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DOE OSTI2023

Multiscale Development and Validation of the Stainless Steel Alloy Corrosion (SStAC) Tool for High Temperature Engine Materials

The goal of this project was to create a simulation tool to assist in part design, reducing costs by eliminating the need for conservative material selection, and enabling alloy optimization to improve corrosion resistance. Thus, it helps decrease costs for existing engines and assists in the material and engine design for the engines of the future. To meet our stated goal, we developed the Stainless-Steel Alloy Corrosion (SStAC) tool, which: (1) Models corrosion of engine valves fabricated from 21-2N valve steel in an engine environment at temperatures up to 800 °C. (2) Runs in 1D for a fast estimate of the corrosion rate, and in 2D or 3D for more detailed simulations that represent any part geometry and predict the precise location and rate of corrosion and its impact on the mechanical and thermal behavior. (3) Was implemented using the open-source Multiphysics Object Oriented Simulation Environment (MOOSE). (4) Couples the corrosion model with mechanics and thermal transport models. The SStAC tool can predict the corrosion rate of 21-2N engine valves with less than 10% error.

36 MATERIALS SCIENCE↗

DOE OSTI2023

Effects of surface vacancy-adatom pair formation on PFC tungsten surface morphological response

Abstract We report a simulation study of the effect of He-irradiation-induced surface vacancy-adatom pair formation on the surface morphological evolution of plasma-facing component (PFC) tungsten and examine a number of factors that impact such evolution. Our analysis is based on self-consistent dynamical simulations according to an atomistically-informed, continuum-scale surface evolution model that has been developed following a hierarchical multiscale modeling strategy and can access the spatiotemporal scales of relevance to fuzz formation. The model accounts for the flux of surface adatoms generated as a result of the surface vacancy-adatom pair formation effect upon He implantation, which contributes to the anisotropic growth of surface nanostructural features due to the different rates of adatom diffusion along and across step edges of islands on the tungsten surface. We have carried out atomic-scale computations of optimal diffusion pathways along and across island step edges on the W(110) surface and calculated Ehrlich–Schwoebel (ES) barriers in adatom diffusion along and across such step edges. This aspect of surface adatom diffusion contributes to anisotropic surface atomic fluxes, terrace and step diffusive currents, and has been incorporated into our PFC surface evolution model, which predicts the formation of preferentially aligned nanoridge stripe patterns on the PFC surface. We establish that these anisotropic diffusive currents accelerate nanotendril growth on the PFC surface and the onset of surface nanostructure pattern formation. We also explore systematically the dependence of the PFC surface morphological response on the surface temperature and He ion incident flux, characterize in detail the resulting surface topographies and growth kinetics, and compare the predicted surface morphologies with experimental observations. Our simulation predictions for the emerging surface nanostructure patterns under certain plasma exposure conditions are consistent with experimental findings in the literature.

36 MATERIALS SCIENCE↗

NASA NTRS2021

Micromechanics Modeling of Textiles for Re-Entry Parachute Applications

Recent flight test projects and NASA missions have highlighted the challenges associated with accurately and efficiently modeling the behavior of parachute deployment systems needed for parachute design. Moreover, parachute deployment has been identified as one of the higher risk components for such missions. The analysis of textile fabrics used for atmospheric entry is inherently complex due to the multiple scales present in the fabric structure, including individual fiber filaments at the microscale, yarn bundles of fibers at the mesoscale, and the overall woven fabric at the macroscale. Computational tools for simulating fabric behavior must be able to account for the different mechanisms present at each scale without sacrificing computational efficiency. This work examines the generalized multiscale method of cells micromechanics theory, which has previously been used for the analysis of reinforced composite structures, to unreinforced textile fabrics. Modifications to the existing composite multiscale framework, implemented in NASA’s Multiscale Analysis Tool (NASMAT), include the specific mechanics unique to unreinforced textile fabrics, and overcoming the assumptions of a fixed fiber angle. It looks to assess the feasibility of using the NASMAT tool for efficient prediction of the response of unreinforced fabrics to loading such that it can ultimately be applied to fluid structure interaction tools for the prediction of parachute deployment systems. In this work, fabric behavior is simulated in NASMAT through homogenization of a triply periodic repeating unit cell, where the geometry of the subcells can change as a function of loading to represent the relative rotation and uncrimping that can occur in fabric tows. Predictions from the amended NASMAT code are compared to experimental data for uniaxial and off-axis tension to verify the ability of the code to incorporate lower-scale mechanics in prediction of unreinforced fabrics under loading.

