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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 55 records · Page 3
All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

Material Model Parameters Optimization in Liquid Mercury Target Dynamics Simulation With Machine Learning Surrogates

A pulsed spallation target is subjected to very short (∼0.7μs) but intense loads (23.3 kJ) from repeated proton pulses, which knock away neutrons from the mercury atoms’ nuclei for a wide range application in physics, engineering, medicine, petroleum exploration, biology, chemistry, etc. The effect of this pulsed loading on the stainless-steel target module which contains the flowing mercury target material is difficult to predict not only due to its short but intense explosive-like physical reaction, but also the nonlinear material behavior of the liquid mercury in the structure. Injecting small helium bubbles in the mercury has been an efficient method of mitigating the pressure wave at high power level stage. However, prediction of the resultant loading on the target is more difficult when helium gas is intentionally injected into the mercury. A 2-phase material model that incorporates the Rayleigh-Plesset (R-P) model is expected to address this complex multi-physics dynamics problem by including the bubble dynamics in the liquid mercury. A parameter sensitivity study was firstly employed to understand their impact on the simulation strains. The investigated parameters included E, μ, γ, σ, n, VFgas, and gas cumulative volume curve control parameters a and b. Verification and validation results from sparse polynomial expansions (SPE) method and directional Gaussian smoothing (DGS) optimization show that the surrogate model had training error of ∼7% and validation error of ∼15%, indicating that machine learning methods and surrogate models can help optimize the uncertain parameters in the complex 2-phase material model. This approach is expected to fill the knowledge gap between unknown liquid-gas mixture material model and measured vessel strain responses.

Lin, Lianshan↗
DOE OSTI2017

A non-orthogonal material model of woven composites in the preforming process

Woven composites are considered as a promising material choice for lightweight applications. An improved non-orthogonal material model that can decouple the strong tension and weak shear behaviour of the woven composite under large shear deformation is proposed for simulating the preforming of woven composites. The tension, shear and compression moduli in the model are calibrated using the tension, bias-extension and bending experiments, respectively. The interaction between the composite layers is characterized by a sliding test. The newly developed material model is implemented in the commercial finite element software LS-DYNA® and validated by a double dome study.

36 MATERIALS SCIENCE↗
DOE OSTI2016

Finite Element Simulation of Compression Molding of Woven Fabric Carbon Fiber/Epoxy Composites: Part I Material Model Development

Woven fabric carbon fiber/epoxy composites made through compression molding are one of the promising choices of material for the vehicle light-weighting strategy. Previous studies have shown that the processing conditions can have substantial influence on the performance of this type of the material. Therefore the optimization of the compression molding process is of great importance to the manufacturing practice. An efficient way to achieve the optimized design of this process would be through conducting finite element (FE) simulations of compression molding for woven fabric carbon fiber/epoxy composites. However, performing such simulation remains a challenging task for FE as multiple types of physics are involved during the compression molding process, including the epoxy resin curing and the complex mechanical behavior of woven fabric structure. In the present study, the FE simulation of the compression molding process of resin based woven fabric composites at continuum level is conducted, which is enabled by the implementation of an integrated material modeling methodology in LS-Dyna. Specifically, the chemo-thermo-mechanical problem of compression molding is solved through the coupling of three material models, i.e., one thermal model for temperature history in the resin, one mechanical model to update the curing-dependent properties of the resin and another mechanical model to simulate the behavior of the woven fabric composites. Preliminary simulations of the carbon fiber/epoxy woven fabric composites in LS-Dyna are presented as a demonstration, while validations and models with real part geometry are planned in the future work.

