SEARCH · Search NASA

Results for “Precision Machining”

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.

SourceResearch connectionFrom yearThrough year

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 73 records · Page 4

All sources NASA NTRS DOE OSTI

DOE OSTI2026

Constructing field-aligned coordinate systems for gyrokinetic simulations of tokamaks in X-point geometries

Structures in tokamak plasmas are elongated along the direction of the magnetic field and short in the directions perpendicular to the magnetic field. Many tokamak simulation codes take advantage of this by using a field-aligned coordinate system. However, field-aligned coordinate systems have a coordinate singularity at magnetic X-points where the poloidal magnetic field vanishes, which makes it difficult to use field-aligned coordinate systems when simulating the core and scrape-off layer simultaneously. Here, we present an algorithm for grid generation and computing geometric quantities in a standard field-aligned coordinate system that avoids the singularity and allows one to conduct two-dimensional gyrokinetic axisymmetric simulations in X-point geometries. Convergence tests of advection, boundary value problems and geometric quantities all show greater than first-order convergence even in the vicinity of the X-point. We also demonstrate the geometric consistency of our algorithm with an example simulation of the spherical tokamak for energy production, which shows machine-precision particle conservation.

fusion plasma↗

DOE OSTI2020

Anti-symmetric representation of the extended magnetohydrodynamic equations

We introduce the anti-symmetric representation of the extended magnetohydrodynamic (MHD) equations. In this representation, the use of the anti-symmetric flux operator (∇·ν+ν·∇) results in conservation theorems with discrete analogs. Inherently robust numerical applications are achieved with little effort, and conservation to machine precision is possible with simple numerical schemes. Starting from the two-fluid equations, we construct a single-fluid MHD model based on generalized center-of-mass variables for the mass (√ρ), momentum (√ρν), and pressure (√ p ). This model is shown to possess identical conservation properties to the two-fluid system, with the only restriction being the use of a single temperature. Common approximations to the Braginskii heat fluxes and to the gyroviscous stress tensor are cast into our representation for convenience. The discrete conservation properties are verified using the classic Orszag–Tang vortex problem. In addition to the favorable mass, momentum, and energy conservation properties, the time reversibility of the simulations is demonstrated.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2024

A self-consistent Hamiltonian model of the ponderomotive force and its structure preserving discretization

In the presence of an inhomogeneous oscillatory electric field, charged particles experience a net force, averaged over the oscillatory timescale, known as the ponderomotive force. We derive a one-dimensional Hamiltonian model which self-consistently couples the electromagnetic field to a plasma which experiences the ponderomotive force. We derive a family of structure preserving discretizations of the model of varying order in space and time using conforming and broken finite element exterior calculus spectral element methods. In all variants of our discretization framework, the method is found to conserve the Casimir invariants of the continuous model to machine precision and the energy to the order of the splitting method used.

Physics↗

DOE OSTI2026

Low-energy ion beam sputtering of polycrystalline diamond

Ion beam milling is a highly versatile and precise technique for the microfabrication of diamond films, enabling controlled material removal at both micrometer and sub-micrometer scales while accommodating complex geometries and surface features. Comprehensive sputtering yield data are essential for process optimization. In this work, we systematically measure the sputter yield of polycrystalline diamond bombarded with $\textrm{N}_2^+$, Ne + , Ar + , Kr + , and Xe + ions over an energy range of 300–900 eV and beam incidence angles of 0°−80°, providing data critical for precision machining applications. Results show that the sputter yield increases with both ion energy and the incidence angle and decreases with increasing ion mass. For $\textrm{N}_2^+$ ions, the sputter yield is largely insensitive to ion energy and exceeds values expected for pure physical sputtering. The concurrent formation of volatile C 2 N 2 molecules during $\textrm{N}_2^+$ ion bombardment suggests that the process is dominated by chemical sputtering. The absence of a peak in the dependence of the sputter yield on the beam incidence angle expected at oblique incidence angles is attributed to the effects of surface roughness.

