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DOE OSTI2023

Physical vapor deposition simulator by graphical processor unit ray casting

This paper presents fast, accurate software for modeling physical vapor deposition systems over irregular surfaces. The model is implemented using graphics processing unit (GPU) ray casting. Applied models are viewed as a cross section of the area of interest. Given evaporation rate, time, and angular profiles in a vacuum system, an iterative time-step approach for calculating deposition profiles is calculated in the GPU architecture following a ballistic modeling approach. Thin-film technologies for the electronics industry will require evaporations on complex surfaces. Depending on the nature of the surface, a uniform thin film across the topology is wanted for various device parameters. The ray casting method is tested against various profiles. The code is freely distributed on GitHub (see https://github.com/adam-r-thomas/PVDS).

Engineering↗

DOE OSTI2017

Pececillo

Pececillo is a proxy-app for the open source Truchas metal processing code (LA-CC-15-097). It implements many of the physics models used in Truchas: free-surface, incompressible Navier-Stokes fluid dynamics (e.g., water waves); heat transport, material phase change, view factor thermal radiation; species advection-diffusion; quasi-static, elastic/plastic solid mechanics with contact; electomagnetics (Maxwell's equations). The models are simplified versions that retain the fundamental computational complexity of the Truchas models while omitting many non-essential features and modeling capabilities. The purpose is to expose Truchas algorithms in a greatly simplified context where computer science problems related to parallel performance on advanced architectures can be more easily investigated. While Pececillo is capable of performing simulations representative of typical Truchas metal casting, welding, and additive manufacturing simulations, it lacks many of the modeling capabilites needed for real applications.

Jibben, Zechariah↗

DOE OSTI2017

Pececillo

Carlson, Neil↗

NASA NTRS1984

Development of a VOR/DME model for an advanced concepts simulator

The report presents a definition of a VOR/DME, airborne and ground systems simulation model. This description was drafted in response to a need in the creation of an advanced concepts simulation in which flight station design for the 1980 era can be postulated and examined. The simulation model described herein provides a reasonable representation of VOR/DME station in the continental United States including area coverage by type and noise errors. The detail in which the model has been cast provides the interested researcher with a moderate fidelity level simulator tool for conducting research and evaluation of navigator algorithms. Assumptions made within the development are listed and place certain responsibilities (data bases, communication with other simulation modules, uniform round earth, etc.) upon the researcher.

Steinmetz, G. G.↗

DOE OSTI2018

Simulation of Air Entrainment during Mold Filling: Comparison with Water Modeling Experiments

Oxide inclusions form during pouring of metal castings as a result of air entrainment. Recently, a model was developed by the authors to predict the volumetric air entrainment during pouring. It was found that the velocity, diameter, and turbulence intensity of the liquid stream affect the air entrainment rate during pouring. In this study, the developed air entrainment model is validated with water modeling experiments. In the water modeling studies, water was poured using a bottom pour ladle. The effects of nozzle opening, head height, nozzle diameter, and nozzle extension are simulated. The predictions compare favorably with the experimental measurements. Results indicate that low head height and short pouring time have a beneficial effect on reducing the air entrainment during pouring. In addition, a fully open nozzle and the use of a nozzle extension further reduce the amount of entrained air.

36 MATERIALS SCIENCE↗

DOE OSTI2019

Effect of Nozzle Port Angle on Transient Flow and Surface Slag Behavior During Continuous Steel-Slab Casting

Undesirable flow variations can cause severe instabilities at the interface between liquid mold flux and molten steel across the mold top-region during continuous steel casting, resulting in surface defects in the final products. A three-dimensional Large Eddy Simulation (LES) model using the volume of fluid method for the slag and molten steel phases is validated with plant measurements, and applied to gain new insights into the effects of nozzle port angle on transient flow, top slag/steel interface movement, and slag behavior during continuous slab casting under nominally steady conditions. Upward-angled ports produce a single-roll flow pattern with lower surface velocity, due to rapid momentum dissipation of the spreading jet. However, strong jet wobbling from the port leads to greater interface variations. Severe level drops allow easy entrapment of liquid flux by the solidifying steel shell at the meniscus. Sudden level rises may also be detrimental, leading to overflow of the solidified meniscus region. Downward-angled ports produce a classic double-roll pattern with less jet turbulence and a more stable interface everywhere except near the narrow faces. Finally, the flow patterns, surface velocity, and level predicted from the validated LES model are compared with steady-state standard k-ε model predictions.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Manufacturing of Al-Ce/Metal-Matrix-Composites (MMC) for Harsh Environments

