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At least 883 records · Page 49

AdditiveFOAM: A Continuum Multiphysics Code for Additive Manufacturing

AdditiveFOAM is a computational framework that simulates transport phenomena in Additive Manufacturing (AM) processes. It is built on OpenFOAM (Weller et al., 1998), the leading free, open-source software package for computational fluid dynamics (CFD). OpenFOAM offers an extensible platform for solving complex multiphysics problems using state-of-the-art finite volume methods. AdditiveFOAM leverages these capabilities to develop specialized tools aimed at addressing challenges in AM processing. Metal additive manufacturing, also known as metal 3D printing, is an advanced manufacturing technique that creates physical parts from a three-dimensional (3D) digital model by melting metal powder or wire feedstock. A significant area of research in metal AM focuses on process planning to mitigate anomalous features during printing that are deleterious to part performance (e.g., porosity and cracking), as well as controlling localized microstructure and material properties. Given the high costs and substantial time requirements associated with experimental methods for qualifying new materials and processes, there is a compelling incentive for researchers to utilize advanced computational simulations. In this context, AdditiveFOAM offers a simulation framework to better understand undesirable features in printing, thereby enhancing process planning and reducing the reliance on labor-intensive experimental campaigns.

Coleman, John [Oak Ridge National Laboratory (ORNL↗

Geant4-based multiphysics simulation toolkit for analysis of radiation detector performance

Often only a single physical process or component is investigated in the simulation of radiation detector systems. The results are then considered to be representative of what is expected in the correlating physical experiment. Although singular assessments may serve as a good estimate, the overall performance of a radiation detector system depends on several physical processes and the performance of all components within the system. Our Geant4-based multiphysics simulation toolkit couples radiation transport with optical photon processes, providing simulations of radiation detector systems components from the scintillator through the photocathode of the photodetector. Work to incorporate the back-end detector components, including the complete photodetector and subsequent electronics (e.g., amplifiers, digitizers), is underway. Geant4 is used to model the radiation transport and optical photon processes that occur in the front-end detector system components when exposed to a chosen source. These components include the scintillator, detector housing, optical coupling to the photodetector, and photocathode of the photodetector. Characteristics of several detector systems that have been studied include time response; pulse height spectra; number of photoelectrons per MeV; detector efficiency versus incident quanta energy; and effects on detector response due to change in geometries, materials, and reflectivity. Comparison of these characteristics by means of this toolkit enables the selection of the optimal individual components; thus, it is possible to specify the radiation detector system best suited to meet the requirements of any physical experiment.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

Development of Critical Experiments to Provide Validation Data for Multiphysics Coupling Methods (Final Report)

