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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 19 records

Convective Heat Transfer Coefficients of Automatic Transmission Fluid Jets with Implications for Electric Machine Thermal Management: Preprint

Thermal management for electric machines (motors/ generators) is important as the automotive industry continues to transition to more electrically dominant vehicle propulsion systems. Cooling of the electric machine(s) in some electric vehicle traction drive applications is accomplished by impinging automatic transmission fluid (ATF) jets onto the machine's copper windings. In this study, we provide the results of experiments characterizing the thermal performance of ATF jets on surfaces representative of windings, using Ford's Mercon LV ATF. Experiments were carried out at various ATF temperatures and jet velocities to quantify the influence of these parameters on heat transfer coefficients. Fluid temperatures were varied from 50 degrees C to 90 degrees C to encompass potential operating temperatures within an automotive transaxle environment. The jet nozzle velocities were varied from 0.5 to 10 m/s. The experimental ATF heat transfer coefficient results provided in this report are a useful resource for understanding factors that influence the performance of ATF-based cooling systems for electric machines.

33 ADVANCED PROPULSION SYSTEMS↗

Laser-induced damage characteristics of fused silica surfaces polished to different depths using fluid jet polishing

Deterministic finishing methods of optical components for high-peak-power laser applications that can meet the requirements for high laser damage resistance are not sufficiently developed to meet all needs. This is especially the case for ultraviolet (UV) laser applications. Fused silica is the material of choice for optics operating at UV wavelengths owing to its intrinsically large bandgap, high transparency, and excellent uniformity. Here we report on the laser damage behavior of fused silica surfaces finished by fluid jet polishing (FJP) as a function of removal depth. Fused silica test substrates were processed by FJP to depths ranging from 0.7 μm to 18 μm. Laser damage testing was conducted on these surfaces at 351 nm and 1-ns pulse lengths for both, 1-on-1 and R-on-1 testing protocols. The results for 1-on-1 testing showed no degradation in the laser-induced damage threshold (LIDT) of the substrates. Instead, a gradual improvement starting at a depth of 2.1 μm was observed and continued to the 18-μm surface. At 18-μm of removal, the LIDT was 16% higher than a surface that was not finished by FJP. For R-on-1 testing, all surfaces treated by FJP demonstrated an improvement in laser damage resistance. At depths greater than 5 μm, the improvements were significantly more pronounced and a 30% increase in the LIDT was realized.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

Performance characterization of freeform finished surfaces of potassium dihydrogen phosphate using fluid jet polishing with a nonaqueous slurry

Abstract Potassium dihydrogen phosphate (KDP) and its deuterated analog (DKDP) are unique nonlinear optical materials for high power laser systems. They are used widely for frequency conversion and polarization control by virtue of the ability to grow optical-quality crystals at apertures suitable for fusion-class laser systems. Existing methods for freeform figuring of KDP/DKDP optics do not produce surfaces with sufficient laser-induced–damage thresholds (LIDT’s) for operation in the ultraviolet portion of high-peak-power laser systems. In this work, we investigate fluid jet polishing (FJP) using a nonaqueous slurry as a sub-aperture finishing method for producing freeform KDP surfaces. This method was used to selectively polish surface areas to different depths on the same substrate with removals ranging from 0.16 μm to 5.13 μm. The finished surfaces demonstrated a slight increase in roughness as the removal depth increased along with a small number of fracture pits. Laser damage testing with 351 nm, 1 ns pulses demonstrated excellent surface damage thresholds, with the highest values in areas devoid of fracture pits. This work demonstrates, for the first time, a method that enables fabrication of a waveplate that provides tailored polarization randomization that can be scaled to meter-sized optics. Furthermore, this method is based on FJP technology that incorporates a nonaqueous slurry specially designed for use with KDP. This novel nonaqueous FJP process can be also used for figuring other types of materials that exhibit similar challenging inherent properties such as softness, brittleness, water-solubility, and temperature sensitivity.

