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Mechanisms by which heat release affects the flow field in a chemically reacting, turbulent mixing layer
The mechanisms by which heat release affects the fluid dynamics in a turbulent reacting mixing layer are studied by direct numerical simulation. In agreement with previous laboratory experiments, the heat release is observed to lower the rate at which the mixing layer grows and to reduce the rate at which chemical products are formed. The baroclinic torque and thermal expansion in the mixing layer are shown to produce changes in the flame vortex structure that act to produce more diffuse vortices than in the constant density case, resulting in lower rotation rates of fluid elements. Previously unexplained anomalies observed in the mean velocity profiles of reacting jets and mixing layers are shown to result from vorticity generation by baroclinic torques. The density reductions also lower the generation rates of turbulent kinetic energy and the turbulent shear stresses, resulting in less turbulent mixing of fluid elements. Calculations of the energy in the various wave numbers show that the heat release has a stabilizing effect on the growth rates of individual modes. A linear stability analysis of a simlified model problem confirms this, showing that low density fluid in the mixing region will result in a shift of the frequency of the unstable modes to lower wave numbers (longer wavelengths). The growth rates of the unstable modes decrease, contributing to the slower growth of the mixing layer.
Finite Element Analysis of Poroelastic Composites Undergoing Thermal and Gas Diffusion
A theory for time-dependent thermal and gas diffusion in mechanically time-rate-independent anisotropic poroelastic composites has been developed. This theory advances previous work by the latter two authors by providing for critical transverse shear through a three-dimensional axisymmetric formulation and using it in a new hypothesis for determining the Biot fluid pressure-solid stress coupling factor. The derived governing equations couple material deformation with temperature and internal pore pressure and more strongly couple gas diffusion and heat transfer than the previous theory. Hence the theory accounts for the interactions between conductive heat transfer in the porous body and convective heat carried by the mass flux through the pores. The Bubnov Galerkin finite element method is applied to the governing equations to transform them into a semidiscrete finite element system. A numerical procedure is developed to solve the coupled equations in the space and time domains. The method is used to simulate two high temperature tests involving thermal-chemical decomposition of carbon-phenolic composites. In comparison with measured data, the results are accurate. Moreover unlike previous work, for a single set of poroelastic parameters, they are consistent with two measurements in a restrained thermal growth test.
Effect of annealing on the laser induced damage of polished and CO{sub 2} laser-processed fused silica surfaces
We investigate the effect of different heat treatments on the laser-induced damage probabilities of fused silica samples. Isothermal annealing in a furnace is applied, with different temperatures in the range 700–1100 °C and 12 h annealing time, to super-polished fused silica samples. The surface flatness and laser damage probabilities at 3 ns, 351 nm are measured before and after the different annealing procedures. We have found a significant improvement of the initial laser damage probabilities of the silica surface after annealing at 1050 °C for 12 h. A similar study has been conducted on CO{sub 2} laser-processed sites on the surface of the samples. Before and after annealing, we have studied the morphology of the sites, the evolution of residual stress, and the laser-induced damage threshold measured at 351 nm, 3 ns. In this case, we observe that the laser damage resistance of the laser created craters can reach the damage level of the bare fused silica surface after the annealing process, with a complete stress relieve. The obtained results are then compared to the case of local annealing process by CO{sub 2} laser irradiation during 1 s, and we found similar improvements in both cases. The different results obtained in the study are compared to numerical simulations made with a thermo-mechanical model based on finite-element method that allows the simulation of the isothermal or the local annealing process, the evolution of stress and fictive temperature. The simulation results were found to be very consistent with experimental observations for the stresses evolution after annealing and estimation of the heat affected area during laser-processing based on the density dependence with fictive temperature. Following this work, the temperature for local annealing should reach 1330–1470 °C for an optimized reduction of damage probability and be below the threshold for material removal, whereas furnace annealing should be kept below the annealing point to avoid sample deformation.
