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Tool-workpiece stick-slip conditions and their effects on torque and heat generation rate in the friction stir welding
Friction stir welding (FSW) has found increased applications in automotive and aerospace industries due to its advantages of solid-state bonding, no fusion and melting, and versatility in various working conditions and material combinations. However, the relationship among processing parameters, material properties, and bonding extent and fidelity remains largely empirical, primarily because of the lack of the mechanistic understanding of the tool-workpiece frictional behavior that affects our subsequent understanding of microstructural evolution and interface bonding formation. While the tool-workpiece stick-slip condition is believed to dictate the resulting torque and heat generation rate during the welding process, it remains rare and elusive to conduct a quantitative experimental measurement of such interfacial field. On the other hand, numerical simulations based on Computational Fluid Dynamics (CFD) rely on ad hoc assumptions of interfacial pressure and shear-stress conditions, but predictions can only be validated via the medium- and far-range temperature field which is known to be insensitive to the interfacial frictional behavior. This work first presents a comparison among two CFD-based simulation methodologies and the Coupled Eulerian Lagrangian (CEL) model in finite element method, the last of which uses the Coulomb friction so that the stick-slip is naturally developed. Based on the Hill-Bower similarity relationship in the contact analysis, an analytical model is developed here to prove why a constant stick-slip fraction will be developed in the steady state, to correlate the stick-slip fraction to processing parameters such as the tool spin rate, and further to derive dimensionless functions for torque and heat-generation-rate predictions. Pros and cons of various numerical approaches in predicting stick-slip are discussed, and our analytical model has been found to agree well with our numerical simulation and literature experimental results. These analyses provide the critical strain-rate and temperature fields that are needed for the bonding analysis in our future work.
Heat generation rates in lithium thionyl chloride cells
An empirical equation that is useful for good first approximation in thermal modeling is presented. Indications and measurements of electrochemical heat effects were investigated. The particular cells of interest are of the D size, with spiral wound configuration and were instrumented with a thermocouple. It is found that cathode limited cells can explode on reversal at moderate temperatures.
Design and Heat Generation Rate Analysis of LEU-UAlx Dispersion Target Plates for Irradiation in the High Flux Isotope Reactor
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Heat of Mixing During Fast Charge/Discharge of a Li-Ion Cell: A Study on NMC523 Cathode
Predicting temperature rise accurately during fast charge/discharge of a Li-ion cell is essential to avoid thermal runaway and extend battery life. While modeling the temperature rise, it is necessary to model the heat generation correctly. Heat of mixing, one of the four main sources of heat generation in a Li-ion battery, has often been considered insignificant and therefore excluded from modeling. When included, it is modeled using the expression from a Taylor expansion approximation. In this work, we have shown the conditions when including the heat of mixing becomes important and quantified the error associated with using the Taylor expansion, especially under high charge/discharge conditions. Consequently, we carry out the calculation of the rate of enthalpy change and the heat generation rate from the most fundamental equation for the rate of the total enthalpy change without simplifying assumptions or approximations. The heat generation rate calculated doing so naturally includes irreversible, reversible and mixing heat. We then exclusively separate out the heat of mixing by subtracting the rate of enthalpy change by reaction from the rate of the total enthalpy change. Results show that the contribution of heat of mixing in the total heat generated increases with the charge/discharge rate and is as large as 23% for a 6 C discharge. This result suggests that while modeling heat generation for fast charge/discharge, it is necessary to include the heat of mixing and avoid calculating it using the Taylor expansion approximation.
