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At least 397 records · Page 22

Exceptional strength and wear resistance in an AA7075/TiB 2 composite fabricated via friction consolidation

The friction consolidation method successfully reinforced aluminum 7075 alloy (AA7075) with high-volume fractions (12 and 24 vol%) of titanium diboride (TiB 2 ) by high pressure and severe plastic deformation at elevated temperatures. The consolidated AMCs have a uniform dispersion of submicron- and micron-sized TiB 2 particles in the AA7075 matrix, with significant refinement of the matrix grain size and the particles. The addition of TiB 2 significantly increases hardness by up to 50 %, Young’s modulus by up to 62 %, and ultimate tensile strength by up to 28 % to 672 MPa, while reducing ductility by 80 %. Wear resistance of 7075/24 vol% TiB 2 improves seven-fold compared to baseline, making it comparable to that of carburized steels. Microstructure-based finite element modeling provided a theoretical strength limit of ~730 MPa for the composites and indicated that high triaxiality in conjunction with severe equivalent plastic strain in a narrow area between the TiB 2 particles led to early fracture initiations, limiting the ductility.

36 MATERIALS SCIENCE↗

Integrability technique for fluid flow induced deformation of a boundary hair

The deformation of a dense carpet of hair due to Stokes flow in a channel can be described by a nonlinear integrodifferential equation for the shape of a single hair, which possesses several solutions for a given choice of parameters. Although it was posed in a previous study and it bears a resemblance to the pendulum problem from mechanics, this equation has not been analytically solved until now. Despite the presence on an integral with a nonlinear functional dependence on the dependent variable, the system is integrable. We compare the analytically obtained solution to a finite-difference numerical approach, identify the physically realizable solution branch, and briefly study the solution structure through a conserved energylike quantity. Time-dependent fluid-structure interactions are a rich and complex subject to investigate, and we argue that the solution discussed herein can be used as a basis for understanding these systems.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗

Numerical relativity simulations of prompt collapse mergers: Threshold mass and phenomenological constraints on neutron star properties after GW170817

We determine the threshold mass for prompt (no bounce) black hole formation in equal-mass neutron star (NS) mergers using a new set of 227 numerical relativity simulations. We consider 23 phenomenological and microphysical finite-temperature equations of state (EOS), including models with hyperons and first-order phase transitions to deconfined quarks. We confirm the existence of EOS-insensitive relations between the threshold mass, binary tidal parameter at the threshold (Λth), maximum mass of nonrotating NSs, and radii of reference mass NSs. We combine the EOS-insensitive relations, phenomenological constraints on NS properties, and observational data from GW170817 to derive an improved lower limit on radii of maximum mass and a 1.6 M ⊙ NS of 9.81 and 10.90 km, respectively. We also constrain the radius and quadrupolar tidal deformability (Λ) of a 1.4 M ⊙ NS to be larger than 10.74 km and 172, respectively. We consider uncertainties in all independent parameters—fitting coefficients as well as GW170817 masses while reporting the range of radii constraints. We discuss an approach to constrain the upper as well as lower limit of NS maximum mass using future binary NS detections and their identification as prompt or delayed collapse. With future observations, it will be possible to derive even tighter constraints on the properties of matter at and above nuclear density using the method proposed in this work.

79 ASTRONOMY AND ASTROPHYSICS↗

Approach and rotation of reconnecting topological defect lines in liquid crystal

Topological defects are a universal concept across many disciplines, such as crystallography, liquid-crystalline physics, low-temperature physics, cosmology, and even biology. In nematic liquid crystals, topological defects called disclinations have been widely studied. For their three-dimensional (3D) dynamics, however, only recently have theoretical approaches dealing with fully 3D configurations been reported. Further, recent experiments have observed 3D disclination line reconnections, a phenomenon characteristic of defect line dynamics, but detailed discussions were limited to the case of approximately parallel defects. In this paper, we focus on the case of two disclination lines that approach at finite angles and lie in separate planes, a more fundamentally 3D reconnection configuration. Observing and analyzing such reconnection events, we find the square-root law of the distance between disclinations and the decrease of the interdisclination angle over time. We compare the experimental results with theory and find qualitative agreement on the scaling of distance and angle with time, but quantitative disagreement on distance and angle relative mobilities. To probe this disagreement, we derive the equations of motion for systems with reduced twist constant and also carry out simulations for this case. These, together with the experimental results, suggest that deformations of disclinations may be responsible for the disagreement. Published by the American Physical Society 2024

