolants. They also have a wide range of microstructural and chemical makeups, resulting in multifaceted and often out-of-equilibrium interactions. Machine learning (ML) is increasingly being used to tackle these complex time-dependent interactions and aid researchers in developing models and making predictions, sometimes with better accuracy than traditional modeling that focuses on one or two parameters at a time. Conventional practices of acquiring new experimental data in nuclear materials research are often slow and expensive, limiting the opportunity for data-centric ML, but new methods are changing that paradigm. Here we review high-throughput computational and experimental data approaches, especially robotic experimentation and active learning that is based on Gaussian process and Bayesian optimization. We show ML examples in structural materials (e.g., reactor pressure vessel (RPV) alloys and radiation detecting scintillating materials) and highlight new techniques of high-throughput sample preparation and characterizations, and automated radiation/environmental exposures and real-time online diagnostics. Herein, this review suggests that ML models of material constitutive relations in plasticity, damage, and even electronic and optical responses to radiation are likely to become powerful tools as they develop. Finally, we speculate on how the recent trends of using natural language processing (NLP) to aid the collection and analysis of literature data, interpretable artificial intelligence (AI), and the use of streamlined scripting, database, workflow management, and cloud computing platforms that will soon make the utilization of ML techniques as commonplace as the spreadsheet curve-fitting practices of today.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Re-splitting δ f method for electro-magnetic gyrokinetic particle-in-cell (PIC) simulation of tokamak plasmas

A new method based on a re-splitting δ f technique is proposed to mitigate the cancellation problem in electro-magnetic gyrokinetic PIC simulation. This new scheme, together with the pull-back mitigation (PBM) scheme (Mishchenko et al., 2014), have recently been implemented in the GEM code (Chen et al., 2003). These two algorithms are systematically compared with the original GEM algorithm for the simulation of the ion temperature gradient (ITG) mode, the kinetic ballooning mode (KBM), the toroidal Alfvén eigenmode (TAE) and the energetic particle mode (EPM). The three algorithms agree well for all of these modes. Moreover, both the re-splitting method and PBM can mitigate the cancellation problem and improve the computational efficiency.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2019

Orb5: A global electromagnetic gyrokinetic code using the PIC approach in toroidal geometry

This paper presents the current state of the global gyrokinetic code Orb5 as an update of the previous reference [Jolliet et al., Comp. Phys. Commun. 177 409 (2007)]. The Orb5 code solves the electromagnetic VlasovMaxwell system of equations using a PIC scheme and also includes collisions and strong flows. The code assumes multiple gyrokinetic ion species at all wavelengths for the polarization density and drift-kinetic electrons. Variants of the physical model can be selected for electrons such as assuming an adiabatic response or a “hybrid” model in which passing electrons are assumed adiabatic and trapped electrons are drift-kinetic. A Fourier filter as well as various control variates and noise reduction techniques enable simulations with good signal-to-noise ratios at a limited numerical cost. They are completed with different momentum and zonal flow-conserving heat sources allowing for temperature-gradient and flux-driven simulations. The code, which runs on both CPUs and GPUs, is well benchmarked against other similar codes and analytical predictions, and shows good scalability up to thousands of nodes.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
DOE OSTI2019

Stability of Fe-bearing hydrous phases and element partitioning in the system MgO–Al 2 O 3 –Fe 2 O 3 –SiO 2 –H 2 O in Earth’s lowermost mantle

We performed high pressure–temperature ( P-T ) experiments on a model composition of hydrous subducted slabs in the MgO–Al 2 O 3 –Fe 2 O 3 –SiO 2 –H 2 O system using laser-heated diamond anvil cells. The phase assemblages were characterized combining in-situ synchrotron X-ray diffraction and ex-situ transmission electron microscope techniques. The hydrous δ-phase AlOOH–FeOOH–MgSiO 2 (OH) 2 –SiO 2 coexists with bridgmanite (Bdg), post-perovskite (pPv), or both in a broad P-T range of 104–126 GPa and 1750–2500 K. The hydrous pyrite-type FeOOHx phase was observed in-situ over a P-T range of 112–123 GPa and 1750–2300 K, coexisting with the pPv phase. Chemical analysis on recovered samples showed that considerable amount of Fe 2 O 2 (OH) 2 (8–13 mol%) and SiO 2 (9–13 mol%) in the δ-phase does not reduce its thermal stability compared to the Al-endmember, indicating that the Fe-bearing δ-phase can transport water to the lowermost mantle along the mantle geotherm. In this hydrous system, we observed that Al depletion in both the Bdg and pPv phases can significantly reduce the width of the Bdg to pPv transition in contrast to a wide two-phase coexistence region in a dry Al-rich system. Meanwhile, the Fe enrichment in the pPv phase relative to the coexisting Bdg phase lowers the transition pressure to the depth of the D" discontinuity. Accordingly, the depth and thickness of the Bdg to pPv transition in subducted basaltic crustal materials can explain the seismically detected D" discontinuity. Partial melting could be triggered by dehydration of the Fe-bearing hydrous phases due to a steep temperature gradient at the core mantle boundary (CMB), and therefore the ultralow-velocity zones (ULVZs) might be the regions where partial melting occurs at the lowermost mantle.

58 GEOSCIENCES↗
DOE OSTI2018

Accurate and inexpensive thermal time-of-flight sensor for measuring refrigerant flow in minichannels

Thermal flow meters are good candidates for measuring flow rates in small diameter channels because they can be integrated into compact geometries and consist of only a few simple components. A new thermal time-of-flight (TOF) flow sensor is developed in this report for measuring liquid refrigerant velocities in minichannels. The sensor consists of a small heater and two downstream thermocouples. The heater is pulsed to induce a temperature rise in the fluid, and the time for the temperature pulse to reach the downstream thermocouples is measured. Insights from the data and a simplified one-dimensional transient model are used to calibrate the device. The calibration relates the time of flight to both the average refrigerant velocity and local temperature gradients in the fluid. The calibrated TOF device can detect refrigerant velocities between 1 and 20, mm s -1 , measuring 98.7% of the data to within ±3% of the full scale (±0.6 mm s -1 ).

42 ENGINEERING↗