Materials science↗

DOE OSTI2023

Correcting Hohlraum Drive Asymmetry with Glow Discharge Polymerization Coated Capsule Shims

In inertial confinement fusion target design, the shape discrepancy between the cylindrical hohlraum and the spherical capsule creates a low mode asymmetry in the implosion. One way to correct such asymmetry is to shim the target capsule surface with extra mass in specific locations following a 3D P4 Legendre mode. Previously, the desired surface pattern was precision machined out of the capsule. The resulting 2DConA experiments that investigated the implosion’s shape demonstrated the shimming method’s success. However, machining leaves large defects on the capsule surface which will degrade neutron yield in a DT implosion. An alternative shimming approach is to grow the pattern on the capsule surface using a glow discharge polymerization coating process in a stencil lithography application. In this study, we discuss the fabrication, characterization and challenges of making shimmed target capsules with this new method.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2023

i-SPin: an integrator for multicomponent Schrödinger-Poisson systems with self-interactions

Abstract We provide an algorithm and a publicly available code to numerically evolve multicomponent Schrödinger-Poisson (SP) systems with a SO( n ) symmetry, including attractive or repulsive self-interactions in addition to gravity. Focusing on the case where the SP system represents the non-relativistic limit of a massive vector field, non-gravitational self-interactions (in particular spin-spin interactions) introduce complexities related to mass and spin conservation which are not present in purely gravitational systems. We address them with an analytical solution for the `kick' step in the algorithm, where we are able to decouple the multicomponent system completely. Equipped with this analytical solution, the full field evolution is second order accurate, preserves spin and mass to machine precision, and is reversible. Our algorithm allows for an expanding universe relevant for cosmology, and the inclusion of external potentials relevant for laboratory settings.

Astronomy & Astrophysics↗

DOE OSTI2022

Energy conserving and well-balanced discontinuous Galerkin methods for the Euler–Poisson equations in spherical symmetry

ABSTRACT This paper presents high-order Runge–Kutta (RK) discontinuous Galerkin methods for the Euler–Poisson equations in spherical symmetry. The scheme can preserve a general polytropic equilibrium state and achieve total energy conservation up to machine precision with carefully designed spatial and temporal discretizations. To achieve the well-balanced property, the numerical solutions are decomposed into equilibrium and fluctuation components that are treated differently in the source term approximation. One non-trivial challenge encountered in the procedure is the complexity of the equilibrium state, which is governed by the Lane–Emden equation. For total energy conservation, we present second- and third-order RK time discretization, where different source term approximations are introduced in each stage of the RK method to ensure the conservation of total energy. A carefully designed slope limiter for spherical symmetry is also introduced to eliminate oscillations near discontinuities while maintaining the well-balanced and total-energy-conserving properties. Extensive numerical examples – including a toy model of stellar core collapse with a phenomenological equation of state that results in core bounce and shock formation – are provided to demonstrate the desired properties of the proposed methods, including the well-balanced property, high-order accuracy, shock-capturing capability, and total energy conservation.

79 ASTRONOMY AND ASTROPHYSICS↗

DOE OSTI2020

Generalized Kompaneets formalism for inelastic neutrino-nucleon scattering in supernova simulations

Based on the Kompaneets approximation, we develop a robust methodology to calculate spectral redistribution via inelastic neutrino-nucleon scattering in the context of core-collapse supernova simulations. The resulting equations conserve lepton number to machine precision and scale linearly, not quadratically, with number of energy groups. The formalism also provides an elegant means to derive the rate of energy transfer to matter which, as it must, automatically goes to zero when the neutrino radiation field is in thermal equilibrium. Furthermore, we derive the next higher order in $ϵ/mc^2$ correction to the neutrino Kompaneets equation. Unlike other Kompaneets schema, ours also generalizes to the case of anisotropic angular distributions, while retaining the conservative form that is a hallmark of the classical Kompaneets equation. In this work, our formalism enables immediate incorporation into supernova codes that follow the spectral angular moments of the neutrino radiation fields.