36 MATERIALS SCIENCE↗

Approach and rotation of reconnecting topological defect lines in liquid crystal

Topological defects are a universal concept across many disciplines, such as crystallography, liquid-crystalline physics, low-temperature physics, cosmology, and even biology. In nematic liquid crystals, topological defects called disclinations have been widely studied. For their three-dimensional (3D) dynamics, however, only recently have theoretical approaches dealing with fully 3D configurations been reported. Further, recent experiments have observed 3D disclination line reconnections, a phenomenon characteristic of defect line dynamics, but detailed discussions were limited to the case of approximately parallel defects. In this paper, we focus on the case of two disclination lines that approach at finite angles and lie in separate planes, a more fundamentally 3D reconnection configuration. Observing and analyzing such reconnection events, we find the square-root law of the distance between disclinations and the decrease of the interdisclination angle over time. We compare the experimental results with theory and find qualitative agreement on the scaling of distance and angle with time, but quantitative disagreement on distance and angle relative mobilities. To probe this disagreement, we derive the equations of motion for systems with reduced twist constant and also carry out simulations for this case. These, together with the experimental results, suggest that deformations of disclinations may be responsible for the disagreement.

36 MATERIALS SCIENCE↗

TReactMech v4.217

TReactMech couples geomechanical processes (poroelasticity, failure, and inelastic strain) with multiphase nonisothermal flow (derived from TOUGH2) and reactive geochemical transport. At its core is the reactive-transport code TOUGHREACT v4.13. TReactMech is an efficient hybrid parallel simulator, solving the geomechanics using finite elements and MPI/PetSc, the multiphase flow using integrated finite difference and MPI/PETSc, and the reactive chemistry using OpenMP. The advantages of TReactMech are in its multiphase flow capabilities (e.g., supercritical CO2, supercritical water, air) and parallel geomechanics including full 3-D stress tensor, shear and tensile failure, coupled to porosity and permeability changes. It is backwardly compatible with TOUGH2 and TOUGHREACT v4.13, allowing for easier transitions between the codes. TReactMech can be used to simulate many natural and engineered subsurface systems, including geothermal reservoirs, borehole heat exchangers, geologic carbon sequestration, geologic storage of nuclear waste, groundwater resources, weathering, sediment diagenesis, seafloor hydrothermal circulation, hydrofracturing in unconventional reservoirs, and injection/production-induced surface deformation.

Sonnenthal, Eric↗

Evaluating the bond strength and fracture mechanisms of cold-sprayed zinc coating on AZ91 magnesium substrate via a combined experimental and computational approach

Magnesium (Mg) alloys are ideal candidates for automotive applications due to their high strength to weight ratio, castability, recyclability etc., however, they lack corrosion and oxidation resistance. Solid-state deposition techniques, such as cold spray, have been demonstrated to enhance their corrosion resistance as it relies on the severe plastic deformation of powder particles upon impact with the substrate to form a metallurgical bond with the substrate and within the coating. At cold sprayed interfaces, a heterogeneous microstructure is formed that includes some porosity, oxides and intermetallics which can significantly affect coating performance. Thus, establishing a direct correlation between the interface microstructure and its properties can aid in designing optimal cold spray parameters. In this study, we investigated the microstructure and mechanical properties of a zinc (Zn) coating deposited on a high pressure die cast (HPDC) AZ91 Mg substrate via high resolution scanning transmission electron microscopy, in situ micro-tensile testing, and finite element method (FEM) modeling. Micro-tensile pillars fabricated using the plasma focused ion beam (PFIB) successfully isolates the coating-substrate interface within the gauge length. The average bond strength of Zn-Mg interface was determined to be ∼140 MPa with failure occurring partially at the interface and mostly into the coatings. A detailed microstructural characterization revealed evidence of a strong metallurgical bonding at the Zn-Mg interface and formation of the C14 MgZn 2 laves phase interlayer resulting in a mixed mode of fracture during the micro-tensile experiments. FEM modeling reveals the stress distribution along the interfaces and suggests that a MgZn 2 layer thickness between 200–400 nm is optimum to increase the bond strength and minimize the triaxiality. Such a site-specific interfacial analysis with correlative computational modeling provides crucial insight into the overall performance of cold spray interfaces.