Computational simulation has become one of the most important tools in the modern toolbox for nuclear reactor design. Reactor simulations, like the reactors themselves, involve multiple physical processes including neutronics, fluid flow and heat transfer (thermal-hydraulics), thermo-mechanics, fuel behavior, chemistry, and balance of plant. Each process can affect the behavior of the others, and advanced computational tools have been developed that couple separate physics models together to simulate the feedback effects. The objective of this work is to generate experimental data to support the validation of multi-physics reactor codes. It specifically targets the SHARP toolset from the NEAMS Reactor Product Line, but it is intended to be useful in any set of coded that couples thermal-hydraulics with neutronics simulations. The project takes advantage of the inherent flexibility of the RPI Reactor Critical Facility (RCF), a low power open-pool research reactor. The standard configuration of the RCF is used to explore the effects of moderator temperature on neutronic behavior and reactivity. Because the low power of the reactor generates no appreciable temperature change in the moderator, the moderator temperature is artificially changed with two 18 kW electric immersion heaters. The temperature feedback effects can be observed by recording the change in the reactor power as the reactor goes from a supercritical state, to critical, to a subcritical state. To expand the temperature range and temperature rate of change that can be investigated, an experimental apparatus consisting of a heated water loop was designed and installed in the RCF. In this setup, water from a heated reservoir tank is pumped through a pipe placed through the center of the reactor core. The water in the reservoir can be heated to around 70 °C and pumped through the system. The pump has a variable flow rate and electronic control, so a number of scenarios can be developed. A slug of water can be pushed through the system to generate a reasonably fast change in reactivity. The pump speed can be increased or decreased over the course of a measurement, or even oscillated at different periods, to observe the response of the reactor. To complement the experimental data generated by the RCF, a set of computational models have been developed. They are intended to illustrate the usefulness of the experimental data generated in validating coupled multi-physics simulations. A model previously constructed in MCNP has been used in conjunction with safety analysis at the RCF for many years and was modified to support the design of the heated water loop experiment. This model was translated into Serpent 2, a similar Monte Carlo code, which provided the added advantage of being able to produce collapsed cross-section data files for use in the deterministic neutron transport codes that are part of the SHARP toolset. A complete reconstruction of the RCF model, both with and without the heated fluid loop experiment, were necessary for use with the SHARP codes, PROTEUS (neutronics) and Nek5000 (thermal hydraulics), as these require an unstructured mesh format to operate. The computational requirements for fully coupled three dimensional simulations are significant, and challenges to full implementation and comparison with RCF experiments remain. A wide variety of experiments have been conducted for eventual benchmarking and validation of multi-physics reactor codes. A complete database of detailed time- and temperature-dependent measurements have been generated and stored. Several examples of the experimental results are presented here, with refinement and analysis of experiments ongoing. While these experiments still only address a finite range of operating conditions, in particular being limited to water in the sub-boiling regime, they represent a unique (to date) look at the feedback between temperature and neutronic behavior suited for validation of the coupling routines in multi-physics codes. It is hoped that these will be the foundation of future benchmarks that will provide confidence in the tools that will be used to develop the next generation of nuclear reactor systems.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Ripple Effects: Bed Form Morphodynamics Cascading Into Hyporheic Zone Biogeochemistry

The water quality and ecosystem health of river corridors depend on the biogeochemical processes occurring in the hyporheic zones (HZs) of the beds and banks of rivers. HZs in riverbeds often form because of bed forms. Despite widespread and persistent variation in river flow, how the discharge- and grain size-dependent geometry of bed forms and how bed form migration collectively and systematically affects hyporheic exchange flux, solute transport, and biogeochemical reaction rates are unknown. As such, we investigated these linked processes through morphodynamically consistent multiphysics numerical simulation experiments. Several realistic ripple geometries based on bed form stability criteria using mean river flow velocity and median sediment grain size were designed. Ripple migration rates were estimated based primarily on the river velocity. The ripple geometries and migration rates were used to drive hyporheic flow and reactive transport models which quantified HZ nitrogen transformation. Results from fixed bed form simulations were compared with matching migrating bed form scenarios. We found that the turnover exchange due to ripple migration has a large impact on reactant supply and reaction rates. The nitrate removal efficiency increased asymptotically with Damköhler number for both mobile and immobile ripples, but the immobile ripple always had a higher nitrate removal efficiency. Since moving ripples remove less nitrogen, and may even be net nitrifying at times, consideration for bed form morphodynamics may therefore lead to reduction of model-based estimates of denitrification. The connection between nitrate removal efficiency and Damköhler number can be integrated into frameworks for quantifying transient, network-scale, HZ nitrate dynamics.

54 ENVIRONMENTAL SCIENCES↗

Simulating Catalysis with Realistic Pellet Geometries Using Mesoflow: A Case Study of Catalytic Propane Dehydrogenation