In Operando Calorimetric Measurements for Activated Carbon Electrodes in Ionic Liquid Electrolytes under Large Potential Windows
This study aims to investigate the effect of the potential window on heat generation in carbon-based electrical double layer capacitors (EDLCs) with ionic-liquid (IL)-based electrolytes using in operando calorimetry. The EDLCs consisted of two identical activated-carbon electrodes with either neat 1-butyl-1-methylpyrrolidinium bis(trifluoromethane-sulfonyl)imide ([Pyr 14 ][TFSI]) electrolyte or 1.0 m [Pyr 14 ][TFSI] in propylene carbonate (PC) as electrolyte. The instantaneous heat generation rate at each electrode was measured under galvanostatic cycling for different potential windows ranging from 1 to 4 V. First, the heat generation rates at the positive and negative electrodes differed significantly in neat IL owing to the differences in the ion sizes and diffusion coefficients. However, these differences were minimized when the IL was diluted in PC. Second, for EDLC in neat [Pyr 14 ][TFSI] at high potential window (4 V), a pronounced endothermic peak was observed at the beginning of the charging step at the positive electrode owing to TFSI - intercalation in the activated carbon. On the other hand, for EDLC in 1.0 m [Pyr 14 ][TFSI] in PC at potential window above 3 V, an endothermic peak was observed only at the negative electrode owing to the decomposition of PC. Third, for both neat and diluted [Pyr 14 ][TFSI] electrolytes, the irreversible heat generation rate increased with increasing potential window and exceeded Joule heating. This was attributed to the effect of potential-dependent charge redistribution resistance. Additionally, a further increase in the irreversible heat generation rate was observed for the largest potential windows owing to the degradation of the PC solvent. Finally, for both types of electrolyte, the reversible heat generation rate increased with increasing potential window because of the increase in the amount of ion adsorbed/desorbed at the electrode/electrolyte interface.
Thermal mathematical modeling of a multicell common pressure vessel nickel-hydrogen battery
A two-dimensional and time-dependent thermal model of a multicell common pressure vessel (CPV) nickel-hydrogen battery was developed. A finite element solver called PDE/Protran was used to solve this model. The model was used to investigate the effects of various design parameters on the temperature profile within the cell. The results were used to help find a design that will yield an acceptable temperature gradient inside a multicell CPV nickel-hydrogen battery. Steady-state and unsteady-state cases with a constant heat generation rate and a time-dependent heat generation rate were solved.
A Computational Fluid Dynamic and Heat Transfer Model for Gaseous Core and Gas Cooled Space Power and Propulsion Reactors
A computational model based on the axisymmetric, thin-layer Navier-Stokes equations is developed to predict the convective, radiation and conductive heat transfer in high temperature space nuclear reactors. An implicit-explicit, finite volume, MacCormack method in conjunction with the Gauss-Seidel line iteration procedure is utilized to solve the thermal and fluid governing equations. Simulation of coolant and propellant flows in these reactors involves the subsonic and supersonic flows of hydrogen, helium and uranium tetrafluoride under variable boundary conditions. An enthalpy-rebalancing scheme is developed and implemented to enhance and accelerate the rate of convergence when a wall heat flux boundary condition is used. The model also incorporated the Baldwin and Lomax two-layer algebraic turbulence scheme for the calculation of the turbulent kinetic energy and eddy diffusivity of energy. The Rosseland diffusion approximation is used to simulate the radiative energy transfer in the optically thick environment of gas core reactors. The computational model is benchmarked with experimental data on flow separation angle and drag force acting on a suspended sphere in a cylindrical tube. The heat transfer is validated by comparing the computed results with the standard heat transfer correlations predictions. The model is used to simulate flow and heat transfer under a variety of design conditions. The effect of internal heat generation on the heat transfer in the gas core reactors is examined for a variety of power densities, 100 W/cc, 500 W/cc and 1000 W/cc. The maximum temperature, corresponding with the heat generation rates, are 2150 K, 2750 K and 3550 K, respectively. This analysis shows that the maximum temperature is strongly dependent on the value of heat generation rate. It also indicates that a heat generation rate higher than 1000 W/cc is necessary to maintain the gas temperature at about 3500 K, which is typical design temperature required to achieve high efficiency in the gas core reactors. The model is also used to predict the convective and radiation heat fluxes for the gas core reactors. The maximum value of heat flux occurs at the exit of the reactor core. Radiation heat flux increases with higher wall temperature. This behavior is due to the fact that the radiative heat flux is strongly dependent on wall temperature. This study also found that at temperature close to 3500 K the radiative heat flux is comparable with the convective heat flux in a uranium fluoride failed gas core reactor.