36 MATERIALS SCIENCE↗

High-resolution time-resolved experiments on mixing and entrainment of buoyant jets in stratified environments

Fluid jets interacting with a stratified layer play an important role in the safety of several reactor designs. In the containment of nuclear power plants, fluid jets dominate the transport and mixing of gaseous species and consequent hydrogen distribution in case of a severe accident. The mixing phenomena in the containment are driven by buoyant high-momentum injections (jets) and low momentum injection plumes. Mixing near the postulated break is initially dominated by high flow velocities. Plumes with moderate flow velocities are instead relevant in the break compartment during the long-term pressurization phase, or in any of the apertures between two connected compartments if the mass flows are sufficiently high and the density differences between efflux and ambient are sufficiently low. Phenomena of interest include free plumes (as produced by the efflux from the break compartment in a larger room or directly from a break flow), wall plumes (such those produced by low mass flows through inter-compartment apertures), and propagating stratification fronts in the ambient (for any stably stratified conditions). These phenomena have been highly ranked about nuclear reactor design, especially regarding of safety protocols. During a Pressurized Thermal Shock (PTS) scenario, the interaction between the cold ECCS injection plume and the stratified fluid present in the cold (or hot) leg is important in order to determine the temperature at the time-dependent temperature at the inlet of the reactor pressure vessel (RPV) and the potential to cause a thermal shock on the RPV wall. In sodium-cooled fast reactors (SFRs), core channels are typically hydro-dynamically isolated so that there exists a considerable temperature variation at the exit of adjacent fuel assemblies. All the above phenomena are characterized by the interaction of buoyant jets with the stratified flow. In stratified layers baroclinic forces create significant redistribution of turbulent kinetic energy and scales, which leads to anisotropy. This important physical phenomenon is highly three dimensional and is challenging to capture even with high-fidelity CFD simulations, due in part to lack of sufficiently resolved validation data. Furthermore, the experimental data available in the open literature do not feature the level of fidelity needed for an extensive validation of turbulence models in lower order CFD. To shed new lights into the crucial phenomena object of the present research project, it was proposed to conduct coordinated experiments and simulations at the University of Michigan and the George Washington University. The project has resulted in an experimental database of high-resolution time-resolved measurements of jets in uniform and stratified environments. The novel experimental data will be used to validate computational fluid dynamic (CFD) codes, including both Large Eddy Simulations (LES) and unsteady Reynolds-averaged Navier-Stokes equations (URANS) methodologies. In the Experimental and Multiphase flow (ECMF) laboratory at Univerisity of Michigan, we built two experimental facilities to investigate also the effect of scaling. The first facility, DESTROJER (DEnsity Stratified Turbulent ROund free Jet ExpeRiment), featuring a contoured jet nozzle with a diameter of D=12.7mm and a 1m×1m×1m cubic tank, which is made of acrylic glass for optical access. The ratio between the tank width and the nozzle diameter is equal to 78, which ensures that there is no direct interaction between the jet and the side walls. A second, modular experimental facility, features three different tank sizes of size 10×10×30, 20×20×30, 30×30×30 cm3 respectively (all tanks have the same height of 30 cm), and a jet diameter of 2mm. For the modular facility, tank-to-nozzle ratio of 50, 100, and 150 are obtained respectively. Experiments with different-density jet impactions and sharp interface with a density difference of 3.16% In the Laboratory at George Washington University, complementary experiments have been carried out at a facility featuring the same dimensions as DESTROYER. Experiments with different jet diameters have been carried out as well. High-resolution time-resolved measurements have been performed at all facilities using high-speed particle image velocimetry (PIV) and planar laser-induced fluorescence (PLIF). In this way, simultaneous measurements of velocity and density fields have been carried out. At the University of Michigan, wire-mesh sensors have been designed and built to gather high-resolution, time-dependent data of the stratified front in the tank. These measurements are important to provide accurate initial conditions for the CFD simulations. An important outcome of the project has been the development of novel techniques to achieve refractive index matching (RIM) of acqueous solutions with high density differences. RIM is crucial if optical techniques such as PIV are used to measure velocity fields. Previous to this project, experiments up to 3% density difference had been reported in the literature. With the methodology developed in this project, we have been able to push the envelop to density differences up to 9%. The experiments have been used to validate Reynolds Averaged Navier-Stokes (RANS) turbulence models and Large Eddy Simulations (LES) models. Both NEK5000 and the commercial CFD code STAR-CCM+ have been used. The experimental data will be made available to the community through the NE-KAMS databasehave been successfully conducted in the scaled facility.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