36 MATERIALS SCIENCE↗
DOE OSTI2012

WaterTransport in PEM Fuel Cells: Advanced Modeling, Material Selection, Testing and Design Optimization

Water management in Proton Exchange Membrane, PEM, Fuel Cells is challenging because of the inherent conflicts between the requirements for efficient low and high power operation. Particularly at low powers, adequate water must be supplied to sufficiently humidify the membrane or protons will not move through it adequately and resistance losses will decrease the cell efficiency. At high power density operation, more water is produced at the cathode than is necessary for membrane hydration. This excess water must be removed effectively or it will accumulate in the Gas Diffusion Layers, GDLs, between the gas channels and catalysts, blocking diffusion paths for reactants to reach the catalysts and potentially flooding the electrode. As power density of the cells is increased, the challenges arising from water management are expected to become more difficult to overcome simply due to the increased rate of liquid water generation relative to fuel cell volume. Thus, effectively addressing water management based issues is a key challenge in successful application of PEMFC systems. In this project, CFDRC and our partners used a combination of experimental characterization, controlled experimental studies of important processes governing how water moves through the fuel cell materials, and detailed models and simulations to improve understanding of water management in operating hydrogen PEM fuel cells. The characterization studies provided key data that is used as inputs to all state-of-the-art models for commercially important GDL materials. Experimental studies and microscopic scale models of how water moves through the GDLs showed that the water follows preferential paths, not branching like a river, as it moves toward the surface of the material. Experimental studies and detailed models of water and airflow in fuel cells channels demonstrated that such models can be used as an effective design tool to reduce operating pressure drop in the channels and the associated costs and weight of blowers and pumps to force air and hydrogen gas through the fuel cell. Promising improvements to materials structure and surface treatments that can potentially aid in managing the distribution and removal of liquid water were developed; and improved steady-state and freeze-thaw performance was demonstrated for a fuel cell stack under the self-humidified operating conditions that are promising for stationary power generation with reduced operating costs.

30 DIRECT ENERGY CONVERSION↗
DOE OSTI2018

Revisiting the Pipe Bomb V&V Problem using the BCJ Material Model

For weapon safety assessments, Sandia has an interest in accurately predicting failure of pressure vessels at high temperature. In order to assess Sandia's predictive capability for these problems, a simplified validation problem for thermo-mechanical failure due to pressurization was developed and is referred to as the pipe bomb problem. In this study, several pipes were heated in a non-isothermal manner and pressurized until failure. The previous attempt to accurately predict the pipe bombs' failure pressures demonstrated a notable unconservative prediction. Due to this large bias in the simulation failure pressures toward higher pressures, we assumed that a mechanism driving failure or another aspect of the tests was missed in the original models. The goal of this work was to investigate potential sources of this bias focusing on geometric uncertainty and material model assumptions. As with the previous work, our simulations of the pipe bomb experiments using the BCJ material model over predicted the failure pressures. While success cannot be claimed for the simulated failure pressures, we believe we accurately identified the remaining sources of error in the simulations. Specifically, the temperature mapping algorithm and the geometry are believed to be the primary contributors to the errors. As a result, future work should focus on improving the temperature mapping algorithm and consider using temperature fields determined by a calibrated thermal model that includes convection. Additionally, CT scans of remaining portions of the pipe bomb material inner diameter should be taken to further understand the variability this unmachined surface introduced to the pipe bomb specimens.

42 ENGINEERING↗
DOE OSTI2025

Conference Travel Fellowships: The 10th Annual International Conference on Multiscale Materials Modeling, Baltimore, Maryland, October 19-22, 2020 (Final Technical Report)

The original scope aimed to broaden participation in the 10th International Conference on Multiscale Materials Modeling (MMM 10) by supporting travel and accommodation for 10 junior scientists from U.S. Institutions. A funding request of $\$$10,000 was submitted to partially offset the cost of registration and local accommodation for these early-career participants. Since the award was made close to the date MMM 10 was to be held, we requested a no-cost extension to defer this travel support to the 11th International Conference on Multiscale Materials Modeling (MMM 11), which was held in Prague Congress Center in the Czech Republic. The scope of the travel award remained the same: supporting travel and accommodation for 10 junior scientists from U.S. Institutions.