79 ASTRONOMY AND ASTROPHYSICS↗

DOE OSTI2020

Simulating pitch angle scattering using an explicitly solvable energy-conserving algorithm

Particle distribution functions evolving under the Lorentz operator can be simulated with the Langevin equation for pitch angle scattering. This approach is frequently used in particle based Monte-Carlo simulations of plasma collisions, among others. However, most numerical treatments do not guarantee energy conservation, which may lead to unphysical artifacts such as numerical heating and spectra distortions. In this paper, we present a novel structure-preserving numerical algorithm for the Langevin equation for pitch angle scattering. Similar to the well-known Boris algorithm, the proposed numerical scheme takes advantage of the structure-preserving properties of the Cayley transform when calculating the velocity-space rotations. The resulting algorithm is explicitly solvable, while preserving the norm of velocities down to machine precision. We demonstrate that the method has the same order of numerical convergence as the traditional stochastic Euler-Maruyama method. The numerical scheme is benchmarked by simulating the pitch angle scattering of a particle beam, and comparing with the analytical solution. Benchmark results show excellent agreement with theoretical predictions, showcasing the remarkable long time accuracy of the proposed algorithm.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2024

Enhancing the Q-Factor of a Practical Qubit Niobium Three-Dimensional λ/4-Resonator Through Surface Treatment

Quantum computing stands as a revolutionary frontier in information technology, with the potential to solve complex problems far beyond the capacity of classical computers. At the heart of this disruptive innovation are qubits, forming the fundamental backbone of quantum computing. A leading-edge solution for constructing robust, enduring qubits involves embedding a Josephson junction within a high Q-factor, superconducting three-dimensional cavity. Further, our recent innovation lies in developing a uniquely optimized, quarter-wave resonator-based superconducting cavity, functioning at 6 GHz, specifically tailored for quantum computers. In this work, we elucidate our advancement towards elevating the Q-factor tenfold, an achievement made possible through the enhancement of machining precision, the application of rigorous postprocessing techniques—including mechanical, chemical, and surface treatments—as well as the refinement of our testing methods.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗

DOE OSTI2023

ALESQP: An Augmented Lagrangian Equality-Constrained SQP Method for Optimization with General Constraints

Here we present a new algorithm for infinite-dimensional optimization with general constraints, called ALESQP. In short, ALESQP is an augmented Lagrangian method that penalizes inequality constraints and solves equality-constrained nonlinear optimization subproblems at every iteration. The subproblems are solved using a matrix-free trust-region sequential quadratic programming (SQP) method that takes advantage of iterative, i.e., inexact linear solvers, and is suitable for large-scale applications. A key feature of ALESQP is a constraint decomposition strategy that allows it to exploit problem-specific variable scalings and inner products. We analyze convergence of ALESQP under different assumptions. We show that strong accumulation points are stationary. Consequently, in finite dimensions ALESQP converges to a stationary point. In infinite dimensions we establish that weak accumulation points are feasible in many practical situations. Under additional assumptions we show that weak accumulation points are stationary. We present several infinite-dimensional examples where ALESQP shows remarkable discretization-independent performance in all of its iterative components, requiring a modest number of iterations to meet constraint tolerances at the level of machine precision. Also, we demonstrate a fully matrix-free solution of an infinite-dimensional problem with nonlinear inequality constraints.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2023

