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DOE OSTI2024

Software Verification of VARPOW

The VARPOW program is a post-processing utility program for DIF3D, specifically DIF3DVARIANT, and it was developed to provide interface files for the thermal analysis program DASSH. The basic methodology of VARPOW is to take the neutron and gamma flux (moments) calculated by DIF3D (or GAMSOR) and combine them with the heating (coefficient) cross sections to calculate the spatial power distributions using the DIF3DVARIANT spatial basis. VARPOW can use the output from GAMSOR (both steady state neutron and gamma flux calculations) or standard DIF3D/REBUS calculations (neutron flux only). The correct approach for defining the power distribution is to use GAMSOR as its purpose was to properly compute the gamma heating throughout the modeled domain. The power densities calculated by VARPOW are broken into fuel, cladding and coolant terms for which isotope-wise categorization is needed. VARPOW has built in options the user can select for the isotope categorization or VARPOW can import a file that details the isotope categorization. VARPOW can export the solution in the polynomial basis of DIF3D-VARIANT or the monomial basis of DIF3D-VARIANT. The purpose of this work is to verify the power distribution results calculated by VARPOW from both the GAMSOR and DIF3D input options and verify that the input and output options are consistent with the manual. Hand calculation and independent numerical calculation are used for this verification work.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2024

Software Verification of VARPOW

The VARPOW program is a post-processing utility program for DIF3D, specifically DIF3DVARIANT, and it was developed to provide interface files for the thermal analysis program DASSH. The basic methodology of VARPOW is to take the neutron and gamma flux (moments) calculated by DIF3D (or GAMSOR) and combine them with the heating (coefficient) cross sections to calculate the spatial power distributions using the DIF3DVARIANT spatial basis. VARPOW can use the output from GAMSOR (both steady state neutron and gamma flux calculations) or standard DIF3D/REBUS calculations (neutron flux only). The correct approach for defining the power distribution is to use GAMSOR as its purpose was to properly compute the gamma heating throughout the modeled domain. The power desnities calculated by VARPOW are broken into fuel, cladding and coolant terms for which isotope-wise categorization is needed. VARPOW has built in options the user can select for the isotope categorization or VARPOW can import a file that details the isotope categorization. VARPOW can export the solution in the polynomial basis of DIF3D-VARIANT or the monomial basis of DIF3D-VARIANT. The purpose of this work is to verify the power distribution results calculated by VARPOW from both the GAMSOR and DIF3D input options and verify that the input and output options are consistent with the manual. Hand calculation and independent numerical calculation are used for this verification work.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗

DOE OSTI2026

Software Verification of VARPOW

The VARPOW program is a post-processing utility program for DIF3D, specifically DIF3DVARIANT, and it was developed to provide interface files for the thermal analysis program DASSH. The basic methodology of VARPOW is to take the neutron and gamma flux (moments) calculated by DIF3D (or GAMSOR) and combine them with the heating (coefficient) cross sections to calculate the spatial power distributions using the DIF3DVARIANT spatial basis. VARPOW can use the output from GAMSOR (both steady state neutron and gamma flux calculations) or standard DIF3D/REBUS calculations (neutron flux only). The correct approach for defining the power distribution is to use GAMSOR as its purpose was to properly compute the gamma heating throughout the modeled domain. The power desnities calculated by VARPOW are broken into fuel, cladding and coolant terms for which isotope-wise categorization is needed. VARPOW has built in options the user can select for the isotope categorization or VARPOW can import a file that details the isotope categorization. VARPOW can export the solution in the polynomial basis of DIF3D-VARIANT or the monomial basis of DIF3D-VARIANT. Recently the clad neutron damage calculation capability was introduced into VARPOW, and it now allows a pathway to get distributions of clad DPA. The purpose of this work is to verify the power distribution, fast neutron flux and clad DPA results calculated by VARPOW from both the GAMSOR and DIF3D input options and verify that the input and output options are consistent with the manual. Hand calculation and independent numerical calculation are used for this verification work.