Nickel-hydrogen battery self-discharge mechanism and methods for its inhibition
A review of our studies on the elucidation of the self-discharge mechanism of the Ni/H2 battery and methods to inhibit this phenomena is presented. The results show that (1) the rate of heat generation from nickel hydroxide powders and from electrodes increases with increase of hydrogen pressure, simultaneously, the open-circuit potential of the nickel hydroxide electrode is shifted in a negative direction more rapidly, indicating the transformation of NiOOH to Ni(OH)2; (2) heat generation rates measured in the microcalorimeter are considerably faster for electrolyte starved electrodes than for electrolyte-flooded electrodes; (3) there is a good correlation between the extent of self-discharge, as determined by heat generation in microcalorimetric measurement and capacity change; and (4) the self-discharge in Ni/H2 battery occurs via direct reduction of the active material by pressurized hydrogen. The addition of cadmium to the electrode reduces the self-discharge.
NMDQi Thermal-hydraulic Optimization, Analysis, and Scoping Tool (TOAST)
The Thermal-hydraulic Optimization, Analysis, and Scoping Tool (TOAST) is developed to support the thermal-hydraulic aspects for the design of optimal irradiation vehicles for the Nuclear Materials Discovery and Qualification initiative (NMDQi). TOAST is currently a MATLAB-based tool that utilizes a simplified steady-state analytical model where a radial thermal resistance circuit is utilized to account for conduction through up to 2 capsules, a gas gap, a thermal bond, a sample cladding, and a sample, as well as the convection from a water coolant outside the capsules. The geometry is discretized axially along the user-defined height of a basket with a user-defined number of points/nodes, essentially turning TOAST into a semi-2D heat transfer analysis utility for cylindrical irradiation vehicles with practically any configuration, solving for temperatures radially at multiple axial locations. TOAST utilizes a Graphical User Interface (GUI) in-which a user can define the geometrical layout, the materials utilized for each component, the coolant characteristics, and the required solution. The user can define the geometry by inputting the diameters, thicknesses, and heights for each component, whereas the materials are defined via the user-provided constant or variable thermal conductivities. The user can select the coolant's inlet temperature, pressure, and the pressure drop across the height of the problem (which is used to calculate the velocity of the flow). Finally, the user can choose to solve for a sample heat generation rate limit by inputting temperature limits for the sample and capsules or can choose to purely solve for the axial temperature distributions of each component by inputting a pre-selected heat generation rate. Either way, TOAST provides the user with axial temperature distributions of all the components including the coolant, and the heat generation rate limit as well as the maximum outlet coolant temperature. The user can also choose to do one of 6 sensitivity analyses in TOAST. The sensitivity analyses yield plots of the sensitivity of the heat generation rate limit, the maximum coolant temperature, and the pressure limit for the annular components due to perturbations in 1-2 unknown variables based on the selected sensitivity analysis. Benchmarks between computations in TOAST and equivalent 2D axis symmetric ABAQUS models are presented, showing that TOAST results are within less than 3% of ABAQUS results in most cases, and a maximum of 8% difference in some cases. The benchmarks also revealed that this uncertainty is tied to the selection of an appropriate Nusselt number correlation and appropriate thermal conductivities, which the user can do from the GUI. Regardless, TOAST is demonstrated as a computationally efficient, highly accessible, and accurate utility for optimization and scoping s of studies different irradiation vehicles.
Potentiometric entropy and operando calorimetric measurements reveal fast charging mechanisms in PNb 9 O 25
The Wadsley–Roth compound PNb 9 O 25 is a promising fast charging lithium ion battery anode material with high operating voltage to prevent solid electrolyte interface formation. Here, in this work, we present potentiometric entropy measurements featuring signatures of semiconductor-to-metal transition and intralayer ordering upon lithiation in the anode material PNb 9 O 25 that could not be observed with in situ X-ray diffraction. In addition, the instantaneous heat generation rates at the PNb 9 O 25 working electrode and at the lithium metal counter electrode during galvanostatic cycling were measured individually for the first time by operando isothermal calorimetry. The heat generation rate decreased at the PNb 9 O 25 electrode upon lithiation due to the decrease in electrical resistivity caused by the semiconductor-to-metal transition observed in potentiometric entropy measurements. Furthermore, the heat generation rate at the lithium metal electrode was positive during delithiation due to the exothermic plating of Li + ions on the lithium metal counter electrode associated with dendrite formation. Furthermore, calorimetric measurements established that the entropy change dominated the reversible heat generation rate at each electrode. Finally, the contribution of enthalpy of mixing was relatively small even at high C-rates thanks to the high Li + ion mobility in PNb 9 O 25 confirming its promises as a fast charging anode material.