Experimental Evaluation of Dual-Opposed Jet Mixer Pump Performance for Slurry Mixing

Million-gallon double-shell tanks at Hanford are used to store transuranic, high-level, and low-level radioactive wastes. These wastes consist of a large volume of salt-laden solution covering a smaller volume of settled sludge primarily containing metal hydroxides. These wastes will be retrieved and processed into immobile waste forms suitable for permanent disposal. Retrieval is an important step in implementing these disposal scenarios. The retrieval concept evaluated is to use submerged dual-nozzle jet mixer pumps with horizontally oriented nozzles located near the tank floor that produce horizontal jets of fluid to mobilize the settled solids. The mixer pumps are oscillated through 180 about a vertical axis so the high velocity fluid jets sweep across the floor of the tank. After the solids are mobilized, the pumps will continue to operate at a reduced flow rate producing lower velocity jets sufficient to maintain the particles in a uniform suspension (concentration uniformity). Several types of waste and tank configurations exist at Hanford. The jet mixer pump systems and operating conditions required to mobilize sludge and maintain slurry uniformity will be a function of the waste type and tank configuration. The focus of this work was to conduct a 1/12-scale experiment to develop an analytical model to relate slurry uniformity to tank and mixer pump configurations, operating conditions, and sludge properties. This experimental study evaluated concentration uniformity in a 1/12-scale experiment varying the Reynolds number (Re), Froude number (Fr), and gravitational settling parameter (Gs) space. Simulant physical properties were chosen to obtain the required Re and Gs where Re and Gs were varied by adjusting the kinematic viscosity and mean particle diameter, respectively. Test conditions were achieved by scaling the jet nozzle exit velocity in a 75-in. diameter tank using a mock-up of a centrally located dual-opposed jet mixer pump located just above the tank floor. Concentration measurements at sampling locations throughout the tank were used to assess the degree of uniformity achieved during each test. Concentration data was obtained using a real time in-situ ultrasonic attenuation probe and post-test analysis of discrete batch samples. The undissolved solids concentration at these locations was analyzed to determine whether the tank contents were uniform (≤ ±10% variation about mean) or nonuniform (> ±10% variation about mean) in concentration. Concentration inhomogeneity was modeled as a function of dimensionless parameters. The parameters that best describe the maximum solids volume fraction that can be suspended were found to be 1) the Fr based on nozzle average discharge velocity and tank contents level and 2) the dimensionless particle size based on nozzle diameter. The dependence on the jet Re does not appear to be statistically significant.

correlation↗

3D hybrid fluid-particle jet simulations and the importance of synchrotron radiative losses

Context. Relativistic jets in active galactic nuclei are known for their exceptional energy output, and imaging the synthetic synchrotron emission of numerical jet simulations is essential for a comparison with observed jet polarization emission. Aims. Through the use of 3D hybrid fluid-particle jet simulations (with the PLUTO code), we overcome some of the commonly made assumptions in relativistic magnetohydrodynamic (RMHD) simulations by using non-thermal particle attributes to account for the resulting synchrotron radiation. Polarized radiative transfer and ray-tracing (via the RADMC-3D code) highlight the differences in total intensity maps when (i) the jet is simulated purely with the RMHD approach, (ii) a jet tracer is considered in the RMHD approach, and (iii) a hybrid fluid-particle approach is used. The resulting emission maps were compared to the example of the radio galaxy Centaurus A. Methods. We applied the Lagrangian particle module implemented in the latest version of the PLUTO code. This new module contains a state-of-the-art algorithm for modeling diffusive shock acceleration and for accounting for radiative losses in RMHD jet simulations. The module implements the physical postulates missing in RMHD jet simulations by accounting for a cooled ambient medium and strengthening the central jet emission. Results. We find a distinction between the innermost structure of the jet and the back-flowing material by mimicking the radio emission of the Seyfert II radio galaxy Centaurus A when considering an edge-brightened jet with an underlying purely toroidal magnetic field. We demonstrate the necessity of synchrotron cooling as well as the improvements gained when directly accounting for non-thermal synchrotron radiation via non-thermal particles.