Zhong, Zhaopeng [Argonne National Laboratory (ANL)↗

DOE OSTI2022

Development of Integrated Thermal Fluids Modeling Capability for MSRs

The DOE Nuclear Energy Advanced Modeling and Simulation (NEAMS) program supports a full range of computational thermal fluids analysis capabilities and code developments for a broad class of light-water and advanced reactor concepts. The research and development approach under thermal fluids technical area synergistically combines three length and time scales in a hierarchal multi-scale approach. To demonstrate the feasibility and capabilities of a multi-scale thermal fluids capability using these codes, a key joint effort has been pursued to develop an integrated system-and engineering-scale thermal fluids analysis capability with the MOOSE-based codes, through integration of SAM and Pronghorn, both based on the MOOSE framework. This report summarizes the progress in developing an integrated system- and engineering-scale thermal fluids analysis capability based on SAM and Pronghorn for molten salt reactors (MSRs), which gained significant interest in recently years. Two coupling approaches were studied, i.e. separate domain or domain-segregated coupling approach and the domain-overlapping approach. A series of coupled multi-physics models have been developed for a common reference molten salt fast reactor (MSFR) concept, ranging from standalone SAM system model to integrated SAM-Pronghorn-Griffin models. Both the steady state and the transient simulations are performed to the state-of-the-art simulation capabilities of NEAMS software suite in MSFR system applications. This report also covers further development and testing of the gas transport model in SAM for MSR modeling support. The presence of noncondensable gas in MSR systems would have strong impacts on fission gas removal and transport of noble metals throughout the system. Fission products removed through the off-gas system can also impact reactivity and can act as an additional point of heat removal. To ensure that the gas transport model is adequately tested, the supported modeling capabilities and features of SAM were identified, and a suite of tests were developed to test the model for each identified feature. Validation and UQ testing were also performed for the model and demonstrated that the buoyancy term, which was originally developed using non-salt/helium gas experimental data, can capture the experimental gas bubble velocity and diameter to within experimental and code uncertainty. An existing MSRE model was also modified in this work to include the gas transport model and to demonstrate the gas model behavior for realistic conditions of interest.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2021

DART-PFLOTRAN: An ensemble-based data assimilation system for estimating subsurface flow and transport model parameters

Ensemble-based Data Assimilation (EDA), based on the Monte Carlo approach, has been effectively applied to estimate model parameters through inverse modeling in subsurface flow and transport problems. However, implementation of EDA approach involves a complicated workflow that include setting up and executing ensemble forward model simulations, processing observations and model simulation results for parameter updates, and repeat for sequential or iterative EDA. To facilitate the management of such workflow and lower the barriers for adopting EDA-based parameter estimation in subsurface science, we develop a generic software frame-work linking the Data Assimilation Research Testbed (DART) with a massively parallel subsurface FLOw and TRANsport code PFLOTRAN. The new DART-PFLOTRAN leverages both the core data assimilation engines in DART and the computational power afforded by PFLOTRAN. In addition to the standard smoother and filtering options, DART-PFLOTRAN enables an iterative EDA workflow based on the Ensemble Smoother for Multiple Data Assimilation method (ES-MDA) to improve estimation accuracy for nonlinear forward problems. Here, we verify the implementation of ES-MDA in DART-PFLOTRAN using two synthetic cases designed to estimate static permeability and dynamic exchange fluxes across the riverbed, respectively, from continuous temperature measurements made across a depth profile. One-dimensional hydro-thermal simulations are performed in both cases to relate temperature responses with the parameters of interest. In the case of estimating dynamic parameters, we demonstrate the flexibility of DART-PFLOTRAN in automating sequential ES-MDA workflow, which will significantly reduce the time researchers spend on managing complex workflows in similar applications. Both studies yield accurate estimations of the parameters compared to their synthetic truth, while ES-MDA leads to more accurate estimation when a high level of nonlinearity exist between observed responses and unknown parameters. With a code base in Python and Fortran, DART-PFLOTRAN paves the way for applications in large-scale subsurface inverse modeling by automating the complex workflow of sequential ES-MDA that can be executed on various computing platforms.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2021

Population balance modeling of polyurethane foam formation with pressure‐dependent growth kernel

Abstract Polyurethane foams are widely used materials often chosen for their useful characteristics such as low thermal conductivity, ease of application, and high strength‐to‐weight ratios. Computational models are needed to predict the dynamics of the flow and expansion, and the resulting material properties, to improve manufacturing processes. In this paper, a model for PMDI, a water‐blown polyurethane foam, is presented. By extending a kinetics‐based approach by adding bubble‐scale information via a population balance equation (PBE) using the quadrature method of moments, we can track bubble size distributions during foaming. We present results from a three‐dimensional computational fluid dynamics model using arbitrary Lagrangian–Eulerian interface tracking implemented in finite element software. The model compares favorably with experimental data, including dynamics, bubble distributions measured by both camera and diffusion wave spectroscopy, and post‐test bubble size from scanning electron microscopy and density measurements from x‐ray computed tomography.