Verification and Validation Tests of the Gamma Library of the ARC Software Package (Rev.1)
As part of the verification and validation (V&V) efforts of the Argonne Reactor Code (ARC) software system to support the Versatile Test Reactor (VTR) project of the U.S. Department of Energy (DOE), work has been performed to verify and validate the gamma (or photon) library of the multigroup cross section generation code MC 2 -3 of the ARC system, which is the essential part of the coupled neutron and gamma heating calculations to determine the heat generation rate or power distribution in the core. This V&V study was carried out in three steps: 1) review of the procedures and utility programs for generating the MC 2 -3 gamma library, 2) verification tests of cross sections and KERMA factors by comparing the total heat generation rate of coupled neutron and gamma calculation with that obtained with reaction Q values under the assumption of local gamma energy deposition and by comparing the prompt heat generation rate with that calculated with the MCNP6.2 code, and 3) validation tests of cross sections and KERMA factors by analyzing the ZPPR-15D gamma dose data measured with thermoluminescent dosimeters (TLD).
Transport Processes in a Li-ion Cell during an Internal Short-Circuit
Internal short-circuit in a lithium-ion cell causes an abrupt increase in cell temperature and triggers subsequent thermal runaway. In this work, we present a detailed electrochemical-thermal model to investigate the physical behavior during an internal short-circuit. Simulations at wide range of heat transfer coefficients and short-circuit resistances are conducted to illustrate electrochemical and thermal behavior under a wide range of conditions. The Joule heating at the shorted region promotes electrochemical reactions nearby, causing in-plane non-uniformity of electrolyte and active material transport. Furthermore, it is found that diffusion in solid active materials plays a significant role at very high shorting currents (~20 C), as electrochemical reactions rate are being controlled progressively more by availability of Li + at the interface, due to limitations in diffusion through the active material with increasing discharge rates. This diffusion limitation causes a drop in available energy, and subsequently a decrease in cell equilibrium potential and the heat generation rate at the location of the short. On the other hand, rapid depletion of lithium concentration in the electrolyte and accumulation on the electrode surface results in highly non-uniform transport properties resulting in higher heat generation rates. Hence, the heating regime shifts from "local heating" to "global heating". Based on the findings, important design parameters for battery safety are discussed.
Developing Standards to Qualify a Fine Water Mist Fire Extinguisher for Human Spaceflight
NASA is developing a Fine Water Mist Portable Fire Extinguisher for use on the International Space Station. The International Space Station presently uses two different types of fire extinguishers: a water foam extinguisher in the Russian Segment, and a carbon dioxide extinguisher in the US Segment and Columbus and Kibo pressurized elements. Changes in emergency breathing equipment make Fine Water Mist operationally preferable. Supplied oxygen breathing systems allow for safe discharge of a carbon dioxide fire extinguisher, without concerns of the crew inhaling unsafe levels of carbon dioxide. But the Portable Breathing Apparatus offers no more than 15 minutes of capability, and continued use of hose based supplied oxygen systems increases the oxygen content in a fire situation. NASA has developed a filtering respirator cartridge for use in a fire environment. It is qualified to provide up to 90 minutes of capability, and because it is a filtering respirator it does not add oxygen to the environment. The fire response respirator cartridge does not filter carbon dioxide, so a crew member discharging a CO2 fire extinguisher while wearing this filtering respirator would be at risk of inhaling unsafe levels of CO2. Fine Water Mist extinguishes a fire without creating a large volume of air with reduced oxygen and elevated CO2. Compared to the carbon dioxide based Portable Fire Extinguisher, the flight qualification of Fine Water Mist systems requires special care. Qualification of the CO2 based Portable Fire Extinguisher began with the assumption that any fire on ISS would be extinguished if the air in the fire environment reached a critical concentration of CO2. Qualification of a CO2 based system requires the developers to make assertions and assumptions about vehicle geometry and the ability of the extinguisher to deliver CO2 in different geometric configurations, but the developers did not need to make assertions or assumptions about the size of the fire, the temperature, or the heat generation rate. Fine Water Mist systems extinguish a fire predominantly by removing heat -- so qualification standards must evaluate geometry, but also temperature, heat transfer, and heat generation rate. This paper outlines and describes the methods used to develop standards used to qualify Fine Water Mist systems for a human spaceflight environment.