We present a case study of catalytic propane dehydrogenation with our open-source multiphysics solver, Mesoflow. The solver was developed to simulate reactive flow coupled to heterogeneous catalytic reactions and deactivation in the context of complex, mesoscale geometry. The method leverages cartesian block-structured adaptive mesh refinement to capture realistic catalyst microstructural features acquired directly from X-ray computed tomography data. A kinetic model for propane dehydrogenation and catalyst deactivation was developed based on temporal analysis of products (TAP) reactor experiments. The TAP reactor experiments allow for precise characterization of intrinsic kinetic reaction steps which are implemented into Mesoflow simulations to model the spatial and temporal evolution of reactants, products, and catalyst active sites. The short-term and long-term deactivation behavior is studied by using XCT data collected from fresh and aged catalyst pellets, which exhibit different microstructural features. This study employs time-splitting algorithms to connect disparate reaction and flow timescales, enabling the simulations to achieve realistic deactivation timescales on the order of minutes while the flow time-scales for small particles (100 microns) are several milliseconds. We also introduce a flexible automated python script that writes the necessary files to construct a Mesoflow simulation from user-created chemical mechanisms. We will also introduce a few new features that are added to Mesoflow such as higher order schemes, implicit chemistry integrators and the ability to run on AMD and NVIDIA graphics-processing-units.

AMReX↗

Shunted Piezoelectric Vibration Damping Analysis Including Centrifugal Loading Effects

Excessive vibration of turbomachinery blades causes high cycle fatigue problems which require damping treatments to mitigate vibration levels. One method is the use of piezoelectric materials as passive or active dampers. Based on the technical challenges and requirements learned from previous turbomachinery rotor blades research, an effort has been made to investigate the effectiveness of a shunted piezoelectric for the turbomachinery rotor blades vibration control, specifically for a condition with centrifugal rotation. While ample research has been performed on the use of a piezoelectric material with electric circuits to attempt to control the structural vibration damping, very little study has been done regarding rotational effects. The present study attempts to fill this void. Specifically, the objectives of this study are: (a) to create and analyze finite element models for harmonic forced response vibration analysis coupled with shunted piezoelectric circuits for engine blade operational conditions, (b) to validate the experimental test approaches with numerical results and vice versa, and (c) to establish a numerical modeling capability for vibration control using shunted piezoelectric circuits under rotation. Study has focused on a resonant damping control using shunted piezoelectric patches on plate specimens. Tests and analyses were performed for both non-spinning and spinning conditions. The finite element (FE) shunted piezoelectric circuit damping simulations were performed using the ANSYS Multiphysics code for the resistive and inductive circuit piezoelectric simulations of both conditions. The FE results showed a good correlation with experimental test results. Tests and analyses of shunted piezoelectric damping control, demonstrating with plate specimens, show a great potential to reduce blade vibrations under centrifugal loading.

Min, James B.↗

The Alamo multiphysics solver for phase field simulations with strong-form mechanics and block structured adaptive mesh refinement

Alamo is a high-performance scientific code that uses block-structured adaptive mesh refinement to solve such problems as: the ignition and burn of solid rocket propellant, plasticity, damage and fracture in materials undergoing loading, and the interaction of compressible flow with eroding solid materials. Alamo is powered by AMReX, and provides a set of unique methods, models, and algorithms that enable it to solve solid-mechanics problems (coupled to other physical behavior such as fluid flow or thermal diffusion) using the power of block-structured adaptive mesh refinement.

36 MATERIALS SCIENCE↗

Multiphysics Simulation of the NASA SIRIUS-CAL Fuel Experiment in the Transient Test Reactor Using Griffin

After approximately 50 years, NASA is restarting efforts to develop nuclear thermal propulsion (NTP) for interplanetary missions. Building upon nuclear engine tests performed from the late 1950s to the early 1970s, the present research and testing focuses on advanced materials and fabrication methods. A number of transient tests have been performed to evaluate materials performance under high-temperature, high-flux conditions, with several more experiments in the pipeline for future testing. The measured data obtained from those tests are being used to validate the Griffin reactor multiphysics code for this particular type of application. Griffin was developed at Idaho National Laboratory (INL) using the MOOSE framework. This article describes the simulation results of the SIRIUS-CAL calibration experiment in the Transient Reactor Test Facility (TREAT). SIRIUS-CAL was the first transient test conducted on NASA fuels, and although the test was performed with a relatively low core peak power, the test specimen survived a temperature exceeding 900 K. Griffin simulations of the experiment successfully matched the reactor’s power transient after calibrating the initial control rod position to match the initial reactor period. The thermal-hydraulics model largely matches the time-dependent response of a thermocouple located within the experiment specimen to within the uncertainty estimate. However, the uncertainty range is significant and must be reduced in the future.