79 ASTRONOMY AND ASTROPHYSICS↗

Analytical model for balling defects in laser melting using rivulet theory and solidification

In laser welding and additive manufacturing communities, the balling (humping) defect is primarily attributed to the Plateau–Rayleigh fluid instability (PRI) with a few authors suggesting fluid jetting and volume conservation as alternative mechanisms. As analytical descriptions of these mechanisms are unavailable, combining them into a single formalism is unfeasible. We present a new model of PRI with higher accuracy, accounting for competition with solidification, to compare the expected behavior with known experimental trends when fluid jetting is neglected. We adapt a rivulet instability model from fluid physics to account for the stabilizing effects of the substrate, which the traditional cylindrical-jet geometry does not account for and estimate the instability growth rate. Our model yields a continuous transition from non-balling to balling hitherto lacking in current literature and predicts instability growth at higher wavelengths with strong sensitivity to the solidification front curvature. While the fluid surface is most unstable for shallow melt pools, the absolute magnitude of balling relevant to printing defects scales with melt pool depth and has a maximum for a given melt pool geometry. Synchrotron-based x-ray radiography of thin samples indicates that PRI growth rates and solidification can be comparable in magnitude and thus compete, as we find in this work. We predict that deviations between model predictions and our experimental results demonstrate the importance of fluid flows and heat transport in the balling process. Our experiments further demonstrate at least one mechanism by which the melt pool length and the balling wavelength are not equivalent, as commonly claimed.

Taylor, Z. [Stanford Univ., CA (United States); SL↗

Emergent Nonthermal Fluid from Jets in the Massive Schwinger Model Using Tensor Networks

We analyze the correlation between the energy, momentum, and spatial entanglement produced by two luminal jets in the massive Schwinger model. Using tensor network methods, we show that for m/g > 1/π, in the vicinity of the strong- to weak-coupling transition, a nearly perfect and chargeless effective fluid behavior appears around the midrapidity region with a universal energy-pressure relationship. The evolution of energy and pressure is strongly correlated with the rise of the spatial entanglement entropy, indicating a key role of quantum dynamics. Some of these observations may be used to analyze high multiplicity jet fragmentation events, energy-energy and energy-charge correlators at current collider energies.

Ab initio calculations↗

Experimental study of elliptical jet from supercritical to subcritical conditions using planar laser induced fluorescence

The study of fluid jet dynamics at supercritical conditions involves strong coupling between fluid dynamic and thermodynamic phenomena. Beyond the critical point, the liquid-vapor coexistence ceases to exist, and the fluid exists as a single phase known as supercritical fluid with its properties that are entirely different from liquids and gases. At the critical point, the liquids do not possess surface tension and latent heat of evaporation. Around the critical point, the fluid undergoes large changes in density and possesses thermodynamic anomaly like enhancement in thermal conductivity and specific heat. In the present work, the transition of the supercritical and near-critical elliptical jet into subcritical as well as supercritical environment is investigated experimentally with nitrogen and helium as the surrounding environment. Under atmospheric condition, a liquid jet injected from the elliptical orifice exhibits axis switching phenomena. As the injection temperature increases, the axis switching length also increases. Beyond the critical temperature, the axis switching is not observed. The investigation also revealed that pressure plays a major role in determining the thermodynamic transition of the elliptical jet only for the case of supercritical jet injected into subcritical chamber conditions. At larger pressures, the supercritical jet undergoes disintegration and formation of droplets in the subcritical environment is observed. However, for supercritical jet injection into supercritical environment, the gas-gas like mixing behavior is observed.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗

Interfacial gauge methods for incompressible fluid dynamics

Designing numerical methods for incompressible fluid flow involving moving interfaces, for example, in the computational modeling of bubble dynamics, swimming organisms, or surface waves, presents challenges due to the coupling of interfacial forces with incompressibility constraints. A class of methods, denoted interfacial gauge methods, is introduced for computing solutions to the corresponding incompressible Navier-Stokes equations. These methods use a type of "gauge freedom" to reduce the numerical coupling between fluid velocity, pressure, and interface position, allowing high-order accurate numerical methods to be developed more easily. Making use of an implicit mesh discontinuous Galerkin framework, developed in tandem with this work, high-order results are demonstrated, including surface tension dynamics in which fluid velocity, pressure, and interface geometry are computed with fourth-order spatial accuracy in the maximum norm. Applications are demonstrated with two-phase fluid flow displaying fine-scaled capillary wave dynamics, rigid body fluid-structure interaction, and a fluid-jet free surface flow problem exhibiting vortex shedding induced by a type of Plateau-Rayleigh instability. The developed methods can be generalized to other types of interfacial flow and facilitate precise computation of complex fluid interface phenomena.

42 ENGINEERING↗

Similarity Criteria for the Study of Removal of Spherical Non-metallic Inclusions in Physical Models of Continuous Casting Tundishes: A More Fundamental Approach

Physical modeling is widely used for studying steelmaking processes. The accuracy of this technique depends on the use of appropriate similarity criteria during experimental design. The present work deduced rigorously the similarity criteria for the study of spherical non-metallic inclusions in isothermal physical models of tundishes. Initially, macroscopic quantities were used to simplify the multiphase problem. Then, the similarity criteria were obtained from the dimensionless form of the exact equation of motion for an inclusion in Stokes regime. The validity range of these criteria was discussed and they were compared with common literature practice. Some practical considerations were also presented. This work clarifies various implicit assumptions usually adopted in literature. Additionally, a restrictive criterion to choose the density of the inclusion simulating particles was obtained, which can be satisfied, for example, by hollow glass particles in water models. This criterion is necessary to adequately describe the inclusion motion in regions where fluid elements suffer strong acceleration (e.g., inside nozzles, near flow controllers or in the entering fluid jet). Moreover, it was established an upper limit for the concentration of particles injected in the inlet nozzle of physical models, which do not simulate the phenomenon of inclusion aggregation.

36 MATERIALS SCIENCE↗

Compressible, multiphase semi-implicit method with moment of fluid interface representation

A unified method for simulating multiphase flows using an exactly mass, momentum, and energy conserving Cell-Integrated Semi-Lagrangian advection algorithm is presented. The deforming material boundaries are represented using the moment-of-fluid method. Our new algorithm uses a semi-implicit pressure update scheme that asymptotically preserves the standard incompressible pressure projection method in the limit of infinite sound speed. The asymptotically preserving attribute makes the new method applicable to compressible and incompressible flows including stiff materials; enabling large time steps characteristic of incompressible flow algorithms rather than the small time steps required by explicit methods. Moreover, shocks are captured and material discontinuities are tracked, without the aid of any approximate or exact Riemann solvers. As a result, wimulations of underwater explosions and fluid jetting in one, two, and three dimensions are presented which illustrate the effectiveness of the new algorithm at efficiently computing multiphase flows containing shock waves and material discontinuities with large “impedance mismatch.”

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗

Multiphysics Co-Optimization Design and Analysis of Double-Side Cooled Silicon Carbide-Based Power Module: Preprint

With the rapid growth of Electric Vehicles (EVs) and Hybrid Electric Vehicles (HEVs), much more rigorous design targets have been set for automotive power electronics, including high power density, high reliability, and low cost. Novel power module and inverter technologies based on wide bandgap (WEG) semiconductors have been developed to meet these design targets, while providing optimal power semiconductor operating temperature and promising thermomechanical performance. Compared with conventional cooling techniques which are normally applied only on one side of power module, double-side cooling approach is now believed to be the solution to enable high power density and low thermal resistance of WEG semiconductor-based power electronics. In this work, we develop a three-phase power module that is double-sided cooled using dielectric fluid jet impingement. In each phase, four silicon carbide (SiC) power semiconductors are bonded to copper busbars without electrical insulation layers. A finite element analysis (FEA) model is created for thermal and thermomechanical analysis. Based on FEA modeling results, we select particular dimensions for a parametric study to optimize thermal and mechanical performance. Using a multi-objective genetic algorithm (MOGA)-based optimization method, we have minimized the maximum junction temperature and thermal stresses within the power module. The multiphysics co-optimization approach has enabled an efficient design process of power modules with greatly reduced computational cost, as compared to conventional processes that rely on exhaustive numerical simulations and iterations.