On the microstructure characterization of the AA2098-T351 alloy welded by FSW
Highlights: • The microstructural characterization of the AA2098-T351 Al-Cu-Li alloy welded by FSW was carried out. • There was strong correlation between the results of the various techniques. • DSC was an effective technique for characterization of GP zones complementing the microstructural characterization by TEM. - Abstract: The complex structure of the AA2098-T351 alloy welded by friction stir welding (FSW) was investigated by transmission electron microscopy (TEM), differential scanning calorimetry (DSC) and microhardness measurements. Thermal modelling process of the FSW process was carried out by soldering thermocouples at distances of 6, 9 and 12 mm from the weld centerline, and thermocouple measurements were used as input data into the model. Finite element software COMSOL v5.2 was used for data analysis. The prevailing phases in the base metal (BM) are T1 (Al{sub 2}CuLi) θ′ (Al{sub 2}Cu), δ′/β′(Al{sub 3}(Li,Zr)) and Ω (Al{sub 2}Cu). In the heat affected zone (HAZ), either in the retreating or advancing sides, θ′ phase was not identified. In the thermomechanical affected zone (TMAZ), T1, δ′/β′, GP zones phase were detected in the retreating side, whereas T1 and Guinier-Preston (GP) zones were not observed in the advancing side. This result supports the asymmetric behavior observed in the microhardness profile of the weld. In the stir zone (SZ), GP zones, T1, δ′/β′ (Al{sub 3}(Li,Zr)) and Ω were identified.
A Forward Time Stepping Heat Conduction Model for Spot Melt Additive Manufacturing
Solidification dynamics are crucial for determining microstructure development in additively manufactured parts. Multiphysics models based on finite element or finite volume methods may help gain insight for complicated phenomena such as fluid flow, keyholing, and porosity but are too computationally expensive to use for simulating actual builds. Recent analytic and semi-analytic solutions for moving heat sources in a semi-infinite three-dimensional space provide a way to accurately estimate the solidification conditions for entire builds. The downside to these methods is that, unlike finite element or finite volume methods, they cannot use the temperature distribution of the previous timesteps to march the solution forward in time. This paper provides the mathematical formulation and implementation of a forward time stepping (FTS) approach to an existing semi-analytic solution. The speed and accuracy of the two methods are then compared for various scan patterns. The result is that, for spot melts, the forward time-stepping model provides improvements in both speed and accuracy. This is especially true for longer simulations, where the simulation can be orders of magnitude faster. Finally, the longest simulation analyzed in this paper was roughly 30× faster when using the forward time-stepping model versus the straightforward implementation of the semi-analytic solution.
An HPC-Based Hydrothermal Finite Element Simulator for Modeling Underground Geothermal Behavior with Example Simulations on The Treasure Island and UC Berkeley Campus
This submission contains the source code of the Hydrothermal Finite Element Simulator used for the Treasure Island and UC Berkeley campus geothermal simulation. It contains a report that summarizes the development and validation of this Hydrothermal Finite Element Simulator, with a case study on Treasure Island site. It also contains a report that investigates the feasibility of upgrading the existing campus energy delivery system at UC Berkeley to a fifth-generation district heating and cooling system that includes geothermal heat/cold storage.
NASTRAN variance analysis and plotting of HBDY elements
The NASTRAN Thermal Analyzer has been intended to do variance analysis and plot the thermal boundary elements. The objective of the variance analysis addition is to assess the sensitivity of temperature variances resulting from uncertainties inherent in input parameters for heat conduction analysis. The plotting capability provides the ability to check the geometry (location, size and orientation) of the boundary elements of a model in relation to the conduction elements. Variance analysis is the study of uncertainties of the computed results as a function of uncertainties of the input data. To study this problem using NASTRAN, a solution is made for both the expected values of all inputs, plus another solution for each uncertain variable. A variance analysis module subtracts the results to form derivatives, and then can determine the expected deviations of output quantities.
