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DOE OSTI2024

Effect of a collapsing gas bubble on the shock-to-detonation transition in liquid nitromethane

We studied the shock-induced collapse of butane gas bubbles in the homogeneous explosive nitromethane (NM) to investigate the effects of hot spot formation on the detonation process. A butane bubble was injected into a sample of NM, and a shock wave from a flat plate impactor compressed the bubble, creating a localized hot spot. We measured shock and detonation wave speeds with optical velocimetry, and we used a high-speed camera to image the shock propagation and bubble collapse processes. A multiband optical fiber pyrometer measured the time-resolved thermal radiance, and we used the results and emissivity values extracted from spectral fits to estimate temperatures. We measured the characteristics of the shock-to-detonation transition in NM with and without a bubble. All experiments were performed at shock pressures near 8 GPa, where neat NM can detonate. A single bubble in this system was shown to sensitize NM, leading to a reduced run-to-detonation time. We used hydrodynamic modeling to predict shock wave propagation, the extent of chemical reaction, and subsequent temperature rise from the collapsing bubble. We used a temperature-dependent Arrhenius burn model for simulations, and it yielded much better results than reactive burn models that depend only on pressure and density.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

DOE OSTI2020

Injection Overmolding of Continuous Carbon Fiber Preforms

This project explored and developed a process to injection overmold continuous carbon fiber preforms fabricated with tailored fiber placement. Much early work was focused on the ability to infuse dry carbon fiber tow, fully wetting out the fibers, in an injection molding process. Various approaches were explored, including using commingled fiber and pre-consolidated flexible preforms. The commingled fiber was a blend of carbon fiber and polymer fiber matching the injecting polymer. This approach showed some merit but required an extremely high quality homogeneous mixing of the polymer fibers with the carbon fibers to wet out the carbon fiber tow. Therefore, the project focused on pre-consolidated preforms. The pre-consolidated preform manufacturing method was first developed using compression molded flat plates that were cut into tensile specimen for testing. Work then progressed to an injection molded simplified corner fitting bracket. It was shown that a viable manufacturing method for overmolding continuous carbon fiber preforms could be developed.

36 MATERIALS SCIENCE↗

DOE OSTI2020

Single-pulse (100 ps) extended x-ray absorption fine structure capability at the Dynamic Compression Sector

Determining real-time changes in the local atomistic order is important for a mechanistic understanding of shock wave induced structural and chemical changes. However, the single event and short duration (nanosecond times) nature of shock experiments pose challenges in obtaining Extended X-ray Absorption Fine Structure (EXAFS) measurements - typically used for monitoring local order changes. Here, we report on a new single pulse (~100 ps duration) transmission geometry EXAFS capability for use in laser shock-compression experiments at the Dynamic Compression Sector (DCS), Advanced Photon Source. We used a flat plate of highly oriented pyrolytic graphite (HOPG) as the spectrometer element to energy disperse x-rays transmitted through the sample. It provided high efficiency with approximately 15% of the x-rays incident on the HOPG reaching an x-ray area detector with high quantum efficiency. This combination resulted in good signal-to-noise ratio (~10 3 ), energy resolution of ~10 eV at 10 keV, EXAFS spectra covering 100s of eV, and good pulse to pulse reproducibility of our single pulse measurements. Ambient EXAFS spectra for Cu and Au are compared to reference spectra, validating our measurement system. Comparison of single pulse EXAFS results for ambient and laser shocked Ge(100) shows large changes to the local structure of the short lived state of shocked Ge. The current DCS EXAFS capability can be used to perform single pulse measurements in laser shocked materials from approximately 9-13 keV. These EXAFS developments will be available to all users of the DCS.

47 OTHER INSTRUMENTATION↗

DOE OSTI2022

Low-Carbon District Heating: Performance Modeling of Hybrid Solar, Heat Pump, and Thermal Storage Systems for District Thermal Energy in the United States

District heating requires thermal energy in the temperature range of 40 degrees C - 120 degrees C. Typically, the thermal energy input for these systems has largely been met through fossil energy. However, the temperature range is low enough that it presents an opportunity for low-carbon technologies such as solar thermal and electrified thermal generators like heat pumps to decarbonize the heat generation. In this paper, a heat pump model was applied to estimate the performance and economics of a real-world low-carbon district heating substation. This system is comprised of a flat plate solar collector field paired with a mechanical vapor compression heat pump and hot water thermal storage, augmented by gas-fired boilers. Plant data was used to tune the model and estimate the system's benefits in terms of both standard financial metrics (IRR and payback), and environmental metrics, including avoided CO2 emissions. The model is subsequently employed to estimate the technical and economic potential of solar + heat pump + ther-mal storage hybrid systems as retrofits for district heating systems in eight US Markets.