ADVANCED PROPULSION SYSTEMS↗

Problems of Developing Solid Mineral Deposits on the Sea and Ocean Floor

Brief characteristics of the mineral raw material potential of the deep-sea deposits of ferromanganese nodules in the area of the Clarion-Clipperton Zone leased by Russia in the Pacific Ocean are presented. The creation at the Moscow Mining Institute (MGI) of the USSR’s first Scientific and Technical Problems Laboratory and the results of its work on extraction of minerals from the sea and ocean floor are reviewed. The research works carried out by MGI on underwater mining of ilmenite-rutile-zirconium sands on the Baltic Sea shelf and Iturup Island and tin under conditions of northern seas and the development of the technogenic placer of the East Siberian Sea are analyzed. The concept of using the kinetic energy of coaxially swirled fluid jets in hydrotransport-hoisting devices of vortex slurry preparation, which was tested in the Black Sea and an air-lift mud intake by mechanical and hydraulic loosening for extracting diamond-containing gravel-pebble rocks on the Namibia shelf is given.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

CARS thermometry in laminar sooting ethylene-air co-flow diffusion flames with nitrogen dilution

Temperature measurements were performed in nonpremixed, sooting jet flames using coherent anti-Stokes Raman scattering (CARS). The jet fluid was ethylene diluted with different concentrations of nitrogen, and the co-flow fluid was dry air. The flames were stabilized on a Yale burner, also known as Smooke/Long burner, and the operating conditions were chosen to match previous experiments on the burner by the Yale group and other research groups. The selected flames have also been identified as target flames by the International Sooting Flame Workshop. CARS measurements of temperature provide insight into the structure of these sooting flames and serve as benchmark data for comparison with computations. A dual-pump vibrational CARS system was used here in order to avoid soot interferences. We were able to obtain high quality CARS spectra in all regions of the flame including the highly sooting regions and near the exit of the fuel nozzle, where the nonresonant modulation of the nitrogen CARS spectrum is strong due to the high ethylene concentrations. The measurements are compared with CFD results in literature and discussed in context of measured soot volume fraction, also, from literature.

42 ENGINEERING↗

Study on the Fluid Flow Characteristics of Coherent Jets with CO{sub 2} and O{sub 2} Mixed Injection in Electric Arc Furnace Steelmaking Processes

As an efficient oxygen supplying technology, coherent jets are widely applied in electric arc furnace (EAF) steelmaking processes to strengthen chemical energy input, speed up smelting rhythm, and promote the uniformity of molten bath temperature and compositions. Recently, the coherent jet with CO{sub 2} and O{sub 2} mixed injection (COMI) was proposed and demonstrated great application potentiality in reducing the dust production in EAF steelmaking. In the present study, based on the eddy dissipation concept model, a computational fluid dynamics model of coherent jets with COMI was built with the overall and detailed chemical kinetic mechanisms (GRI-Mech 3.0). Compared with one-step combustion reaction, GRI-Mech 3.0 consists of 325 elementary reactions with 53 components and can predict more accurate results. The numerical simulation results were validated by the combustion experiment data. The jet behavior and the fluid flow characteristics of coherent jets with COMI under 298 K and 1700 K (25 °C and 1427 °C) were studied and the results showed that for coherent jets with COMI, the chemical effect of CO{sub 2} significantly weakened the shrouding combustion reactions of CH{sub 4} and the relative importance of the chemical effect of CO{sub 2} increases with CO{sub 2} concentration increasing. The potential core length of coherent jet decreases with the volume fraction of CO{sub 2} increasing. Moreover, it also can be found that the potential core length of coherent jets was prolonged with higher ambient temperature.

36 MATERIALS SCIENCE↗