33 ADVANCED PROPULSION SYSTEMS↗

Validation of time-dependent shift using the pulsed sphere benchmarks

The detailed behavior of neutrons in a rapidly changing time-dependent physical system is a challenging computational physics problem, particularly when using Monte Carlo methods on heterogeneous high-performance computing architectures. A small number of algorithms and code implementations have been shown to be performant for time-independent (fixed source and k-eigenvalue) Monte Carlo, and there are existing simulation tools that successfully solve the time-dependent Monte Carlo problem on smaller computing platforms. To bridge this gap, a time-dependent version of ORNL’s Shift code has been recently developed. Shift’s history-based algorithm on CPUs, and its event-based algorithm on GPUs, have both been observed to scale well to very large numbers of processors, which motivated the extension of this code to solve time-dependent problems. The validation of this new capability requires a comparison with time-dependent neutron experiments. Lawrence Livermore National Laboratory’s (LLNL) pulsed sphere benchmark experiments were simulated in Shift to validate both the time-independent as well as new time-dependent features recently incorporated into Shift. A suite of pulsed-sphere models was simulated using Shift and compared to the available experimental data and simulations with MCNP. Overall results indicate that Shift accurately simulates the pulsed sphere benchmarks, and that the new time-dependent modifications of Shift are working as intended. Validated exascale neutron transport codes are essential for a wide variety of future multiphysics applications.

Palmer, Camille J.↗

MEMPHIS (Mesoscle Multiphysics Phase Field Simulator v.0

SAND2024-01427O Mesoscale Multiphysics Phase Field Simulator (MEMPHIS) is used for solving interfacial problems and can be applied to many evolutionary problems. Some examples are solidification dynamics, viscous fingering, fracture mechanics, hydrogen embrittlement, vesicle dynamics, electro-mechanical degradation of batteries, aging of microstructures, and segregation. MEMPHIS is written in Fortran 90 in a modular fashion, where model and numerical solvers are decoupled from one another. Sandia National Laboratories is a multimission laboratory managed and operated by National Technology & Engineering Solutions of Sandia, LLC, a wholly owned subsidiary of Honeywell International Inc., for the U.S. Department of Energy’s National Nuclear Security Administration under contract DE-NA0003525.

Dingreville, Remi↗

An Enabling Platform for Achieving Multiscale Multiphysics Analysis of Multiphase Materials

This paper will address current NASA GRC research efforts utilizing the NASA Multiscale Analysis Tool (NASMAT) which address technical gaps in three of the Vision 2040 key discipline areas. NASMAT is a versatile platform for performing computationally efficient multiscale analyses of heterogeneous materials and is available free through the NASA software catalog. It offers the user flexibility to define an arbitrary number of length scales (levels) where a variety of micromechanics theories can be implemented at each level. Micromechanics theories can be selected to balance accuracy and computational efficiency and range from analytical (Mori-Tanaka) to several semi-analytical (method of cells) formulations. The resulting anisotropic, evolving nonlinear, thermomechanical constitutive model can also be coupled with external software and used to perform multiscale analyses of more complex structures. A recent application to model a complex, three-dimensional woven composite, with a particular emphasis placed on multiscale measurements utilized to enhance the quality of the multiscale analysis will be discussed. Since typical NASMAT analyses can be completed on the order of seconds to minutes, a second example will demonstrate the ability to generate large quantities of data useful for sensitivity analysis, uncertainty quantification, or machine learning applications. Current progress on implementing NASMAT within a multiscale digital thread/digital twin framework will also be addressed. These examples will demonstrate that NASMAT is an enabling platform for achieving the goals in Vision 2040.