Laser Patterning Assisted Devitrification and Domain Engineering of Amorphous and Nanocrystalline Alloys
We have investigated laser-patterning and devitrification as a novel method to realize emergent properties in modified regions at the ribbon surface consisting of periodic localized laser spots thermally treated under rapid heating and cooling conditions. Fe-based amorphous ribbons were annealed for systematically varied laser power. Extremely high heating and cooling rates on the order of 10(exp 8)-10(exp 10)K/s have been estimated by finite element analysis simulations. Observations suggest surface melting followed by rapid solidification fast enough to quench and form an amorphous structure upon cooling. Diffusion of heat occurs from the laser irradiated surface region so that a finite volume of material surrounding this region rises in temperature above the crystallization temperature relevant for conventional isothermal annealing experiments. The underlying mechanism of laser annealing and consequences of heat transients involved are discussed in terms of impacts upon micro/nanostructure, residual stresses, and magnetic domain structure surrounding the laser irradiated region. The study illustrates the potential to exploit spatially optimized phase transformations in a scalable manufacturing process of amorphous and nanocrystalline alloys to locally access otherwise inaccessible extreme heating and cooling rates.
Regolith Derived Heat Shield for Planetary Body Entry and Descent System with In Situ Fabrication
This NIAC project investigated an innovative approach to provide heat shield protection to spacecraft after launch and prior to each EDL thus potentially realizing significant launch mass savings. Heat shields fabricated in situ can provide a thermal-protection system for spacecraft that routinely enter a planetary atmosphere. By fabricating the heat shield with space resources from materials available on moons and asteroids, it is possible to avoid launching the heat-shield mass from Earth. Regolith has extremely good insulating properties and the silicates it contains can be used in the fabrication and molding of thermal-protection materials. Such in situ developed heat shields have been suggested before by Lewis. Prior research efforts have shown that regolith properties can be compatible with very-high temperature resistance. Our project team is highly experienced in regolith processing and thermal protection systems (TPS). Routine access to space and return from any planetary surface requires dealing with heat loads experienced by the spacecraft during reentry. Our team addresses some of the key issues with the EDL of human-scale missions through a highly innovative investigation of heat shields that can be fabricated in space by using local resources on asteroids and moons. Most space missions are one-way trips, dedicated to placing an asset in space for economical or scientific gain. However, for human missions, a very-reliable heat-shield system is necessary to protect the crew from the intense heat experienced at very high entry velocities of approximately 11 km/s at approximately Mach 33 (Apollo). For a human mission to Mars, the return problem is even more difficult, with predicted velocities of up to 14 km/s, at approximately Mach 42 at the Earth-atmosphere entry. In addition to human return, it is very likely that future space-travel architecture will include returning cargo to the Earth, either for scientific purposes or for commercial reasons. Platinum, titanium, helium 3, and other metals, elements and minerals are all high-value commodities in limited supply on Earth, and it may be profitable to mine these substances throughout the Solar System and return them to Earth, if an economical method can be found. To date, several private corporations have been launched to pursue these goals. Because the heat shield is the last element to be used in an Earth-return mission, a high penalty is paid in the propellant mass required to carry the heat shield to the destination and back. If the heat shield could be manufactured in space, and then outfitted on the spacecraft prior to the reentry at Earth, then significant propellant and mass savings could be achieved during launch and space operations. Preliminary mission architecture scenarios are described, which explain the potential benefits that may be derived from using an in-situ fabricated regolith heat shield. In order to prove that this is a feasible technology concept, this project successfully fabricated heat shield materials from mineral simulant materials of lunar and Martian regolith by two methods: 1) Sintering and 2) Binding the simulant with a "room-temperature vulcanizing" (RTV) silicone formulated to withstand high temperatures. Initially a third type of fabrication was planned using the hot waste stream from regolith ISRU processes. This fabrication method was discarded since the resulting samples would be too dense and brittle for heat shields. High temperature flame tests at KSC and subsequent arc jet tests at Ames Research Center (ARC) have proved promising. These coupon tests show favorable materials properties and have the potential to be a new way of fabricating heat shields for space entry into planetary atmospheres.