Iterated Gauss-Seidel GMRES

The GMRES algorithm of Saad and Schultz [SIAM J. Sci. Stat. Comput., 7 (1986), pp. 856-869] is an iterative method for approximately solving linear systems Ax = b, with initial guess x0 and residual r0 = b Ax0. The algorithm employs the Arnoldi process to generate the Krylov basis vectors (the columns of Vk ). It is well known that this process can be viewed as a QR factorization of the matrix Bk = [r0, AVk] at each iteration. Despite an O (..epsilon..)..kappa.. (Bk ) loss of orthogonality, for unit roundoff ..epsilon..and condition number ..kappa.. , the modified Gram-Schmidt formulation was shown to be backward stable in the seminal paper by Paige et al. [SIAM J. Matrix Anal.Appl., 28 (2006), pp. 264-284]. We present an iterated Gauss-Seidel formulation of the GMRES algorithm (IGS-GMRES) based on the ideas of Ruhe [Linear Algebra Appl., 52 (1983), pp. 591-601] and Swirydowicz et al. [Numer. Linear Algebra Appl., 28 (2020), pp. 1-20]. IGS-GMRES maintains orthogonality to the level O (..epsilon..)..kappa.. (Bk ) or O (..epsilon..), depending on the choice of one or two iterations; for two Gauss-Seidel iterations, the computed Krylov basis vectors remain orthogonal to working accuracy and the smallest singular value of Vk remains close to one. The resulting GMRES method is thus backward stable. We show that IGS-GMRES can be implemented with only a single synchronization point per iteration, making it relevant to large-scale parallel computing environments. We also demonstrate that, unlike MGS-GMRES, in IGS-GMRES the relative Arnoldi residual corresponding to the computed approximate solution no longer stagnates above machine precision even for highly nonnormal systems.

Arnoldi-QR↗

DOE OSTI2024

Lattice Green’s Functions for High-Order Finite Difference Stencils

Lattice Green's Functions (LGFs) are fundamental solutions to discretized linear operators, and as such they are a useful tool for solving discretized elliptic PDEs on domains that are unbounded in one or more directions. The majority of existing numerical solvers that make use of LGFs rely on a second-order discretization and operate on domains with free-space boundary conditions in all directions. Under these conditions, fast expansion methods are available that enable precomputation of 2D or 3D LGFs in linear time, avoiding the need for brute-force multi-dimensional quadrature of numerically unstable integrals. Here we focus on higher-order discretizations of the Laplace operator on domains with more general boundary conditions, by (1) providing an algorithm for fast and accurate evaluation of the LGFs associated with high-order dimension-split centered finite differences on unbounded domains, and (2) deriving closed-form expressions for the LGFs associated with both dimension-split and Mehrstellen discretizations on domains with one unbounded dimension. Through numerical experiments we demonstrate that these techniques provide LGF evaluations with near machine-precision accuracy, and that the resulting LGFs allow for numerically consistent solutions to high-order discretizations of the Poisson's equation on fully or partially unbounded 3D domains.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2020

Simulating pitch angle scattering using an explicitly solvable energy-conserving algorithm

Particle distribution functions evolving under the Lorentz operator can be simulated with the Langevin equation for pitch angle scattering. This approach is frequently used in particle based Monte-Carlo simulations of plasma collisions, among others. However, most numerical treatments do not guarantee energy conservation, which may lead to unphysical artifacts such as numerical heating and spectra distortions. We present a novel structure-preserving numerical algorithm for the Langevin equation for pitch angle scattering. Similar to the well-known Boris algorithm, the proposed numerical scheme takes advantage of the structure-preserving properties of the Cayley transform when calculating the velocity-space rotations. The resulting algorithm is explicitly solvable, while preserving the norm of velocities down to machine precision. We demonstrate that the method has the same order of numerical convergence as the traditional stochastic Euler-Maruyama method.

Zhang, Xin↗

DOE OSTI2020

Cylinder Test

In 1941 G.I. Taylor proposed the cylinder test as an experiment to determine the properties of explosive products. The test consists of a hollow metal cylinder containing an unreacted cylindrical charge of explosives. The charge is detonated at one end of the cylinder and, as the detonation wave propagates, the product gas expands behind it. As the product gas is produced, the pressure acting on the metal increases and begins to push the walls outward. Consider the time at which the detonation wave has reached the halfway point between the two ends of the cylinder. In front of the wave nothing has changed and the metal tube has the same initial radius. Behind the wave, the radius of the tube has expanded. The farther behind the wave a section of tube is, the larger its radius has become. The longer the wall is exposed to the pressurized gas, the more it expands, so that the radius is largest where the detonation was initiated. The metal most commonly used for this experiment is soft copper. Its material properties are well known and soft copper is also easy to shape with precision machining. During the cylinder test the radial expansion of the cylinder is measured over time and this data is used to determine the amount of work applied to the cylinder wall by the product gas as a function of time. Since volume increases in this problem, the time dependence can be seen as a volume dependence. The volume dependent work yields a path in thermodynamic space. The cylinder test experiment can be modeled using simulation. The simulation gives you the answer, but it cannot tell you why. The goal of the proposed work is to use analytic analysis methods to give insight into the simulation solution.