36 MATERIALS SCIENCE↗
DOE OSTI2017

Mechanistic materials modeling for nuclear fuel performance

Fuel performance codes are critical tools for the design, certification, and safety analysis of nuclear reactors. However, their ability to predict fuel behavior under abnormal conditions is severely limited by their considerable reliance on empirical materials models correlated to burn-up (a measure of the number of fission events that have occurred, but not a unique measure of the history of the material). In this paper, we propose a different paradigm for fuel performance codes to employ mechanistic materials models that are based on the current state of the evolving microstructure rather than burn-up. In this approach, a series of state variables are stored at material points and define the current state of the microstructure. The evolution of these state variables is defined by mechanistic models that are functions of fuel conditions and other state variables. The material properties of the fuel and cladding are determined from microstructure/property relationships that are functions of the state variables and the current fuel conditions. Multiscale modeling and simulation is being used in conjunction with experimental data to inform the development of these models. Finally, this mechanistic, microstructure-based approach has the potential to provide a more predictive fuel performance capability, but will require a team of researchers to complete the required development and to validate the approach.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2024

Unifying Quantum Materials Modeling and Experiments: The Role of Machine Learning Interatomic Potentials

Computational experiments have emerged as a powerful complement to traditional experiments in the design of new materials. The development of machine learning (ML) and deep learning techniques, combined with database construction and data mining, has significantly enhanced traditional quantum mechanical methods. This synergy enables the rapid development of structure-property relationships. In this talk, I will discuss our recent efforts in applying Machine Learning Interatomic Potentials (MLIAPs) to accelerate materials modeling across various material classes and challenging applications where traditional methods fall short. First, I will highlight the success of MLIAPs in accurately modeling the melting behavior of complex materials. Our results demonstrate high fidelity with experimental observations and also with calculated reference melting temperatures. In the second application, I will discuss how MLIAPs are trained and applied to elucidate the interplay between segregation tendencies and surface reconstructions in CuNi alloys under oxidizing conditions. A key factor in the success of these MLIAP applications is the design of minimalistic yet flexible datasets along with a computational framework for training MLIAPs.

Saidi, Wissam↗
DOE OSTI2019

Sensitivity Analysis of Material Model Parameters to Reproduce Crushing of Composite Tubes

The ability to predict the behavior of composite structures under impact conditions is an important challenge for engineering analysis since it requires modeling beyond the elasticity and into failure initiation and propagation. Crushing of laminate composites is the result of a combination of several and complex failure mechanisms, which are not always possible to reproduce together in a single finite element analysis (FEA). In this paper, models based on lamina-level failure criteria have been used to predict the onset of damage; once failure initiates, the mechanisms of failure propagation require reducing the material properties using several degradation schemes. Among the composite material models available in LS-DYNA, MAT-ENHANCED-COMPOSITE-DAMAGE (MAT-54) has been chosen for modeling the axial crushing of composite tubes with various resistant sections and wall slope, given the reduced experimental input parameters to insert into the card definition. Comparison with experimental data shows that such material model is able to successfully reproduce the crushing behavior, even if the numerical results are strictly correlated with some model parameters which cannot be measured experimentally or are purely mathematical expedients. Therefore, extensive calibration of these parameters by trial-and-error is necessary to achieve successful simulation results. Once done it for a structure made of the same composite material, it is possible to adopt the same card configuration for all the other cases, obtaining good agreement between numerical and experimental results. After, the attempt to model the same geometries using the MAT-LAMINATED-COMPOSITE-FABRIC (MAT-58) card with the same parameter values previously calibrated has been done obtaining results comparable with the experimental data.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Investigation of assumptions and approximations in the virtual fields method for a viscoplastic material model

The Virtual Fields Method (VFM) is an inverse technique used for parameter estimation and calibration of constitutive models. Many assumptions and approximations—such as plane stress, incompressible plasticity, and spatial and temporal derivative calculations—are required to use VFM with full-field deformation data, for example, from Digital Image Correlation (DIC). Here, this work presents a comprehensive discussion of the effects of these assumptions and approximations on parameters identified by VFM for a viscoplastic material model for 304L stainless steel. We generated synthetic data from a Finite-Element Analysis (FEA) in order to have a reference solution with a known material model and known model parameters, and we investigated four cases in which successively more assumptions and approximations were included in the data. We found that VFM is tolerant to small deviations from the plane stress condition in a small region of the sample, and that the incompressible plasticity assumption can be used to estimate thickness changes with little error. A local polynomial fit to the displacement data was successfully employed to compute the spatial displacement gradients. The choice of temporal derivative approximation (i.e., backwards difference versus central difference) was found to have a significant influence on the computed rate of deformation and on the VFM results for the rate-dependent model used in this work. Finally, the noise introduced into the displacement data from a stereo-DIC simulator was found to have negligible influence on the VFM results. Evaluating the effects of assumptions and approximations using synthetic data is a critical first step for verifying and validating VFM for specific applications. Finally, the results of this work provide the foundation for confidently using VFM for experimental data.