Bond strength↗

Modeling and Simulation of Fuel Dispersal During the Loss-of-Coolant Accident

This document is the compilation of the milestone portion to a larger end of project NEUP report. The executive summary of the modeling portion is provided below: In the event of cladding rupture during a postulated LOCA in a pressurized water reactor, fuel particles, along with fission gases, can be expelled into the reactor core from the fractured fuel rod, a phenomenon referred to as fuel dispersal. The initial stage of fuel dispersal is strongly influenced by the high-pressure ejection of fuel fragments, the size and geometry of the ruptured cladding, and the depressurization history of the fuel rod during the postulated LOCA transient. Depending on the location of the burst orifice relative to the quench front, the dispersal event represents an intricate three-phase flow and heat transfer phenomenon, where high-temperature fuel particles carried by the fission gases interact with the coolant within the narrow subchannels of the fuel assemblies, inducing localized phase change. Given the unique multiphysics nature of this phenomena, the current study develops a dedicated computational framework to predict the mass distribution and cooling of dispersing fuel particles, facilitating post-accident assessment and management of the fuel assemblies. Considering the scale of nuclear reactor applications, a continuum three-fluid model is proposed for simulating the transport of solids within the reactor core. With high-temperature fuel fragments within the liquid media, nucleation sites inducing phase changes are dispersed within the flow domain. Coupled with the fact that the transient dispersal event occurs on different time scales than other three-phase flow applications, this study derives a time-averaged three-fluid flow model without losing generality. The assumptions regarding the continuum treatment of the solid phase and the modeling of fuel dispersal behavior are incorporated to simplify the governing equations and derive applicable closure relations. The computational validation of the model was conducted using adiabatic experimental results obtained from ongoing research at Oregon State University, focusing on characterizing fuel dispersal behavior during simulated LOCA conditions. Settlement characteristics of the solids, quantified by the probability distribution of equivalent particles, closely matched the probability density functions reported in experimental studies. The transport of fuel particles within a scaled 5 × 5 lattice of a pressurized-water reactor rod bundle geometry was modeled through a two-fluid Eulerian framework. The required boundary conditions were evaluated from the fuel performance code BISON in a postulated large-break LOCA scenario. The modeling framework considered solid fuel particles as granular matter, interacting with the gaseous dry steam phase and fission gases through the governing interfacial momentum exchange between the participating fluids. The simulation results provided the volume fraction of the solids obtained at the bottom surface of the enclosing tank geometry. Postulated LOCA leading to fuel dispersal phenomena involves the strong coupling between fuel thermomechanics, cladding deformation, thermal-hydraulics, and fuel particle transport. Incorporation of such a strong coupling in numerical simulation is performed by coupling the multiphysics solvers. In the case of fuel dispersal, a strong coupled simulation can be performed by coupling the BISON code for fuel performance, the TRACE code for system-level thermal hydraulics, and fuel particle transport in Multiphysics Object-Oriented Simulation Environment (MOOSE). For such intricate infrastructure, the MOOSE Framework eases the data transfer between codes. The recent version of MOOSE has incorporated the Navier-Stokes module for the fluid flow. An exploratory exercise was done to gain familiarity with finite volume capabilities in the MOOSE framework to incorporate the Spalart-Allmaras (SA) turbulence model. New finite-volume and auxiliary kernels were introduced to assemble the SA transport equation, compute turbulent viscosity, and evaluate wall distance and diagnostic turbulence terms, fully integrated with existing Navier-Stokes modules. A turbulent lid-driven cavity at a Reynolds number of approximately 10,000 is used for verification. MOOSE shows the robust solver convergence and produces the turbulent features. But it underpredicts the velocity profile and turbulent quantities, emphasizing the need to develop improved SA near-wall treatments (e.g., low-Re corrections or wall functions) as a key direction for future work.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