Micromechanics↗

NASA NTRS2016

Multiscale Modeling of Carbon/Phenolic Composite Thermal Protection Materials: Atomistic to Effective Properties

Next generation ablative thermal protection systems are expected to consist of 3D woven composite architectures. It is well known that composites can be tailored to achieve desired mechanical and thermal properties in various directions and thus can be made fit-for-purpose if the proper combination of constituent materials and microstructures can be realized. In the present work, the first, multiscale, atomistically-informed, computational analysis of mechanical and thermal properties of a present day - Carbon/Phenolic composite Thermal Protection System (TPS) material is conducted. Model results are compared to measured in-plane and out-of-plane mechanical and thermal properties to validate the computational approach. Results indicate that given sufficient microstructural fidelity, along with lowerscale, constituent properties derived from molecular dynamics simulations, accurate composite level (effective) thermo-elastic properties can be obtained. This suggests that next generation TPS properties can be accurately estimated via atomistically informed multiscale analysis.

Materials Science↗

DOE OSTI2020

The Strong Impact of Weak Horizontal Convergence on Continental Shallow Convection

Idealized large-eddy simulation (LES) is a basic tool for studying three-dimensional turbulence in the planetary boundary layer. LES is capable of providing benchmark solutions for parameterization development efforts. However, real small-scale atmospheric flows develop in heterogeneous and transient environments with locally varying vertical motions inherent to open multiscale interactive dynamical systems. These variations are often too subtle to detect them by state-of-the-art remote and in situ measurements, and are typically excluded from idealized simulations. The present study addresses the impact of weak [i.e., O(10-6) s-1] short-lived low-level large-scale convergence/divergence perturbations on continental shallow convection. The results show a strong response of shallow nonprecipitating convection to the applied weak large-scale dynamical forcing. Evolutions of CAPE, mean liquid water path, and cloud-top heights are significantly affected by the imposed convergence/divergence. In contrast, evolving cloud-base properties, such as the area coverage and mass flux, are only weakly affected. To contrast those impacts with microphysical sensitivity, the baseline simulations are perturbed assuming different observationally based cloud droplet number concentrations and thus different rainfall. For the tested range of microphysical perturbations, the imposed convergence/divergence provides significantly larger impact than changes in the cloud microphysics. Simulation results presented here provide a stringent test for convection parameterizations, especially important for large-scale models progressing toward resolving some nonhydrostatic effects.

Meteorology & Atmospheric Sciences↗

DOE OSTI2023

Integrated Multiscale Model for Design of Robust 3D Solid-state Lithium Batteries

In FY23, we successfully established the multiscale modeling framework for probing the effects of materials microstructure on cell performance of 3D solid-state batteries. The framework covers physicochemical processes co-evolving at the atomistic and microstructure scales. Our simulations revealed the mechanism of initial interfacial degradation, formation of secondary phases, and the structure-property relationship for ion transport and mechanical stability at the interface. In addition, we also established the microstructure-performance relationships by performing sensitivity tests of various microstructure features and extracting their impact on cell performance during charge-discharge cycles. We have successfully applied our multiscale, multiphysics modeling capability to common electrode and electrolyte materials that are of interests to VTO and the experimental teams within the US-Germany collaboration. The insights we obtained from these simulations provide valuable design principles to optimize materials properties for advanced 3D solid-state batteries.