304L stainless steel↗
DOE OSTI2021

Sensitivity Analysis of Tunable Equation of State Material Model In Pulsed Mercury Target Simulation

A pulsed neutron spallation target is subjected to very short but intense loads from repeated proton pulses. Approximately 60% of the energy from each proton pulse is deposited into the mercury target material and the stainless-steel target structure, leading to a high-pressure region in both the stationary target structure and the flowing mercury. The high-pressure region propagates and leads to fluid-structure interaction. The resultant loading on the target structure containing liquid mercury is difficult to predict, although various simulation approaches and material models for the mercury have been tried. To date, the best match of simulation to experimental data is obtained by using an equation of state (EOS) material model with a specified tensile cutoff pressure, which simulates the cavitation threshold. The inclusion of a threshold to represent cavitation is key to the successful predictions of stress waves triggered by the high-energy pulse striking the mercury and vessel. However, recent measurements of target structure strain show that significant discrepancies remain between the measured and simulated strain values in the EOS mercury model. These differences grow when noncondensable helium gas is intentionally injected into the flowing mercury to reduce the loading on the structure. An EOS-based proportional–integral–derivative (PID) mercury model has been proposed to reduce the gap between the measured and simulated vessel strain responses for targets with gas injection. The conceptual and numerical description and initial investigation of the PID model are presented in previous work. Further studies of this PID model — including the sensitivity of the structure’s strain response to model parameters (the tensile cutoff, PID parameters Kp, Ki, and Kd) — are reported in this article. Results show the strain response is more sensitive to changes in the tensile cutoff value than to changes in the model parameters Kp, Ki, and Kd. These results will aid in future work where the model parameters will be optimized to match simulation data to strain measurements.

Lin, Lianshan↗
DOE OSTI2019

TUNABLE EOS MATERIAL MODEL IN THE SIMULATION OF PULSED MERCURY SPALLATION TARGET VESSEL

A pulsed spallation target is subjected to very short (~1μs) but intense loads from repeated proton pulses. The effect of this pulsed loading on the stainless-steel target module which contains the flowing mercury target material is difficult to predict. Different simulation approaches and material models for the mercury have been tried. To date the best match of simulation results to experimental data was obtained with an equation of state (EOS) material model with a specified tensile cutoff pressure which simulates the cavitation threshold [1]. The inclusion of a threshold to represent cavitation was a key parameter in achieving successful predictions of stress waves triggered by the high energy pulse striking the mercury and vessel. However, recent measurements of strain responses of target modules show that significant differences between the measured strain and the strain simulated with EOS mercury model still exist. These differences grow to irreconcilable values when non-condensable helium gas is intentionally injected into the flowing mercury. A novel EOS mercury model embedded into ABAQUS VUMAT has been investigated in this project, which introduces the concept of proportional, integral, and derivative (PID) control into the mercury EOS model. By tuning the new introduced PID parameters (Kp, Ki and Kd), we replace the specified cutoff pressure with an adjustable spring-damper-like material behavior which may better match the complex dynamics of the mercury and helium mixture. This approach is expected to reduce the gap between measured and simulated vessel strain responses. Primitive application of this tunable EOS mercury model on prototypic shape experimental target has shown its capability and potentiality of improving mechanical behaviors of EOS mercury with cutoff pressure considered.