An integrated EOS, pore‐crush, strength and damage model framework for near‐field ground‐shock

Abstract An integrated Equation of State (EOS) and strength/pore‐crush/damage model framework is provided for modeling near to source (near‐field) ground‐shock response, where large deformations and pressures necessitate coupling EOS with pressure‐dependent plastic yield and damage. Nonlinear pressure‐dependence of strength up to high‐pressures is combined with a Modified Cam‐Clay‐like cap‐plasticity model in a way to allow degradation of strength from pore‐crush damage, what we call the “Yp‐Cap” model. Nonlinear hardening under compaction allows modeling the crush‐out of pores in combination with a fully saturated EOS, that is, for modeling partially saturated ground‐shock response, where air‐filled voids crush. Attention is given to algorithmic clarity and efficiency of the provided model, and the model is employed in example numerical simulations, including finite element simulations of underground explosions to exemplify its robustness and utility.

54 ENVIRONMENTAL SCIENCES↗

Extremized nonlinear and linearized responses in soft metamaterials enabled by gradient-based design and grayscale digital light processing

In this study, we develop a gradient-based design approach that exploits grayscale digital light processing (DLP) 3D printing for extremizing the nonlinear and linearized response of soft metamaterials — materials that harness engineered geometric instabilities to undergo large and programmable changes in configuration. Grayscale DLP approaches modulate local mechanical properties at the pixel scale by tuning the light intensity within a single grayscale image, unlocking an exceptionally large design space. To effectively navigate this space, we develop smooth mappings between local light intensity values and global quantities of interest that characterize the behavior of soft metamaterials. Enabling these smooth mappings are robust and differentiable nonlinear finite element simulations powered by a trust region solver. A PDE-constrained optimization problem is then solved to invert these mappings and produce light intensity distributions that endow the printed part with varying stiffness and flexibility in distinctive regions. It is shown that optimizing the distribution of soft and stiff phases throughout a metamaterial structure results in markedly different buckling and self-contact configurations to drive extremized nonlinear compression and linearized vibration responses. Optimized light intensity distributions are translated to grayscale images and directly used to print soft metamaterial samples, showing remarkable agreement between the buckling and self-contact response in simulated and measured deformed configurations.

Additive manufacturing↗

Data-Driven Surrogate Modeling with Microstructure-Sensitivity of Viscoplastic Creep in Grade 91 Steel

Abstract To support the development of advanced steel alloys tailored to withstand extreme conditions, it is imperative to account for the mechanical performance of components, while considering the influence of local microstructure on the macroscopic response. To this end, this study focuses on the development of microstructure-sensitive constitutive models for the mechanical response of Grade 91 steel exposed to extreme thermo-mechanical environments. Polynomial chaos expansion (PCE) surrogates are used to emulate high-fidelity polycrystal simulations of the viscoplastic response of Grade 91 steel as a function of the microstructure fingerprint (e.g., dislocations and precipitates). To cover a wide temperature–stress domain, two separate PCE surrogates—one that captures softening and the other that captures hardening behavior—are combined using another (sparse) Gaussian process regression model. The resulting constitutive creep surrogate model is integrated within the MOOSE finite element framework to simulate the intricate effects of microstructure, in particular MX-phase precipitates, on a component with a graded microstructure. Surrogate sensitivity analysis is applied to quantify the relevant impact of spatially varying microstructure on the creep response in a test-case involving a Grade 91 alloy with a prototypical weld.

36 MATERIALS SCIENCE↗

FY23 Simulation of Elastic-Plastic Failure Propagation

This memo summarizes the simulation of ductile failure propagation work conducted under the ASC project “V&V of Ductile Failure” conducted during FY 23. Physically, the failure propagation consists of crack propagation in the material. In the numerical setting—specifically in a finite element model—propagation can be accomplished through element death when critical conditions occur locally at an element that is then deleted from the simulation. The validation of the finite element models is evaluated by direct comparison between the experimental and simulation results regarding the rate of crack growth and its influence on the load-deflection response of the specimens tested. This work considers two geometries that display stable crack propagation under displacement-controlled conditions. The first geometry consists of hat specimens loaded in compression with nominally identical geometries but made with three different materials: Steel A286, Al 7075-T651 and 304L stainless steel. The three materials represent a range of ductility values that affect the response and crack propagation within the specimen. The crack induced propagates under an essentially mode-II type of deformation. The second geometry consists of a pre-cracked 304L stainless steel compact tension test specimen loaded so as to induce a mode-I deformation at the crack.