Ortiz, Weston↗

DOE OSTI2025

Metabolic skinflint or spendthrift? Insights into ground sloth integument and thermophysiology revealed by biophysical modeling and clumped isotope paleothermometry

Abstract Remains of megatheres have been known since the 18th -century and were among the first megafaunal vertebrates to be studied. While several examples of preserved integument show a thick coverage of fur for smaller ground sloths living in cold climates such as Mylodon and Nothrotheriops , comparatively very little is known about megathere skin. Assuming a typical placental mammal metabolism, it was previously hypothesized that megatheres would have had little-to-no fur as they achieved giant body sizes. Here the “hairless model of integument” is tested using geochemical analyses to estimate body temperature to generate novel models of ground sloth metabolism, fur coverage, and paleoclimate with Niche Mapper software. The simulations assuming metabolic activity akin to those of modern xenarthrans suggest that sparse fur coverage would have resulted in cold stress across most latitudinal ranges inhabited by extinct ground sloths. Specifically, Eremotherium predominantly required dense 10 mm fur with implications for seasonal changes of coat depth in northernmost latitudes and sparse fur in the tropics; Megatherium required dense 30 mm fur year-round in its exclusive range of cooler, drier climates; Mylodon and Nothrotheriops required dense 10–50 mm fur to avoid thermal stress, matching the integument remains of both genera, and further implying the use of behavioral thermoregulation. Moreover, clumped isotope paleothermometry data from the preserved teeth of four genera of ground sloth yielded reconstructed body temperatures lower than those previously reported for large terrestrial mammals (29 ± 2°–32 ± 3° C). This combination of low metabolisms and thick fur allowed ground sloths to inhabit various environments.

Deak, Michael D.↗

DOE OSTI2023

Characterization of the Fast-Neutron Irradiator and the Fast-Flux Tube Irradiation Fixtures at the Pennsylvania State Breazeale Reactor

Accurate knowledge of the neutron spectrum at a nuclear research reactor is a prerequisite for planning irradiation experiments, as well as for evaluating irradiation exposure results. The neutron-flux spectrum in the fast-neutron irradiator (FNI) and the fast-flux tube (FFT) irradiation fixtures at the Pennsylvania State Breazeale Reactor (PSBR) were characterized using the multi-foil neutron activation method. These irradiation fixtures make use of graded shielding to produce unique neutron fields. Multiple foil sets were irradiated in the fixtures with different exposure times and reactor powers to understand the stability over a wide range of operating conditions. Measured results were evaluated against a MCNP6 simulation to produce a measurement-informed neutron flux-energy spectrum for each fixture using STAYSL_PNNL. Simulated estimates of the FNI fixture, a newer fixture (~25 years old), demonstrated excellent agreement with measured results; the FFT did not. Thermal neutron measurements from the FFT suggest there is additional thermal leakage not captured in the simulation model. In conclusion, possible explanations for the discrepancy include burn-out or degradation (i.e., micro-cracking, gaps, etc.) in the boral and cadmium liners over the lifetime of the fixture (~40 years old).

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2021

Validation and Verification for INL Modelica-based TEDS models Via Experimental Results