Regolith Derived Heat Shield for Planetary Body Entry and Descent System with In Situ Fabrication
This NIAC project investigated an innovative approach to provide heat shield protection to spacecraft after launch and prior to each EDL thus potentially realizing significant launch mass savings. Heat shields fabricated in situ can provide a thermal-protection system for spacecraft that routinely enter a planetary atmosphere. By fabricating the heat shield with space resources from materials available on moons and asteroids, it is possible to avoid launching the heat-shield mass from Earth. Regolith has extremely good insulating properties and the silicates it contains can be used in the fabrication and molding of thermal-protection materials. Such in situ developed heat shields have been suggested before by Lewis. Prior research efforts have shown that regolith properties can be compatible with very-high temperature resistance. Our project team is highly experienced in regolith processing and thermal protection systems (TPS). Routine access to space and return from any planetary surface requires dealing with heat loads experienced by the spacecraft during reentry. Our team addresses some of the key issues with the EDL of human-scale missions through a highly innovative investigation of heat shields that can be fabricated in space by using local resources on asteroids and moons. Most space missions are one-way trips, dedicated to placing an asset in space for economical or scientific gain. However, for human missions, a very-reliable heat-shield system is necessary to protect the crew from the intense heat experienced at very high entry velocities of approximately 11 km/s at approximately Mach 33 (Apollo). For a human mission to Mars, the return problem is even more difficult, with predicted velocities of up to 14 km/s, at approximately Mach 42 at the Earth-atmosphere entry. In addition to human return, it is very likely that future space-travel architecture will include returning cargo to the Earth, either for scientific purposes or for commercial reasons. Platinum, titanium, helium 3, and other metals, elements and minerals are all high-value commodities in limited supply on Earth, and it may be profitable to mine these substances throughout the Solar System and return them to Earth, if an economical method can be found. To date, several private corporations have been launched to pursue these goals. Because the heat shield is the last element to be used in an Earth-return mission, a high penalty is paid in the propellant mass required to carry the heat shield to the destination and back. If the heat shield could be manufactured in space, and then outfitted on the spacecraft prior to the reentry at Earth, then significant propellant and mass savings could be achieved during launch and space operations. Preliminary mission architecture scenarios are described, which explain the potential benefits that may be derived from using an in-situ fabricated regolith heat shield. In order to prove that this is a feasible technology concept, this project successfully fabricated heat shield materials from mineral simulant materials of lunar and Martian regolith by two methods: 1) Sintering and 2) Binding the simulant with a "room-temperature vulcanizing" (RTV) silicone formulated to withstand high temperatures. Initially a third type of fabrication was planned using the hot waste stream from regolith ISRU processes. This fabrication method was discarded since the resulting samples would be too dense and brittle for heat shields. High temperature flame tests at KSC and subsequent arc jet tests at Ames Research Center (ARC) have proved promising. These coupon tests show favorable materials properties and have the potential to be a new way of fabricating heat shields for space entry into planetary atmospheres.
Application of the general thermal field model to simulate the behaviour of nanoscale Cu field emitters
Strong field electron emission from a nanoscale tip can cause a temperature rise at the tip apex due to Joule heating. This becomes particularly important when the current value grows rapidly, as in the pre-breakdown (the electrostatic discharge) condition, which may occur near metal surfaces operating under high electric fields. The high temperatures introduce uncertainties in calculations of the current values when using the Fowler–Nordheim equation, since the thermionic component in such conditions cannot be neglected. In this paper, we analyze the field electron emission currents as the function of the applied electric field, given by both the conventional Fowler–Nordheim field emission and the recently developed generalized thermal field emission formalisms. We also compare the results in two limits: discrete (atomistic simulations) and continuum (finite element calculations). The discrepancies of both implementations and their effect on final results are discussed. In both approaches, the electric field, electron emission currents, and Joule heating processes are simulated concurrently and self-consistently. We show that the conventional Fowler–Nordheim equation results in significant underestimation of electron emission currents. We also show that Fowler–Nordheim plots used to estimate the field enhancement factor may lead to significant overestimation of this parameter especially in the range of relatively low electric fields.