36 MATERIALS SCIENCE↗

Properties of the neutron star crust: Quantifying and correlating uncertainties with improved nuclear physics

A compressible liquid-drop model (CLDM) is used to correlate uncertainties associated with the properties of the neutron star (NS) crust with theoretical estimates of the uncertainties associated with the equation of state (EOS) of homogeneous neutron and nuclear matter. For the latter, we employ recent calculations based on Hamiltonians constructed using chiral effective-field theory (χEFT). Fits to experimental nuclear masses are employed to constrain the CLDM further, and we find that they disfavor some of the χEFT Hamiltonians. The CLDM allows us to study the complex interplay between bulk, surface, curvature, and Coulomb contributions, and their impact on the NS crust. It also reveals how the curvature energy alters the correlation between the surface energy and the bulk symmetry energy. Here our analysis quantifies how the uncertainties associated with the EOS of homogeneous matter implies significant uncertainties for the composition of the crust, its proton fraction, and the volume fraction occupied by nuclei. We find that the finite-size effects impact the crust composition but have a negligible effect on the net isospin asymmetry of matter. The isospin asymmetry is largely determined by the bulk properties and the isospin dependence of the surface energy. The most significant uncertainties associated with matter properties in the densest regions of the crust, the precise location of the crust-core transition, are found to be strongly correlated with uncertainties associated with the Hamiltonians. By adopting a unified model to describe the crust and the core of NSs, we tighten the correlation between their global properties such as their mass-radius relationship, moment of inertia, crust thickness, and tidal deformability with uncertainties associated with the nuclear Hamiltonians.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗

Magnetostrictive Ultrasonic Waveguide Transducer for In-Pile Thermometry

Real-time and reliable temperature measurement on nuclear fuels is crucial for the safe operation of existing pressurized-water reactors and future advanced nuclear reactors. Magnetostrictive materials deform when subjected to a magnetic field or exhibit magnetization variation when stressed. Here, based on these properties, this study prototyped an ultrasonic thermometer (UT) consisting of a magnetostrictive waveguide, a dc coil providing appropriate magnetic biasing, and an ac coil generating an acoustic impulse and detecting the resulting acoustic echoes. By tracking the time of flight between the excitation pulse and the echoes, the UT can potentially detect nuclear fuel cladding temperature from a long distance. In this study, magnetostrictive iron–gallium alloys, or Galfenol, were selected as the waveguide due to their large magnetostriction, superior temperature survivability, excellent radiation resilience, and high mechanical robustness. A multiphysics finite-element model considering electrical, magnetic, and mechanical dynamics in the magnetostrictive UT was then developed. The model exhibited an error of 0.24% in time-of-flight simulation and, therefore, enabled computer-aided design and guided signal processing. Between room temperature and 120 °C, the new Galfenol-based UT exhibits a linear sensitivity of 162.8×10 ₋6 °C ₋1 , which is 51.7% higher than a previous magnetostrictive UT based on iron–cobalt–vanadium alloys.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

Large-scale parametric modeling of spent nuclear fuel dynamics in the 30 cm package drop scenario