This report provides an overview on the verification and validation (V&V) of the Thermal Energy Distribution System (TEDS) model developed in the Modelica process modeling ecosystem using experimental data. Model development has led to the creation of a dynamic process model of the experimental TEDS facility housed within the Energy Systems Laboratory (ESL) at Idaho National Laboratory (INL). The model was then used during the preconstruction phase of the experimental effort to inform experimental design (e.g., insulation requirements, bypass line placement, expected performance of components) and to test innovative control schemes prior to the initial operation. The TEDS model developed in Modelica includes the primary components of the TEDS experimental unit: a 200kW Chromalox heater; a single-tank packed-bed thermal energy storage system filled with 0.125-inch alumina (Al2O3) beads; an ethylene-glycol-to-Therminol-66 heat exchanger; system piping; five control valves; and all associated temperature, pressure, and volumetric flow sensors. Using the Institute of Electrical and Electronics Engineers (IEEE) V&V methodologies, considered the gold standard in the engineering field, the model was verified using a combination of static analysis, spatial convergence, and regression tests. Then using dynamic time warping (DTW) initial runs to validate and tune the TEDS model versus the experiment were conducted. This tuning method was accomplished using the INL Risk Analysis Virtual ENvironment (RAVEN) software package. Tuning is required to account for physical phenomena that are less understood within the empirical heat transfer correlations. Through the commencement of this work, a systems-level model of TEDS with associated control systems, sensors, piping diameters, and component capabilities has been created. This model was utilized in the pre-experimental phase to inform system design, insulation thicknesses, and potential control schemes to operate the system effectively and safely. Then, initial experimental startup and operational data were used to demonstrate the validation and tuning methodology. This process demonstrates the classical two-step approach of a model informing experimental design followed by the experiment validation and tuning the model.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2022

$\mathrm{D}$ark$\mathrm{F}$lux: A new tool to analyze indirect-detection spectra of next-generation dark matter models

Here we present DarkFlux, a software tool designed to analyze indirect-detection signatures for next-generation models of dark matter (DM) with multiple annihilation channels. Version 1.0 of this tool accepts user-generated models with 2→2 tree-level dark matter annihilation to pairs of Standard Model (SM) particles and analyzes DM annihilation to γ rays. The tool consists of three modules, which can be run in a loop in order to scan over DM mass if desired: The annihilation fraction module calls an internal installation of MadDM, a dark matter phenomenology plugin for the Monte Carlo event generator MadGraph5 _ aMC@NLO, to compute the thermally averaged cross section $\langle σv\rangle_i$ for each annihilation channel $χχ$ ($\bar{χ}$,$χ^†$)→ i $\∈{SM, SM}. . The module then computes the fractional annihilation rate (annihilation fraction) into each channel. The flux module combines the flux spectrum from each annihilation channel, weighted by the appropriate annihilation fractions, to compute the total flux at Earth due to DM annihilation. In DarkFlux v1.0, this module specifically computes the γ-ray flux for each channel using the publicly available PPPC4DMID tables. The analysis module compares the total flux to observational data and computes the upper limit at 95% confidence level (CL) on the total thermally averaged DM annihilation cross section. In DarkFlux v1.0, this module compares the total γ-ray flux to a joint-likelihood analysis of fifteen dwarf spheroidal galaxies (dSphs) analyzed by the Fermi-LAT collaboration. DarkFlux v1.0 automatically provides data tables and can plot the output of these three modules. In this manual, we briefly motivate this indirect-detection computer tool and review the essential DM physics. We then describe the several modules of DarkFlux in greater detail. Finally, we show how to install and run DarkFlux and provide two worked examples demonstrating its capabilities.

79 ASTRONOMY AND ASTROPHYSICS↗

DOE OSTI2021

SSRS (Stochastic Soaring Raptor Simulator)

SSRS (Stochastic Soaring Raptor Simulator) is a generalizable, probabilistic, and predictive tool for wind energy developers, ecologists, wildlife managers and industry consultants to estimate the potential for soaring raptors to interact with operating wind turbines, without the need for site-specific data collection. Rapid expansion of wind energy development across the world has exposed the risk of turbine collisions for birds and bats. The risk to obligate soaring raptors such as golden eagles is of particular concern due to their small population and influence on ecological balance. Golden eagles rely heavily on updrafts to subsidize their flight, putting them in direct conflict with operational wind turbines that utilize the same wind resource. Understanding the behavior of soaring raptors with varying atmospheric conditions is crucial for predicting and mitigating the risk of turbine collision. This software contains a predictive movement model that simulates individual flight paths of golden eagles during updraft-subsidized long-distance flight, including migration. For a given set of atmospheric conditions, the model simulates thousands of eagles at turbine-scale spatial resolution (50m) to produce a relative presence density map. The simulated eagles rely on updrafts to pursue uninterrupted directional flight with minimal energy expenditure, following fluid-flow principles. The simulator includes a stochastic model of eagle behavior and a systematic method of accounting for spatiotemporal variations in atmospheric conditions. This framework only requires publicly available atmospheric data to estimate orographic and thermal updrafts, ensuring general usability.