district heating↗

DOE OSTI2023

Numerical Investigation of Wall-Cooling Effect on Aero-Optical Distortions for Hypersonic Boundary Layer

Compressible wall-modeled large-eddy simulations of Mach 8 turbulent boundary-layer flows over a flat plate were carried out for the conditions of the hypersonic wind tunnel at Sandia National Laboratories. The simulations provide new insight into the effect of wall cooling on the aero-optical path distortions for hypersonic turbulent boundary-layer flows. Four different wall-to-recovery temperature ratios, 0.3, 0.48, 0.71, and 0.89, are considered. Despite the much lower grid resolution, the mean velocity, temperature, and resolved Reynolds stress profiles from the simulation for a temperature ratio of 0.48 are in good agreement with those from a reference direct numerical simulation. The normalized root-mean-square optical path difference obtained from the present simulations is compared with that from reference direct numerical simulations, Sandia experiments, as well as predictions obtained with a semi-analytical model by Notre Dame University. Here the present analysis focuses on the effect of wall cooling on the wall-normal density correlations, on key underlying assumptions of the aforementioned model such as the strong Reynolds analogy, and on the elevation angle effect on the optical path difference. Wall cooling is found to increase the velocity fluctuations and decrease the density fluctuations, resulting in an overall reduction of the normalized optical path distortion. Compared to the simulations, the basic strong Reynolds analogy overpredicts the temperature fluctuations for cooled walls. Also different from the strong Reynolds analogy, the velocity and temperature fluctuations are not perfectly anticorrelated. Finally, as the wall temperature is raised, the density correlation length, away from the wall but inside the boundary layer, increases significantly for beam paths tilted in the downstream direction.

42 ENGINEERING↗

DOE OSTI2023

Expanded verification and validation studies of hypersonic aerodynamics with multiple physics-fidelity models

Hypersonic aerothermodynamics is an important domain of modern multiphysics simulation. The Multi-Fidelity Toolkit is a simulation tool being developed at Sandia National Laboratories to predict aerodynamic properties for compressible flows from a range of physics fidelities and computational speeds. These models include the Reynolds-averaged Navier–Stokes (RANS) equations, the Euler equations with momentum-energy integral technique (MEIT), and modified Newtonian aerodynamics with flat-plate boundary layer (MNA+FPBL) equations, and they can be invoked independently or coupled with hierarchical Kriging to interpolate between high-fidelity simulations using lower-fidelity data. However, as with any new simulation capability, verification and validation are necessary to gather credibility evidence. This work describes formal code- and solution-verification activities, as well as model validation with uncertainty considerations. Code verification activities on the MNA+FPBL model build on previous work by focusing on the viscous portion of the model. Viscous quantities of interest are compared against those from an analytical solution for flat-plate, inclined-plate, and cone geometries. The code verification methodology for the MEIT model is also presented. Test setup and results of code verification tests on the laminar and turbulent models within MEIT are shown. Solution-verification activities include grid-refinement studies on simulations that model the HIFiRE-1 wind tunnel experiments. These experiments are used for validation of all model fidelities. A thorough validation comparison with prediction error and uncertainty is also presented. Three additional HIFiRE-1 experimental runs are simulated in this study, and the solution verification and validation work examines the effects of the associated parameter changes on model performance. Finally, a study is presented that compares the computational costs and fidelities from each of the different models.

42 ENGINEERING↗

DOE OSTI2025

X-Ray Microtomography Measurements of Coevolving Particle Size and Shape

This study measures simultaneous changes in particle size and shape during grain crushing and proposes quantitative metrics to track their coevolving statistical distribution. Idealized granular materials with widely different initial particle shapes (i.e., spheres, quasi-ellipsoids, plates, and rods) are compressed oedometrically at vertical stress levels sufficient to induce particle breakage. X-ray microtomography and digital image analysis are then used to track changes in particle-scale characteristics. The observations indicate that more irregular particles tend to exhibit a higher degree of breakage compared to more spherical grains subjected to an equivalent stress level. Despite these differences, the measurements also indicate that all the tested particle sets approach a common attractor (expressed in terms of aspect ratio, flatness, and elongation), regardless of their initial morphology. A new shape evolution index is proposed to quantify such trends. With this new metric, it is shown that in all the tested materials, the particle shape evolves faster than size, especially for the more regular morphologies, thus implying that the shape tends to reach its attractor point before the grading reaches its ultimate particle size distribution. Furthermore, this finding underpins an ultimate stage of crushing-driven compression that occurs with particle size reduction but minimal shape changes (i.e., self-replicating shapes due to fractures).