Lin, Lianshan↗
DOE OSTI2016

Metrics for the Complexity of Material Models

Quantitative measures are proposed for characterizing the complexity of material models used in computational mechanics. The algorithms for evaluating these metrics operate on the mathematical equations in the model rather than a code implementation and are different from software complexity measures. The metrics do not rely on a physical understanding of the model, using instead only a formal statement of the equations. A new algorithm detects the dependencies, whether explicit or implicit, between all the variables. The resulting pattern of dependencies is expressed in a set of pathways, each of which represents a chain of dependence between the variables. These pathways provide the raw data used in the metrics, which correlate with the expected ease of understanding, coding, and applying the model. Usage of the ComplexityMetrics code is described, with examples.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2026

Modeling Material Interfaces with the Six-Equation Model in FLEXO

FLEXO is a multiphysics code developed at Sandia National Laboratories for predictive simulation of pulsed power target physics with extended magnetohydrodynamics modeling. Given this application space, FLEXO must be able to perform high-fidelity simulations of pulsed-power systems that include multiple materials. This work presents the augmentation of FLEXO with a six-equation model for multimaterial flow. We design and analyze discretizations of the six-equation model, emphasizing desirable properties for robust multimaterial simulation. We also present solution limiting, bounds preservation, and pressure equilibration/relaxation techniques that enhance the robustness of the overall multimaterial scheme. We present a suite of test problems to document these new capabilities of the FLEXO code.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
DOE OSTI2023

Training material models using gradient descent algorithms

High temperature design requires accurate constitutive models to describe material inelastic deformation and failure behavior. Oftentimes, calibrating accurate models devolves into the problem of fitting the model parameters against experimental test data. Here, we present the pyopmat package, an open source framework for calibrating constitutive models against experiment data subjected to various loading conditions using machine learning techniques. The package calculates the exact gradient of the model response with respect to the parameters using a combination of automatic differentiation and the adjoint method. Given this exact gradient, we compare the performance of several gradient-based optimization techniques in fitting realistic constitutive models against data. Here, we demonstrate the efficiency and accuracy of our package through example problems using both synthetic data, generated using known parameter sets, under monotonic and cyclic loading conditions and also with an example applying the techniques developed here to actual high temperature creep-fatigue test data.

36 MATERIALS SCIENCE↗
DOE OSTI2014

Exploring the Interdependencies Between Parameters in a Material Model

A method is investigated to reduce the number of numerical parameters in a material model for a solid. The basis of the method is to detect interdependencies between parameters within a class of materials of interest. The method is demonstrated for a set of material property data for iron and steel using the Johnson-Cook plasticity model.

36 MATERIALS SCIENCE↗
DOE OSTI2016

Development of Multiscale Materials Modeling Techniques and Coarse- Graining Strategies for Predicting Materials Degradation in Extreme Irradiation Environments

Exposure of metallic structural materials to irradiation environments results in significant microstructural evolution, property changes and performance degradation, which limits the extended operation of current generation light water reactors and restricts the design of advanced fission and fusion reactors [1-8]. This effect of irradiation on materials microstructure and properties is a classic example of an inherently multiscale phenomenon, as schematically illustrated in Figure 1a. Pertinent processes range from the atomic nucleus to structural component length scales, spanning more than 15 orders of magnitude. Time scales bridge more than 22 orders of magnitude, with the shortest being less than a femtosecond [1,8]. Further, the mix of radiation-induced features formed and the corresponding property degradation depend on a wide range of material and irradiation variables. This emphasizes the importance of closely integrating models with high-resolution experimental characterization of the evolving radiation- damaged microstructure, including measurements performed in-situ during irradiation. In this article, we review some recent successes through the use of closely coordinated modeling and experimental studies of the defect cluster evolution in irradiated body-centered cubic materials, followed by a discussion of outstanding challenges still to be addressed, which are necessary for the development of comprehensive models of radiation effects in structural materials.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2015

STREAMM-tools (Simulation Toolkit for Renewable Energy Advanced Materials Modeling) [SWR-15-29]

The Simulation Toolkit for Renewable Energy and Advanced Materials Modeling (STREAMM) is a python package that generates structures and input files for quantum chemical and molecular dynamics codes. STREAMM does not directly conduct simulations rather it is meant to drive quantum chemical and molecular dynamics codes to allow for high-throughput computational analysis of materials. The STREAMM package is written for python2.7 (https://www.python.org/download/releases/2.7/) and incorporates some of the core modules from the pymatgen (http://pymatgen.org/) code.

Sides, Scott↗