An integrated modeling/simulation and experimental approach will be used to design and synthesize Al-Ce/MMC for use in key technologies where improved energy efficiency and performance is harsh environments is required. Modeling and simulation work including thermodynamic modeling, DFT calculations, and continuum modeling of casting processes and mechanical behavior, will be combined with lab-scale synthesis to identify potential matrix and reinforcing phase compositions for large-scale synthesis. The experimental synthesis work will rely on lab-scale casting and gas atomization to identify the optimal matrix compositions for pilot/commercial-scale synthesis is Al-Ce/MMC. Selected Al-Ce/MMC will be synthesized by commercial scale melt processing, powder metallurgy and thermomechanical processing. The corrosion resistance, mechanical properties as a function of temperature, and thermal conductivity of the composites will be characterized to validate target properties are met or exceeded. This work will focus on two selected applications; however, the design framework will have broad applicability for composites for numerous harsh service condition applications. We will have synthesized Al-Ce/MMC that exhibit better performance in harsh environments than currently used materials.

36 MATERIALS SCIENCE↗

NASA NTRSDate not supplied

3D Phase-Field Simulations of Pattern Formation During Freeze Casting

We present the results of a combined experimental and phase-field modeling study of pattern formation during freeze casting. Those studies use unidirectional freezing of simple binary liquid mixtures of water and sugars (sucrose and trehalose) in a temperature gradient, which suffice to produce hierarchical templated structures similar to those observed in more complex multi-component freeze-cast systems including lamellae, undulated ridges, and more exotic “jellyfish-like” substructures. Multiscale 3D phase-field simulations reproduce remarkably well those structures quantitatively and identify key properties of the ice-water interface that control their formation. They further reveal that lamellae form as a result of a novel symmetry-breaking secondary instability of partially faceted cellular structures and pinpoint additional secondary instability mechanisms giving rise to smaller-scale substructures.

Kaihua Ji↗

NASA NTRSDate not supplied

3D Phase-Field Simulations of Pattern Formation During Freeze Casting

Kaihua Ji↗

NASA NTRS1993

Thermosolutal convection and macrosegregation in dendritic alloys

A mathematical model of solidification, that simulates the formation of channel segregates or freckles, is presented. The model simulates the entire solidification process, starting with the initial melt to the solidified cast, and the resulting segregation is predicted. Emphasis is given to the initial transient, when the dendritic zone begins to develop and the conditions for the possible nucleation of channels are established. The mechanisms that lead to the creation and eventual growth or termination of channels are explained in detail and illustrated by several numerical examples. A finite element model is used for the simulations. It uses a single system of equations to deal with the all-liquid region, the dendritic region, and the all-solid region. The dendritic region is treated as an anisotropic porous medium. The algorithm uses the bilinear isoparametric element, with a penalty function approximation and a Petrov-Galerkin formulation. The major task was to develop the solidification model. In addition, other tasks that were performed in conjunction with the modeling of dendritic solidification are briefly described.

Poirier, David R.↗

DOE OSTI2017

Strong lensing analysis of the galaxy cluster MACS J1319.9+7003 and the discovery of a shell galaxy

We present a strong-lensing (SL) analysis of the galaxy cluster MACS J1319.9+7003 (z = 0.33, also known as Abell 1722), as part of our ongoing effort to analyze massive clusters with archival Hubble Space Telescope (HST) imaging. We spectroscopically measured with Keck/Multi-Object Spectrometer For Infra-Red Exploration (MOSFIRE) two galaxies multiply imaged by the cluster. Our analysis reveals a modest lens, with an effective Einstein radius of θ{sub e}(z=2)=12±1{sup ′′}, enclosing 2.1±0.3×10{sup 13} M{sub ⊙}. We briefly discuss the SL properties of the cluster, using two different modeling techniques (see the text for details), and make the mass models publicly available (ftp://wise-ftp.tau.ac.il/pub/adiz/MACS1319/). Independently, we identified a noteworthy, young shell galaxy (SG) system forming around two likely interacting cluster members, 20″ north of the brightest cluster galaxy. SGs are rare in galaxy clusters, and indeed, a simple estimate reveals that they are only expected in roughly one in several dozen, to several hundred, massive galaxy clusters (the estimate can easily change by an order of magnitude within a reasonable range of characteristic values relevant for the calculation). Taking advantage of our lens model best-fit, mass-to-light scaling relation for cluster members, we infer that the total mass of the SG system is ∼1.3×10{sup 11} M{sub ⊙}, with a host-to-companion mass ratio of about 10:1. Despite being rare in high density environments, the SG constitutes an example to how stars of cluster galaxies are efficiently redistributed to the intra-cluster medium. Dedicated numerical simulations for the observed shell configuration, perhaps aided by the mass model, might cast interesting light on the interaction history and properties of the two galaxies. An archival HST search in galaxy cluster images can reveal more such systems.