25 ENERGY STORAGE↗

DOE OSTI2017

Reactive molecular dynamics models from ab initio molecular dynamics data using relative entropy minimization

Here, we present two new multiscale molecular dynamics (MS-RMD) models for the hydrated excess proton in water developed directly from ab initio molecular dynamics (AIMD) simulation data of the same system. The potential of mean force along the proton transfer reaction coordinate and radial distribution functions for the MS-RMD models are shown faithfully reproduce those of AIMD. The models are developed using an algorithm based on relative entropy minimization, thus demonstrating the ability of the method to rapidly generate accurate and highly efficient reactive MD force fields.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2019

Multiscale Modeling of Microstructural Evolution in Fused-Coating Additive Manufacturing

A quantitative phase field model with adaptive-computational-domain-expansion (ACDE) method was developed to simulate the microstructural evolution in fused-coating additive manufacturing process. A heat transfer and fluid flow model was established to investigate the solidification behavior of the molten pool in a single deposited layer. The solidification parameters such as temperature gradient and solidification rate were calculated from the macroscopic model and then fed into the phase field model to get the microstructure at different positions within a single deposited layer. Columnar dendrites were formed at the bottom of the deposited layer, and equiaxed dendrites appeared in the upper part of the layer. The ACDE method is used to improve the simulation efficiency. The metallographic experiments and energy-dispersive spectrometer analysis for composition were conducted on the fused-coating specimen, and the results were in good accordance with the simulations.

36 MATERIALS SCIENCE↗

DOE OSTI2022

Isogeometric large-eddy simulations of turbulent particle-laden flows

In recent years, isogeometric analysis (IGA) has attracted significant attention from the computational mechanics community due to its ability to integrate design and analysis. Besides, IGA is also a higher-order discretization technique for solving partial differential equations, showing high approximation capability per degree of freedom. In this paper, we extend the application realm of IGA to particle-laden flows based on Eulerian–Eulerian description that couples Navier–Stokes equations with a density transport equation through a Boussinesq approximation. The coupled systems are solved by using quadratic non-uniform rational B-spline (NURBS) functions and a recently developed residual-based variational multiscale (VMS) formulation, which introduces coupling between the fine velocity scales and density equation residuals. We deploy the proposed approach to perform large-eddy simulations (LES) of dilute particle-laden flows over a flat surface at Reynolds number = 10,000. We compare the simulation results against direct numerical simulation (DNS) results from the literature. We find that combining VMS and IGA, the proposed approach enables accurate prediction of a wide range of flow/particle statistics with a relatively lower mesh resolution.

Mathematics↗

DOE OSTI2018

Spatial correlation of elastic heterogeneity tunes the deformation behavior of metallic glasses

Metallic glasses (MGs) possess remarkably high strength but often display only minimal tensile ductility due to the formation of catastrophic shear bands. Purposely enhancing the inherent heterogeneity to promote distributed flow offers new possibilities in improving the ductility of monolithic MGs. Here, we report the effect of the spatial heterogeneity of elasticity, resulting from the inherently inhomogeneous amorphous structures, on the deformation behavior of MGs, specifically focusing on the ductility using multiscale modeling methods. A highly heterogeneous, Gaussian-type shear modulus distribution at the nanoscale is revealed by atomistic simulations in Cu 64 Zr 36 MGs, in which the soft population of the distribution exhibits a marked propensity to undergo the inelastic shear transformation. By employing a mesoscale shear transformation zone dynamics model, we find that the organization of such nanometer-scale shear transformation events into shear-band patterns is dependent on the spatial heterogeneity of the local shear moduli. A critical spatial correlation length of elastic heterogeneity is identified for the simulated MGs to achieve the best tensile ductility, which is associated with a transition of shear-band formation mechanisms, from stress-dictated nucleation and growth to structure-dictated strain percolation, as well as a saturation of elastically soft sites participating in the plastic flow. This discovery is important for the fundamental understanding of the role of spatial heterogeneity in influencing the deformation behavior of MGs. We believe that this can facilitate the design and development of new ductile monolithic MGs by a process of tuning the inherent heterogeneity to achieve enhanced ductility in these high-strength metallic alloys.