Oedometric compression↗

DOE OSTI2022

Verification and Validation Activities for the Multi-Fidelity Toolkit

The Multi-Fidelity Toolkit (MFTK) is a simulation tool being developed at Sandia National Laboratories for aerodynamic predictions of compressible flows over a range of physics fidelities and computational speeds. These models include the Reynolds-Averaged-Navier-Stokes (RANS) equations, the Euler equations, and modified Newtonian aerodynamics (MNA) equations, and they can be invoked independently or coupled with hierarchical Kriging to interpolate between high-fidelity simulations using lower-fidelity data. However, as with any new simulation capability, verification and validation are necessary to gather credibility evidence. This work describes formal code- and solution-verification activities as well as model validation with uncertainty considerations. Code verification is performed on the MNA model by comparing with an analytical solution for flat-plate and inclined-plate geometries. Solution-verification activities include grid-refinement studies of HIFiRE-1 wind tunnel measurements, which are used for validation, for all model fidelities. A thorough treatment of the validation comparison with prediction error and validation uncertainty is also presented.

42 ENGINEERING↗

DOE OSTI2022

Direct numerical simulation of hypersonic turbulent boundary layers: effect of spatial evolution and Reynolds number

Direct numerical simulations (DNS) are performed to investigate the spatial evolution of flat-plate zero-pressure-gradient turbulent boundary layers over long streamwise domains ( >300δ i , with δ i the inflow boundary-layer thickness) at three different Mach numbers, 2.5, 4.9 and 10.9, with the surface temperatures ranging from quasiadiabatic to highly cooled conditions. The settlement of turbulence statistics into a fully developed equilibrium state of the turbulent boundary layer has been carefully monitored, either based on the satisfaction of the von Kármán integral equation or by comparing runs with different inflow turbulence generation techniques. The generated DNS database is used to characterize the streamwise evolution of multiple important variables in the high-Mach-number, cold-wall regime, including the skin friction, the Reynolds analogy factor, the shape factor, the Reynolds stresses, and the fluctuating wall quantities. The data confirm the validity of many classic and newer compressibility transformations at moderately high Reynolds numbers (up to friction Reynolds number Re τ ≈1200 ) and show that, with proper scaling, the sizes of the near-wall streaks and superstructures are insensitive to the Mach number and wall cooling conditions. The strong wall cooling in the hypersonic cold-wall case is found to cause a significant increase in the size of the near-wall turbulence eddies (relative to the boundary-layer thickness), which leads to a reduced-scale separation between the large and small turbulence scales, and in turn to a lack of an outer peak in the spanwise spectra of the streamwise velocity in the logarithmic region.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗

DOE OSTI2021

RapidClave® Technology Demonstrations - I

This demonstration sought to show a dramatic reduction in tool cost for RapidClave® tooling, taking advantage of recent modifications made on the RapidClave® system. Instead of building tools with complex internal heating, simple aluminum tools would be produced and heated externally through the recently added hot plate and air blower inside the RapidClave® system. Baselining against this tooling is the legacy RapidClave® tooling, as well as compression tooling, which would be the incumbent processing technique that the RapidClave® is displacing. Both an automotive and aerospace application were used to evaluate the tooling and process. Specifically, a four-piece Volkswagen hood structure was selected as an appropriate automotive geometry, while a wing structure representative of a current wing entering limited production was provided by Cornerstone Research Group for evaluating aerospace applications. In total, six tools were fabricated, and costs were compared against compression tooling quotes of the same tool geometry. A cost savings of over 80% was shown on all the tools. This demonstration also produced parts in the RapidClave® using the abovementioned tools to validate the low-cost tooling and the machine modifications. Solvay recommended two prepreg systems, CYCOM® EP2750 and SolvaLite™ 712, as appropriate for aerospace and automotive applications, respectively. Flat panels of each material were fabricated to verify cure parameters before proceeding with actual part fabrication. On-tool cycle times of approximately 30 minutes was achieved, with modifications identified to lower the time further.

36 MATERIALS SCIENCE↗