Numerical Simulation of Isothermal Flow Across Slant Five-Tube Bundle with Spectral Element Method Code Nek5000
The helical coil steam generator (HCSG) is a specific type of shell-and-tube heat exchanger known for having a higher heat transfer coefficient than many other designs. For this reason, they are considered in small modular reactor and high temperature reactor designs. Investigation of flow behavior in HCSGs is important for better design. In this paper we present our study for modeling the coolant flow in the primary side of the HCSG. We used Nek5000, an open source, high-order spectral element computational fluid dynamics code developed in Argonne National Laboratory. Nek5000 accepts only hexahedral mesh, which makes the meshing process for the complicated HCSG geometry very challenging. A tetrahedral-to-hexahedral meshing strategy was applied to bypass the geometric complexities. In this study large eddy simulation (LES) was performed at the Reynolds number of 9000 based on the inlet velocity and the tube diameter. The employed subgrid-scale model for LES relies on explicit filtering. First- and second-order statistics were compared to available experimental data. We report overall velocity and turbulent kinetic energy showed good agreement with particle image velocimetry data.
On the performance of explicit and implicit algorithms for transient thermal analysis
The status of an effort to increase the efficiency of calculating transient temperature fields in complex aerospace vehicle structures is described. The advantages and disadvantages of explicit and implicit algorithms are discussed. A promising set of implicit algorithms, known as the GEAR package is described. Four test problems, used for evaluating and comparing various algorithms, have been selected and finite element models of the configurations are discribed. These problems include a space shuttle frame component, an insulated cylinder, a metallic panel for a thermal protection system and a model of the space shuttle orbiter wing. Calculations were carried out using the SPAR finite element program, the MITAS lumped parameter program and a special purpose finite element program incorporating the GEAR algorithms. Results generally indicate a preference for implicit over explicit algorithms for solution of transient structural heat transfer problems when the governing equations are stiff. Careful attention to modeling detail such as avoiding thin or short high-conducting elements can sometimes reduce the stiffness to the extent that explicit methods become advantageous.
Applications of perturbation techniques
Two perturbation techniques were applied to two singular perturbation problems in heat transfer to obtain uniformly valid solutions which can serve as benchmarks for finite difference and finite element techniques. In the first problem, the method of strained parameters coupled with the application of a solvability condition is used to obtain a uniform solution for the problem of unsteady heat conduction in a long nearly circular cylinder. In the second problem, the method of matched asymptotic expansion coupled with Van Dyke's matching principle is used to obtain a uniform solution for the problem of one dimensional conduction-convection heat transfer of a uniform fluid flow.
Distributed Fiber Optic Arrays: Integrated Temperature and Seismic Sensing for Detection of CO 2 Flow, Leakage and Subsurface Distribution (Final Report)
This report describes the seismic and heat-pulse monitoring equipment, surveys, results and accomplishments of the fiber optic (FO) project funded by the U.S. Department of Energy (DOE) under Agreement Number DE-FE0012700. The formal title of the project is “Distributed Fiber Optic Arrays: Integrated Temperature and Seismic Sensing for Detection of CO 2 Flow, Leakage and Subsurface Distribution.” The project focuses on the field acquisition of FO data using Distributed Acoustic Sensing (DAS) arrays for subsurface imaging of geologic structure and to track the CO 2 migration in the injection interval using time-lapse techniques. A second component of the project uses a novel heat-pulse monitoring method that relies on Distributed Temperature Sensing (DTS) to evaluate near-field leakage of CO 2 or brine in and around the wellbore. The Southeast Regional Carbon Sequestration (SECARB) partnership hosted the project at the Anthropogenic Test site near Citronelle, Alabama after the original site host, the Kansas Geological Survey (KGS), experienced significant delays in permitting its CO 2 injection well at the Wellington Oil Field site in Kansas. The KGS project was later terminated in 2017 before an injection permit issued. A second field trial was planned for the Livingston Oil Field, located in Louisiana, but the site host ran into financial troubles and the project was terminated in 2015. A replacement field-site host was not found for the Livingston field trial. Both the Wellington, Kansas and Livingston, Louisiana projects were funded by DOE. A novel sensor platform referred