79 ASTRONOMY AND ASTROPHYSICS↗

DOE OSTI2015

An iterative particle filter approach for coupled hydro-geophysical inversion of a controlled infiltration experiment

The modeling of unsaturated groundwater flow is affected by a high degree of uncertainty related to both measurement and model errors. Geophysical methods such as Electrical Resistivity Tomography (ERT) can provide useful indirect information on the hydrological processes occurring in the vadose zone. In this paper, we propose and test an iterated particle filter method to solve the coupled hydrogeophysical inverse problem. We focus on an infiltration test monitored by time-lapse ERT and modeled using Richards equation. The goal is to identify hydrological model parameters from ERT electrical potential measurements. Traditional uncoupled inversion relies on the solution of two sequential inverse problems, the first one applied to the ERT measurements, the second one to Richards equation. This approach does not ensure an accurate quantitative description of the physical state, typically violating mass balance. To avoid one of these two inversions and incorporate in the process more physical simulation constraints, we cast the problem within the framework of a SIR (Sequential Importance Resampling) data assimilation approach that uses a Richards equation solver to model the hydrological dynamics and a forward ERT simulator combined with Archie's law to serve as measurement model. ERT observations are then used to update the state of the system as well as to estimate the model parameters and their posterior distribution. The limitations of the traditional sequential Bayesian approach are investigated and an innovative iterative approach is proposed to estimate the model parameters with high accuracy. The numerical properties of the developed algorithm are verified on both homogeneous and heterogeneous synthetic test cases based on a real-world field experiment.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗

NASA NTRS1982

Changes in blood volume and response to vaso-active drugs in horizontally casted primates

Experiments were performed on horizontally casted primates (male rhesus monkeys) in order to note changes in blood volume caused by horizontal restraint, to compare orthostatic tolerance before and after casting using the responses to upright tilting, to begin to uncover the cardiovascular and neural mechanisms involved in deconditioning, and to compare the data with that obtained from bed-rested human subjects and from humans exposed to weightlessness. Bolus injections of norepinephrine of 2.0 microgram/kg, phenylephrine of 4.0 microgram/kg, and nitroprusside of 2.0 microgram/kg were administered; and aortic pressure and heart rate were recorded during the injections. The results indicate that the horizontally casted primate is a valid animal model for studying the effects of simulated zero-G on the human cardiovascular system.

Dickey, D. T.↗

NASA NTRS2002

Nonlinear Internal Waves in the South China Sea During ASIAEX

Internal wave distribution maps have been compiled from more than one hundred ERS-1/2, RADARSAT and Space Shuttle SAR images in the South China Sea (SCS) from 1993 to 2000. Based on these distribution maps, most of internal waves in the northeast part of SCS were propagating westward. The wave crest can be as long as 200 km with amplitude of 100 m, due to strong current from the Kuroshio branching out into the SCS. In recent Asian Seas International Acoustics Experiment (ASIAEX), moorings have been deployed in April 2000 and May 2001. Simultaneous RADARSAT ScanSAR images have been collected during the field test to integrate with the model and the in-situ measurements in the SCS. During ASIAEX in May 2001, many large internal waves were observed at the test area and were the major features for acoustic volume interaction. The environmental parameters have been calculated based on extensive CTD castings and mooring data. Nonlinear internal wave models have been applied to simulate the wave evolution on the continental shelf and the results compare reasonably with mooring measurements. The evolution and dissipation of huge internal waves on the shelf break, mode-two waves, elevation waves, and wave-wave interaction are very important issues for acoustic propagation. The implication of internal wave effects on acoustic propagation will also be discussed.

ACOUSTIC PROPAGATION↗

NASA NTRS1993

Development of a CFD code for casting simulation

Because of high rejection rates for large structural castings (e.g., the Space Shuttle Main Engine Alternate Turbopump Design Program), a reliable casting simulation computer code is very desirable. This code would reduce both the development time and life cycle costs by allowing accurate modeling of the entire casting process. While this code could be used for other types of castings, the most significant reductions of time and cost would probably be realized in complex investment castings, where any reduction in the number of development castings would be of significant benefit. The casting process is conveniently divided into three distinct phases: (1) mold filling, where the melt is poured or forced into the mold cavity; (2) solidification, where the melt undergoes a phase change to the solid state; and (3) cool down, where the solidified part continues to cool to ambient conditions. While these phases may appear to be separate and distinct, temporal overlaps do exist between phases (e.g., local solidification occurring during mold filling), and some phenomenological events are affected by others (e.g., residual stresses depend on solidification and cooling rates). Therefore, a reliable code must accurately model all three phases and the interactions between each. While many codes have been developed (to various stages of complexity) to model the solidification and cool down phases, only a few codes have been developed to model mold filling.