Packages used to transport spent nuclear fuel (SNF) are required by the U.S. Code of Federal Regulations 10 CFR 71.71 to demonstrate satisfactory performance during a drop scenario. While the CFR is meant to ensure safe package function, it does not evaluate survival of the SNF within. The U.S. Department of Energy Spent Fuel and Waste Science and Technology program is working on closing the knowledge gap related to the response of SNF to external mechanical loads, including the hypothetical 30 cm package drop scenario in the CFR. In support of this effort, LS-DYNA finite element simulations were developed by Pacific Northwest National Laboratory (PNNL) to model generic drop scenarios at both the package and fuel assembly level. The models were validated against one-third scale package and full scale fuel assembly drop test data and were exercised to predict fuel cladding strains in a narrow range of model configurations. This work describes a large-scale parametric study conducted by PNNL using the previously developed and validated PWR finite element model, with the addition of a new generic BWR assembly model. The motivation for the parametric study was to characterize the broad range of SNF responses in the 30 cm package drop scenario. This was accomplished by varying the drop orientation, fuel assembly type (17x17 PWR and 10x10 BWR), burnup, cladding temperature, spacer grid buckling load, package mass, impact limiter stiffness, and mechanical gap conditions within the basket. A MATLAB framework was developed to automate LS-DYNA model generation and execution on PNNL institutional computing resources. In total, over 2000 simulations were performed. For each simulation, the SNF response was quantified in terms of permanent grid deformation, fuel rod contact pressure, and strains within the fuel rods, guide tubes, and water rods. The results provide valuable insight into the range of responses that could be reasonably expected from SNF in the hypothetical drop scenario, as well as the sensitivity to each input parameter. The results of this parametric study are a key component of the testing and modeling strategy the Spent Fuel and Waste Science and Technology program is using to close the external loads knowledge gap.

Kadooka, Kevin↗

Parametric estimation of Poisson's ratio for thin hinged-hinged plates

Cornu's method is an elegant calculation besieged by an impractical approach to obtain accurate estimates for Poisson's ratio. Conventionally, Cornu's method requires several components, and each component can adversely affect the accuracy of the measurement. Furthermore, Cornu's conventional method requires a long beam because beams with short length-to-width ratios cause the estimate of Poisson's ratio to diverge from the true value of Poisson's ratio. We believe that, with the right modifications, Cornu's method can become an attractive approach to obtaining precise estimates for Poisson's ratio from mode shapes. Here we use finite element simulations to show how to use Cornu's method to estimate Poisson's ratio from a mode shape. Our modified Cornu's method removes knife-edges and loading components for a hinged-hinged plate under steady-state excitation. Given the true value of Poisson's ratio, as a performance specification, we show that simple parametric expressions can fit estimates for Poisson's ratio for different length-to-width ratios of thin hinged-hinged plates. Additionally, we show that estimates for Poisson's ratio from higher modes align with the results from the first mode and explain our expectation for this outcome. Furthermore, our results challenge the idea that anticlastic, monoclastic, and synclastic deformation uniquely correspond to positive, zero, and negative estimates of Poisson's ratio, respectively. With the emergence of materials-by-design, we expect that this parametric technique will be able to assist in experimental qualification of thin beam and plate structures with respect to the desired value of Poisson's ratio.

42 ENGINEERING↗

Development and preliminary validation of a mechanistic multiscale model for fuel-cladding chemical interaction in metallic nuclear fuels

Despite decades of fuel rod material and design improvements, fuel-cladding chemical interaction (FCCI) remains the single-most lifetime-limiting behavior for modern metallic fuel rods. Constraining fuel lifetime increases operating costs, limiting the economic viability of commercializing metallic nuclear fuel technology. A mechanistic multiscale model utilizing the finite element method-based MARMOT and BISON codes was developed to more confidently predict cladding-side FCCI and its impact on fuel performance. The new BISON model incorporates mesoscale models for the effects of fuel microstructure evolution on the transport of wastage-inducing lanthanides through the fuel and for the kinetics of cladding wastage layer growth. The mesoscale models, in turn, build on lanthanide transport property data obtained from the atomistic scale. Preliminary validation studies using wastage thickness and cladding profilometry data from four fuel rods irradiated in Experimental Breeder Reactor II experiment X447 and one fuel rod from Fast Flux Test Facility experiment IFR1 show that the new model predicts cladding wastage and its effects on cladding deformation as well as existing empirical FCCI correlations. The new model is expected to aid in the design of new metallic fuel concepts, including fuel additives, cladding liners, and sodium-free annular fuel geometries. In conclusion, future work will focus on broader validation and refinement of the model’s treatment of different fuel alloys and cladding materials.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