to as the Modular Borehole Monitoring (MBM) system deployed at the Citronelle field site was utilized by the FO project. Two different seismic sensor technologies were incorporated in the Citronelle MBM system design including: (1) a semi-permanent, tubing-deployed, 18-level geophone array with custom hydraulic clamps; and (2) two, single mode optical fibers for Distributed Acoustic Sensing (DAS). Incorporation of the 18-level geophone array in the MBM system provided an ideal opportunity to compare the DAS response to conventional geophones. A heat-pulse monitoring system consisting of two, multi-mode optical fibers for Distributed Temperature Sensing (DTS) and copper heater element were also incorporated into the MBM package. This report provides an overview of the design of the MBM, DAS, and DTS equipment and the surveys performed during the study. The heat-pulse monitoring technique was used to diagnose a completion problem with observation well D-9-8 #2 where the MBM system was installed in 2012, thus successfully demonstrating its application for leak detection. In 2015, CO 2 unexpectedly arrived at the observation well approximately one year after CO 2 injection and heat-pulse monitoring ended. It was determined at this time that saltwater intrusion had likely penetrated the stainless-steel capillary tube containing the fibers and copper heater elements, thus preventing the heater from being used. DTS measurements indicated that the fiber had also degraded probably due to hydrogen darkening. It is recommended that the capillary tube be constructed of a more corrosive resistant material (e.g., Inconel) in the future should it be deployed in similar harsh downhole environments. Geophysical imaging of the subsurface and monitoring of the CO 2 were successful using DAS in the vertical seismic profile (VSP) survey configuration. A high resolution VSP image of the subsurface was obtained in 2014 using DAS, which exceeded our expectations in comparison to a lower resolution image obtained by SECARB in 2012 using an 80-level geophone array. A time-lapse image of the redistribution of CO 2 after injection ended in September 2014 was obtained using two DAS VSP surveys from June 2014 and December 2015, thus successfully demonstrating its application. DAS data were also acquired during a crosswell seismic survey conducted in 2014. Unfortunately, the DAS technique was not success in the crosswell survey configuration because the noise level was too high, increasing by a factor of ten, over the high frequency output (100-1,200) of the piezoelectric source.
Tailored Graphene Micropatterns by Wafer-Scale Direct Transfer for Flexible Chemical Sensor Platform
2D materials, such as graphene, exhibit great potential as functional materials for numerous novel applications due to their excellent properties. The grafting of conventional micropatterning techniques on new types of electronic devices is required to fully utilize the unique nature of graphene. However, the conventional lithography and polymer-supported transfer methods often induce the contamination and damage of the graphene surface due to polymer residues and harsh wet-transfer conditions. In this work, a novel strategy to obtain micropatterned graphene on polymer substrates using a direct curing process is demonstrated. Employing this method, entirely flexible, transparent, well-defined self-activated graphene sensor arrays, capable of gas discrimination without external heating, are fabricated on 4 in. wafer-scale substrates. Finite element method simulations show the potential of this patterning technique to maximize the performance of the sensor devices when the active channels of the 2D material are suspended and nanoscaled. This study contributes considerably to the development of flexible functional electronic devices based on 2D materials.
Assessment of reverse gun taylor cylinder experimental configuration
Experimental efforts for Taylor-anvil impact tests have often been limited to near room temperature. The ‘Reverse Gun’ method proposed by Gust in 1982 allows for the Taylor impact specimen to be uniformly heated without temperature losses before impact. Through the use of finite element analysis, we explore two topics in this work. First, we examine whether the reverse gun experimental configuration is comparable to the traditional Taylor-anvil setup. Second, we assess the accuracy of several commonly employed flow strength models in terms of their ability to predict the reverse gun experimental results which involve dynamic loading conditions and complex thermo-mechanical coupling. The reverse gun simulations are performed for tantalum targets at initial temperatures in the range 295 K to 1295 K and velocities from 135 m/s to 242 m/s. We show that with suitable care in the modeling of the preheated reverse gun experiments one can make valuable assessments of flow strength models. Given the conditions explored, these observations probe the thermal softening, strain hardening, and strain rate sensitivity of the material.