Murph, Jesse E.↗

NASA NTRS2017

Macrosegregation Resulting from Directional Solidification Through an Abrupt Change in Cross-Sections

Simulations of the directional solidification of two hypoeutectic alloys (Al-7Si alloy and Al-19Cu) and resulting macrosegregation patterns are presented. The casting geometries include abrupt changes in cross-section from a larger width of 9.5 mm to a narrower 3.2 mm width then through an expansion back to a width of 9.5 mm. The alloys were chosen as model alloys because they have similar solidification shrinkages, but the effect of Cu on changing the density of the liquid alloy is about an order of magnitude greater than that of Si. The simulations compare well with experimental castings that were directionally solidified in a graphite mold in a Bridgman furnace. In addition to the simulations of the directional solidification in graphite molds, some simulations were effected for solidification in an alumina mold. This study showed that the mold must be included in numerical simulations of directional solidification because of its effect on the temperature field and solidification. For the model alloys used for the study, the simulations clearly show the interaction of the convection field with the solidifying alloys to produce a macrosegregation pattern known as "steepling" in sections with a uniform width. Details of the complex convection- and segregation-patterns at both the contraction and expansion of the cross-sectional area are revealed by the computer simulations. The convection and solidification through the expansions suggest a possible mechanism for the formation of stray grains. The computer simulations and the experimental castings have been part of on-going ground-based research with the goal of providing necessary background for eventual experiments aboard the ISS. For casting practitioners, the results of the simulations demonstrate that computer simulations should be applied to reveal interactions between alloy solidification properties, solidification conditions, and mold geometries on macrosegregation. The simulations also presents the possibility of engineering the mold-material to avoid, or mitigate, the effects of thermosolutal convection and macrosegregation by selecting a mold material with suitable thermal properties, especially its thermal conductivity.

Lauer, M.↗

DOE OSTI2024

Deep operator network surrogate for phase-field modeling of metal grain growth during solidification

A deep operator network (DeepONet) has been constructed that generates accurate representations of phase-field model simulations for evolving two dimensional metal grain morphology growing from melt. These representations serve as lower resolution, computationally efficient stand-ins for quick parameter space exploration of solutions to the the Allen-Cahn equations that dictate the phase-field model simulations. The experimental target for the phase-field model is a uranium casting system cooling a 434 g uranium charge from a maximum temperature of 1400° C at an average rate of 30° C / min , traversing the crystallographic phases of the pure metal. Experimental parameters inform the phase-field model, whose higher resolution computational model solutions are used to train the DeepONet in a given parameter space with the aim of developing a faster, more efficient method for predicting the solidifying metal's microstructure at different potential experimental values. The final DeepONet generates high accuracy, lower resolution predictions with cumulative relative approximation error over all timesteps of less than 0.5%, while ensuring solutions remain within physically feasible ranges. Further, these relative error values are comparable with other state-of-the-art DeepONet models for microstructure evolution, while significantly reducing the amount of training data required. Training a convolutional neural network simultaneously with the DeepONet, enforcing realistic values at the complex metal grain boundaries, and mathematically encoding boundary conditions into the structure of the DeepONet improved prediction accuracy and computational efficiency over a standard DeepONet model.

36 MATERIALS SCIENCE↗

DOE OSTI2017

Triple Plate Mold Final Report: Optimization of the Mold Design and Casting Parameters for a Thin U-10mo Fuel Casting

This work describes the experiments and modeling that have been performed to improve and try to optimize the simultaneous casting of three plates of U-10wt%Mo in a single coil vacuum induction melting (VIM) furnace. The plates of interest are 280 mm wide by 203 mm tall by 5 mm thick (11" x 8" x 0.2"). The initial mold design and processing parameters were supplied by Y-12. The mold and casting cavity were instrumented with a number of thermocouples, and the casting performed to determine the thermal history of the mold and casting. The resulting cast plates were radiographed and numerous defects identified. Metallography was performed to help identify the nature of the radiographically observed defects. This information was then used to validate a mold filling and solidification model of that casting. Based on the initial casting, good casting design practice, and process simulation of several design alternatives, a revised design was developed with the goal of minimizing casting defects such as porosity. The redesigned mold had a larger hot-top and had its long axis along the horizontal direction. These changes were to try to develop a strong thermal gradient conducive to good feeding and minimization of micro- and macroporosity in the cast plates. An instrumented casting was then performed with the revised mold design and a linear distributor. This design yielded cast plates with significantly less radiographically identified defects. Unfortunately, there was significant variation in plate weight and metal content in their hot-tops. Fluid flow simulations were then performed on this mold/distributor design. This helped identify the issue with this linear distributor design. Additional simulations were then performed on candidate distributor redesigns and a preferred distributor annular design was identified. This improved annular design was used to produce a third instrumented casting with favorable results. These refined designs and their radiographic characterization are compared to the initial design.

36 MATERIALS SCIENCE↗