Sandhu, Rimple↗

DOE OSTI2024

DECOVALEX-2023: Task F2 Salt Final Report

The subject of Task F of DECOVALEX-2023 concerns performance assessment modelling of radioactive waste disposal in deep mined repositories. The primary objectives of Task F are to build confidence in the models, methods, and software used for performance assessment (PA) of deep geologic nuclear waste repositories, and/or to bring to the fore additional research and development needed to improve PA methodologies. In Task F2- (salt), these objectives have been accomplished through staged development and comparison of the models and methods used by participating teams in their PA frameworks. Coupled-process submodels and deterministic simulations of the entire PA model for a reference scenario for waste disposal in domal salt have been conducted. The task specification has been updated continuously since the initiation of the project to reflect the staged development of the conceptual repository model and performance metrics. Thermal, hydrological, mechanical, and chemical properties of individual components of the engineered and natural system were chosen for relevance by participating teams. The salt reference case system was characterized using data and measurements collected at relevant underground research laboratories (URLs), field sites, and simulation results from teams with specialized modelling capability. Participating teams made a wide range of model assumptions from compartmentalized networks to full 3D models of the salt formation. No single contributed model includes full-fidelity representation of all the features, events, and processes (FEPs) detailed in the task specification, but almost all features and processes are represented in at least one model. Despite differences in the modelling strategies developed by participating teams, all models indicate that salt compaction and radionuclide diffusion are key processes in the repository, and for the FEPs and model scenario considered, little of the disposed radionuclides will migrate beyond the repository seal over the 100,000 year simulations. In general, the model output quantities have the largest differences over the short term and near the waste. The models tend to be more similar further from waste and at later time. Disparities between the models are believed to be due to differing simplifications from the task specification, some of which are chosen simplifications to reduce complexity, and some are restrictions imposed by the modelling tools. A second round of this task has been accepted for DECOVALEX-2027 in conjunction with Task F1 on crystalline PA modelling. The future round includes waste package heating, improved modelling of salt creep closure, additional comparisons of coupled-process sub-models, and the impact of repository engineering design on radionuclide migration in the repository. Participants will also propose and finalize a set of uncertain inputs for the reference case simulations, propagate these uncertainties in a set of realizations, and conduct sensitivity analyses on the simulation results.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2021

Thermal-striping analysis methodology for sodium-cooled reactor design

Computational fluid dynamics simulations have been performed to study the applicability of engineering CFD methods for thermals striping analysis. Thermal striping is the fluctuating temperature profile in a solid caused by fluctuating fluid temperature, and the resulting fluctuating thermal stresses cause high cycle fatigue and eventual material failure. Here this study presents the methodology for thermal striping analysis that including a transient conjugate heat transfer RANS model and benchmark the results against a sodium triple jet experiment. The multiphysics calculations are implemented to analyze the thermal stresses in the solid domain caused by the coupled heat transfer between the fluid and solid domains. Validation data from a liquid sodium triple jet experiment include time-averaged temperature measurements and power spectra of the temperature signal. The numerical results agree well with these experimental measures, demonstrating key features such as the dominant frequency of temperature fluctuations. The applicability of a low-cost wall treatment method is demonstrated, enabling key computational savings. Finally, the performance of two finite element stress analysis software packages is compared, and the validity of the lower-cost method is confirmed. These results demonstrate the applicability of engineering methods for computational thermal striping calculations, enabling thermal striping estimations in large fluid systems such as the core of a Sodium-cooled nuclear reactor.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2024

Berkeley Lab Finite Element Framework (BELFEM) v0.1

The software program, referred to as BELFEM, is a specialized finite element code designed for the magnetodynamic modeling of high-temperature superconducting (HTS) tapes. It incorporates novel mixed finite element formulations, particularly the h-ϕ-formulation with thin-shell simplification, to efficiently simulate larger geometries. This methodology is extremely promising for predicting the electrodynamic performance of HTS tapes used in superconducting cables and magnets, offering the benefit of reduced computational cost. Compared to similar technologies like COMSOL Multiphysics and GetDP, BELFEM's performance benchmarking indicates superior efficiency in its thin-shell implementation. In the future, it will also support features like thermal coupling and inter-tape current sharing, enhancing its utility in research and development, particularly in nuclear fusion applications. The intent is to develop BELFEM as a robust and efficient tool for the HTS community, contributing to the analysis and design of superconducting cables and magnets.