36 MATERIALS SCIENCE↗

DOE OSTI2021

Verification Testing For Solid-Element Material Models 11-19 in DYNA3D/ParaDyn

This technical report documents the creation and implementation of verification tests for solid-element material models 11 through 19 available in DYNA3D/ParaDyn. The verification tests covered all aspects of each material model, except for the Weibull distribution functionality in material models 15 and 19. General test cases were created to verify the elastic and plastic behavior of the material models. Other additional tests were developed to examine the intricacies of each material model. Each test involved the use a kinematic load case and specification of material parameters necessary to activate corresponding features of the material model. The load cases prescribed the full time history of the kinematic motion for the solid elements, and these loads are independent of the material model or element formulation. When possible, closed form solutions were then derived for each verification test in a continuum setting. The DYNA3D simulations for each test were carried out over a unit time interval, t ϵ [0, 1], and the as implemented DYNA3D response was compared to the closed form solutions evaluated at discrete points in time. A relative error measure was determined for each test to justify the proper implementation of the material model. The relative errors comparing the DYNA3D solution to the analytical solution were, in general, on the order of machine precision except where noted. This signifies the proper implementation of solid-element material models 11-19. In the development of these verification tests, six bugs were found and fixed in the source code. Additionally, this work generated eighteen DYNA3D input decks and answer extraction scripts in the DYNA3D/ParaDyn Software Quality Assurance test suite, which are comprised of a total of 285 solid-element tests. Testing for each material model utilizes two input decks and answer extraction scripts, where one focuses on the linear elastic response and the other examines the inelastic and remaining functionalities of the material model. In total, this work added 285 individual verification test problems in the DYNA3D/ParaDyn test suite.

42 ENGINEERING↗

DOE OSTI2021

Preparation of Mechanically Robust, Macroscopic Low-Density Gold Foams by Highly Efficient Electroless Gold Plating

Mechanically robust, macroscopic-sized low-density gold foams with unique morphology of hollow gold shells were prepared by the synthesis of gold-coated polystyrene coreshell particles followed by thermal removal of the polymer core. Here, we reported a simple, highly efficient electroless gold plating procedure to form ultrathin, conformal gold coatings on the surface of polystyrene particles. A modified, scalable casting approach to form uniform, large monoliths (up to 1 cm diameter) and a baking condition to minimize undesirable densification of final foams were also developed. To demonstrate the mechanical stability and integrity of the Au foams, a representative monolithic sample (~0.9 g/ cm3 ) was successfully cut and shaped into a gold foam “washer” by a series of precision machining and processing. A depth-sensing indentation test (nanoindentation) as well as characterizations on other useful properties such as surface areas and electrical conductivity of the Au foams were carried out to understand the mechanical behavior and potential applicability.

Electroless Gold Plating↗

DOE OSTI2021

Multi-species collisions for delta-f gyrokinetic simulations: Implementation and verification with GENE

A multi-species linearized collision operator based on the model developed by Sugama et al. has been implemented in the nonlinear gyrokinetic code, GENE. Such a model conserves particles, momentum, and energy to machine precision, and is shown to have negative definite free energy dissipation characteristics, satisfying Boltzmann’s H-theorem, including for realistic mass ratio. Finite Larmor Radius (FLR) effects have also been implemented into the local version of the code. For the global version of the code, the collision operator has been developed to allow for block-structured velocity space grids, allowing for computationally tractable collisional global simulations. The validity of the collision operator has been demonstrated by relaxation and conservation tests, as well as appropriate benchmarks. The newly implemented operator shall be used in future simulations to study magnetically confined fusion plasma turbulence and transport in more extreme regions with higher collisionality.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