36 MATERIALS SCIENCE↗

DOE OSTI2015

A multiscale approach to model hydrogen bonding: The case of polyamide

We present a simple multiscale model for polymer chains in which it is possible to selectively remove degrees of freedom. The model integrates all-atom and coarse-grained potentials in a simple and systematic way and allows a fast sampling of the complex conformational energy surface typical of polymers whilst maintaining a realistic description of selected atomistic interactions. In particular, we show that it is possible to simultaneously reproduce the structure of highly directional non-bonded interactions such as hydrogen bonds and efficiently explore the large number of conformations accessible to the polymer chain. We apply the method to a melt of polyamide removing from the model only the degrees of freedom associated to the aliphatic segments and keeping at atomistic resolution the amide groups involved in the formation of the hydrogen bonds. The results show that the multiscale model produces structural properties that are comparable with the fully atomistic model despite being five times faster to simulate.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2017

Dynamic fracture of tantalum under extreme tensile stress

The understanding of fracture phenomena of a material at extremely high strain rates is a key issue for a wide variety of scientific research ranging from applied science and technological developments to fundamental science such as laser-matter interaction and geology. Despite its interest, its study relies on a fine multiscale description, in between the atomic scale and macroscopic processes, so far only achievable by large-scale atomic simulations. Direct ultrafast real-time monitoring of dynamic fracture (spallation) at the atomic lattice scale with picosecond time resolution was beyond the reach of experimental techniques. We show that the coupling between a high-power optical laser pump pulse and a femtosecond x-ray probe pulse generated by an x-ray free electron laser allows detection of the lattice dynamics in a tantalum foil at an ultrahigh strain rate of Embedded Image ~2 × 10 8 to 3.5 × 10 8 s -1 . A maximal density drop of 8 to 10%, associated with the onset of spallation at a spall strength of ~17 GPa, was directly measured using x-ray diffraction. The experimental results of density evolution agree well with large-scale atomistic simulations of shock wave propagation and fracture of the sample. Our experimental technique opens a new pathway to the investigation of ultrahigh strain-rate phenomena in materials at the atomic scale, including high-speed crack dynamics and stress-induced solid-solid phase transitions.

36 MATERIALS SCIENCE↗

NASA NTRS1996

Kinetic Space Weather: Toward a Global Hybrid Model of the Polar Ionosphere-Lower Magnetosphere Plasma Transport

During the indicated period of performance, we had a number of publications concerned with kinetic polar ionosphere-lower magnetosphere plasma transport. For the IUGG 1991-4 Quadrennial Report, we reviewed aspects of U.S. accomplishments concerned with polar plasma transport, among other issues. In another review, we examined the computer simulations of multiple-scale processes in space plasmas, including polar plasma outflow and transport. We also examined specifically multiscale processes in ionospheric outflows. We developed a Generalized Semi-Kinetic(GSK) model for the topside-lower magnetosphere which explored the synergistic action of wave heating and electric potentials in the formation of auroral Ion conics, in particular the "pressure cooker" mechanism. We extended the GSK model all the way down to 120 km and applied this code to illustrate the response of the ionosphere- magnetosphere to soft-electron precipitation and convection-driven frictional ion heating, respectively. Later, the convection-driven heating work was extended to a paper for the Journal of Geophysical Research. In addition to the above full published papers, we also presented the first developments of the coupled fluid-semikinetic model for polar plasma transport during this period. The results from a steady-state treatment were presented, with the second presentation being concerned with the effects of photo-electrons on the polar wind, and the first garnering an outstanding student paper award from the American Geophysical Union. We presented the first results from a time-dependent version of this coupled fluid-semikinetic model.