Messe, Christian↗

DOE OSTI2023

DOE STTR Phase I Final Report Report: Machine-learning Based Prediction of Thermal Limits for Conjugated Organic Materials

The SCANN-DT Phase I STTR project led by NLM Photonics and partnering with the National Renewable Energy Laboratory (NREL) sought to apply machine learning techniques based on graph neural networks (GNNs) towards the prediction of decomposition temperatures (Td) of organic semiconductors, based on prior work on bond dissociation energy (BDE) prediction as implemented in NREL’s ALFABET prediction tool. Using a curated set of experimental decomposition energies, the project examined GNN-based, classical quantitative structure-property relationship (QSPR) based on DFT calculations, and combinations of both methods to predict Td. While the best MAEs in Td achieved were near 40°C, below project targets, the project led to improvements in the ALFABET model, improvements in cloud-based implementations of NWChem software, and a substantial dataset of calculations on medium-sized conjugated organic molecules.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2024

Gamma Source Verification for GAMSRC and GAMSOR

Nuclear reactors that rely upon the fission reaction have two modes of thermal energy deposition in the reactor system: neutron absorption and gamma absorption. The gamma rays are typically generated by neutron capture reactions or during the fission process which means the primary driver of energy production is of course the neutron interactions. The GAMSOR program was first built in the mid 1980s to properly account for the gamma heating in an operating reactor core on core internals. The GAMSOR code is sequence of DIF3D calculations to compute the neutron and gamma flux and combine them to define both the neutron and gamma heating throughout the modeled domain. The goal of this manuscript is to present the software verification of GAMSOR. The first step of the GAMSOR sequence of calculations involves of a modified version of DIF3D (called DIF3D-GAMSOR) which generates a gamma source distribution for the follow-on DIF3D gamma transport calculation (step 2). This modified version of DIF3D increases the burden of maintenance and verification work on GAMSOR as one must reverify the DIF3D capabilities which is undesirable. Because the calculation of the gamma source is the only unique aspect of GAMSOR beyond the regular DIF3D capabilities, that part was put in a standalone code called GAMSRC such that one can use the verified DIF3D code in step 1 followed by GAMSRC to carry out the same GAMSOR calculation step. As a consequence, this manuscript is focused on verification of the gamma source files generated by GAMSRC. The verification of the modified version of DIF3D (DIF3D-GAMSOR) will be done less rigorously in that it will be verified that it produces the same output that GAMSRC does and thus GAMSRC is equivalent to GAMSOR on the problems studied here. Hand calculations and independent numerical calculations of the gamma source generation are used for the verification work. This work follows the same methodology of GAMSRC. As expected, the results agree well with those calculated by GAMSRC as will be shown.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2024

Gamma Source Verification for GAMSRC and GAMSOR

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2025

Simulation Tools for Characterizing Stress Distribution in Laser Welded Dissimilar Joints

This project focuses on developing a thermo-metallurgical-mechanical modeling method to accurately predict the microstructural evolution and residual stress in laser welding between dissimilar metals, such as HSLA steel and high carbon equivalent (CE) gear steel. The method leverages a comprehensive material database to model the temperature and rate dependent phase transformations, along with their associated effects on material properties, such as thermal expansion and flow stress, throughout the welding process. A key innovation is the incorporation of phase transformation and phase-specific properties, which enhances the accuracy of residual stress predictions. The mixture material in the fusion zone due to the dissimilar metals will also be addressed in the numerical model. This is especially critical in scenarios involving phase transformations in the fusion zone and heat-affected zone (HAZ), where the phase changes can induce substantial residual stress variations. The material database has been generated using JMatPro. The modeling approach is implemented through a custom User Material (UMAT) subroutine, executed with the commercial finite element software Abaqus.

36 MATERIALS SCIENCE↗