Design, fabrication, and operation of capsules for the irradiation testing of candidate advanced space reactor fuel pins
Fuel irradiation experiments were designed, built, and operated to test uranium mononitride (UN) fuel clad in tungsten-lined T-111 and uranium dioxide fuel clad in both tungsten-lined T-111 and tungsten-lined Nb-1% Zr. A total of nine fuel pins was irradiated at average cladding temperatures ranging from 931 to 1015 C. The UN experiments, capsules UN-4 and -5, operated for 10,480 and 10,037 hr, respectively, at an average linear heat generation rate of 10 kW/ft. The UO2 experiment, capsule UN-6, operated for 8333 hr at an average linear heat generation rate of approximately 5 kW/ft. Following irradiation, the nine fuel pins were removed from their capsules, externally examined, and sent to the NASA Plum Brook Facility for more detailed postirradiation examination. During visual examination, it was discovered that the cladding of the fuel pin containing dense UN in each of capsules UN-4 and -5 had failed, exposing the UN fuel to the NaK in which the pins were submerged and permitting the release of fission gas from the failed pins. A rough analysis of the fission gas seen in samples of the gas in the fuel pin region indicated fission gas release-to-birth rates from these fuel pins in the range of .00001.
Scoping Study of Effects on the Advanced Test Reactor’s Center Flux Trap Due to Various Loadings in the H and Inner A Test Positions
This study determined the effects experienced by the In-Pile Tube, of the Advanced Test Reactor’s center flux trap, due to various loading configurations of the H and Inner A positions. The effects of concern included: the axial profile of the linear heat generation rate of each fuel rodlet, the axial flux shape, and spectrum, in the fuel, and cladding, of each rodlet, and the total fission heating rate of the entire In-Pile Tube. Additionally, the reactivity worth of each configuration, relative to an ATR configuration with water filling all concerning test positions, was determined. The test positions were filled with commonly used test specimens, backup test specimens, and homogeneous substances. The study was performed using the modeling software MCNP6.2.
Heat generation in electric double layer capacitors with neat and diluted ionic liquid electrolytes under large potential window between 5 and 80 °C
Here, this study investigates the effect of temperature on the heat generation and the associated electrochemical phenomena occurring in IL-based EDLCs. The EDLCs consisted of two identical activated carbon electrodes with neat Pyr14TFSI or Pyr14TFSI diluted in propylene carbonate (PC) as electrolytes. The instantaneous heat generation rate at each electrode was measured by isothermal calorimetry between 5 and 80 °C under constant current cycling and potential window of 2.5 V. First, the instantaneous heat generation rate was similar at each electrode in neat IL. However, it was smaller at the negative electrode in diluted IL and featured endothermic dips growing with increasing temperature > 40 °C due to overscreening effects, ion desolvation, and/or decomposition of PC. The irreversible heat generation was similar in each half-cell and decreased with increasing temperature due to the reduction in internal resistance, particularly with neat IL. The irreversible heat generation exceeded Joule heating in all cases, especially at high temperature and low current. This was attributed to ion desorption and charge redistribution in the porous electrodes. Finally, the reversible heat generation for both electrolytes was larger at the positive than at the negative electrode due to the difference in anion and cation sizes.