Horwitz, James L.↗

DOE OSTI2022

A view on the current and future impact of research reactors

Full text of publication follows. The current fleet of nuclear research reactors worldwide is nearly 70 years old. These reactors have proven to be extremely valuable tools of nuclear science and engineering with a broad and interdisciplinary impact. To date, research reactors are utilized as tools for understanding the physics, operations, and safety of nuclear fission systems. In addition, they are used as intense sources of radiation in support of irradiation testing and nondestructive examination of materials. As this fleet of reactors ages, an urgent need exists to establish new facilities that can propel the benefit of these reactors into the 21. century. In fact, an opportunity exists to build research reactors based on technology concepts that are being considered for nuclear energy reactors. This may include high temperature gas cooled and/or molten salt based advanced and micro reactor concepts. Such future reactors should be designed to maintain the broad utility of current reactors in research and education. However, modern research reactors can be purposefully designed and instrumented to access neutronic and thermal hydraulic information that would support the development and validation of reactor multi-physics modeling and simulation techniques. In this case, the entire phenomenological paradigm of the reactor may be captured to understand the neutronic multiscale and its impact on operations and safety. Moreover, the generated data can be channeled to drive anticipatory examination of the state of the reactor. In general, a symbiotic relation may be envisioned between the modern research reactor and power reactor fleets, which could facilitate the safe and efficient implementation of clean nuclear energy. (author)

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

NASA NTRS2015

RACORO Continental Boundary Layer Cloud Investigations: 1. Case Study Development and Ensemble Large-Scale Forcings

Observation-based modeling case studies of continental boundary layer clouds have been developed to study cloudy boundary layers, aerosol influences upon them, and their representation in cloud- and global-scale models. Three 60 h case study periods span the temporal evolution of cumulus, stratiform, and drizzling boundary layer cloud systems, representing mixed and transitional states rather than idealized or canonical cases. Based on in situ measurements from the Routine AAF (Atmospheric Radiation Measurement (ARM) Aerial Facility) CLOWD (Clouds with Low Optical Water Depth) Optical Radiative Observations (RACORO) field campaign and remote sensing observations, the cases are designed with a modular configuration to simplify use in large-eddy simulations (LES) and single-column models. Aircraft measurements of aerosol number size distribution are fit to lognormal functions for concise representation in models. Values of the aerosol hygroscopicity parameter, kappa, are derived from observations to be approximately 0.10, which are lower than the 0.3 typical over continents and suggestive of a large aerosol organic fraction. Ensemble large-scale forcing data sets are derived from the ARM variational analysis, European Centre for Medium-Range Weather Forecasts, and a multiscale data assimilation system. The forcings are assessed through comparison of measured bulk atmospheric and cloud properties to those computed in "trial" large-eddy simulations, where more efficient run times are enabled through modest reductions in grid resolution and domain size compared to the full-sized LES grid. Simulations capture many of the general features observed, but the state-of-the-art forcings were limited at representing details of cloud onset, and tight gradients and high-resolution transients of importance. Methods for improving the initial conditions and forcings are discussed. The cases developed are available to the general modeling community for studying continental boundary clouds.

Boundary layers↗

DOE OSTI2016

Asynchronous in situ connected-components analysis for complex fluid flows

Fluid flow in porous media is at the heart of problems such as groundwater contamination and carbon sequestration, and presents an important challenge for scientific computing. For this class of problem, large three-dimensional simulations are performed to advance scientific inquiry. On massively parallel computing systems, the volume of data generated by such approaches can become a productivity bottleneck if the raw data generated from the simulation is analyzed in a post-processing step. We present a physics-based framework for in situ data reduction that is theoretically grounded in multiscale averaging theory. We show how task parallelism can be exploited to concurrently perform a variety of analysis tasks with data-dependent costs, including the generation of iso-surfaces, morphological analyses, and connected components analysis. A task management framework is constructed to launch asynchronous analysis threads, manage dependencies between different tasks, promote data locality and hide the impact of data transfers. The framework is applied to analyze GPU-based simulations of two-fluid flow in porous media, generating a set of averaged measures that represents the overall system behavior. We demonstrate how the approach can be applied to perform physically-consistent averaging over fluid subregions using connected components analysis. Simulations performed on Oak Ridge National Lab s Titan supercomputer are profiled to demonstrate the performance of the associated multi-threaded in situ analysis for typical production simulation of two-fluid flow.

Mcclure, James↗

NASA NTRS2013

Experimental Characterization and Simulation of Slip Transfer at Grain Boundaries and Microstructurally-Sensitive Crack Propagation

A systematic study of crack tip interaction with grain boundaries is critical for improvement of multiscale modeling of microstructurally-sensitive fatigue crack propagation and for the computationally-assisted design of more durable materials. In this study, single, bi- and large-grain multi-crystal specimens of an aluminum-copper alloy are fabricated, characterized using electron backscattered diffraction (EBSD), and deformed under tensile loading and nano-indentation. 2D image correlation (IC) in an environmental scanning electron microscope (ESEM) is used to measure displacements near crack tips, grain boundaries and within grain interiors. The role of grain boundaries on slip transfer is examined using nano-indentation in combination with high-resolution EBSD. The use of detailed IC and EBSD-based experiments are discussed as they relate to crystal-plasticity finite element (CPFE) model calibration and validation.

Gupta, Vipul↗

DOE OSTI2018

Plasma Surface Interactions: Bridging from the Surface to the Micron Frontier through Leadership Class Computing (Final Technical Progress Report)

The performance demands on plasma-facing components (PFCs) in future fusion power plants are beyond the capability of current materials. In defining the plasma-surface interaction (PSI), it is evident that three coupled spatial regions influence PFC materials evolution and performance. These regions consist of (1) the edge and scrape-off layer region of the plasma, (2) the near-surface material response to extreme thermal and particle fluxes under the influence of, and feedback to, the plasma sheath, and (3) the structural material’s response to an intense, 14 MeV peaked neutron spectrum, which produces very high concentrations of transmuted elements through (n,p) and (n,α) reactions and structural material property degradation. The objective of this project is to develop and deploy validated, high-performance simulation tools capable of predicting the performance of tungsten-based plasma-facing components (PFCs) in a burning fusion plasma environment, which includes modeling surface morphology evolution in either erosion or re-deposition regimes, and the recycling of hydrogen species. This requires the development of a leadership-scale computational code to predict PFC behavior that is well integrated to a suite of multiscale modeling techniques to bridge the scales needed to address complex physical and computational issues at the plasma surface interface and the transition region below the surface where neutron damage processes in the bulk dominate material behavior. Successful completion of this project will provide PFC simulation tools to evaluate steady-state performance of tungsten-based PFC and divertor components in burning plasma environments. This will enable the identification of critical experiments to confirm whether practical PFC solutions exist for magnetic fusion energy beyond ITER. More specifically, the research activities within this project focus on two broadly defined research thrusts: 1) Developing a new simulation code, Xolotl-PSI to predict PFC operating lifetime and performance, that is specifically designed to take advantage of leadership class computing facilities; and 2) Integrating and applying discrete particle-based, as well as continuum-based, multiscale modeling techniques to provide scientific discovery of the mechanisms controlling PFC and bulk materials evolution under fusion plasma and 14-MeV neutron exposure; in this thrust, the challenge of scale-bridging between atomistic/microstructural modeling and the continuum-scale of PFC device performance is achieved through multiscale modeling techniques. Throughout the grant period, research at UMass Amherst focused on the atomic-scale analysis of the dynamics and kinetics (transport and reactions) of small mobile helium clusters near surfaces and grain boundaries in plasma-exposed tungsten, as well as the proper parameterization and incorporation of these processes into our SciDAC team’s continuum-level cluster dynamics code (Xolotl). Our work also included characterization of large-scale molecular-dynamics (MD) simulation results of helium implantation into tungsten based on the findings of our analysis and comparisons of Xolotl simulation predictions with the large-scale MD simulation results for Xolotl validation purposes; emphasis was placed on the impact of helium cluster dynamics/kinetics on tungsten surface morphology, near-surface tungsten structure, and helium retention. Furthermore, our work included initiation of a research program on evaluating the impact of structural defects in tungsten due to plasma exposure (such as helium nanobubbles) on tungsten’s thermophysical properties, focusing on lattice thermal conductivity. Our studies contributed to a fundamental understanding of the effects of plasma-surface interactions on the dynamical response of plasma-facing materials in nuclear fusion devices and the development of predictive hierarchical multiscale computational tools for the quantitative description of the material’s dynamical response to plasma exposure.

36 MATERIALS SCIENCE↗