Multiscale↗

Roadrunner

SAND2026-17073O Roadrunner software provides a comprehensive platform for simulating the mechanical behavior of crystalline materials under various loading conditions, allowing users to investigate the effects of dislocation slip hardening and damage evolution. Developed as a fork of the Multiphysics Object Oriented Simulation Environment (MOOSE) software from Idaho National Laboratory, Roadrunner is optimized for high-performance computing and can simulate large-scale problems, enabling researchers to explore complex scenarios. Its applications include material design and optimization in aerospace and automotive industries, investigation of failure mechanisms in structural materials, and development of predictive models for crystalline materials under various loading conditions. Sandia National Laboratories is a multimission laboratory managed and operated by National Technology & Engineering Solutions of Sandia, LLC, a wholly owned subsidiary of Honeywell International Inc., for the U.S. Department of Energy’s National Nuclear Security Administration under contract DE-NA0003525.

Lim, Hojun [Sandia National Lab. (SNL-CA), Livermo↗

Numerical Improvements in Magnetohydrodynamic, Pulsed Power Simulations of Near-Target Plasmas

Magnetohydrodynamic (MHD) simulations of pulsed power experiments frequently result in unphysical runaway heating when extended to low values of mass density. Traditionally, this has been addressed by the use of conductivity floors below which the plasma is given an arbitrarily low conductivity value. Here, a low-density treatment is presented that allows for low-density material to carry current while maintaining a stable temperature. This treatment is implemented in the Ares multiphysics code. Numerical modifications to the conventional vacuum treatment include an energy-conserving density floor, a modified averaging procedure to determine the thermal conductivity at the edge of adjacent zones, and a modified averaging procedure for determining the thermal conductivity in mixed zones that contain material from differing regions. Additionally, anomalous resistivity and Bohm diffusion models are implemented as simplified models for microphysics-induced enhancement of collisional transport. Importantly, the advantage of these various improvements are illustrated in a simple 1-D pulsed power target where the combined changes result in stable temperatures within the lower density regions.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

Hydrodynamic expansion and near-infrared absorption of x-ray heated aluminum plasmas

We use x-ray pulses from dense argon plasmas at the Z Machine (Sandia National Laboratories) to generate hypersonic aluminum plasmas akin to material ejecta during proposed planetary defense missions, fusion reactor wall excursions, and other high-energy density processes. Near-infrared absorption is used to diagnose the controlled expansion of the plasmas through cylindrical cavities following their generation from x-ray heating of solid aluminum 7075 alloy. The data are compared to multidimensional radiation hydrodynamics simulations utilizing the ALEGRA multiphysics code, accounting for the dynamics of radiation scattering, material phase change, plasma expansion, thermal re-irradiation, and interactions with the cavity and with the infrared beams. To allow for accurate simulation, density functional theory is used to apply the Hagen–Rubens relation for the far-infrared and is adjoined with a detailed configuration accounting model using the Propaceos code, producing opacities spanning 10 −1 –10 4 eV photon energy for aluminum 7075 alloy, and in comparison with pure aluminum. The model is found to agree with experimental data in the higher-fluence regime when the Hagen–Rubens relation is applied. The ejected material, which is observed to travel up to 55 km/s, is comprised of a strongly ionized, non-LTE plasma front at ∼10 eV temperature followed by a weakly ionized LTE gas at higher density. The present findings lend some confidence to the broad-range equation of state and infrared opacity models for weakly ionized aluminum plasmas while demonstrating an approach to their future refinement, with potential application to astrophysical plasmas and other extreme processes.

Adiabatic process↗

Thermal Fluid Modeling Approaches in SAM for High Temperature Gas-Cooled Reactor Applications

This paper provides an overview of the unique modeling and simulation challenges and needs in the system and safety analysis of two common types of High Temperature Gas-cooled Reactor (HTGR) designs. The challenges are associated with the complex core geometry configurations and the change of the dominant heat removal mechanisms between normal operating conditions and decay heat removal transients. This requires that simulation tools utilize models with reasonable length scales and capture both the localized heat transfer and the core-scale heat transfer at the same time. To meet such analysis needs, different methodologies were developed. In conclusion, this includes adopting existing methods and further developing/improving them, as well as proposing innovative methods that leverage advanced computational frameworks such as the Multiphysics Object Oriented Simulation Environment (MOOSE).

HTGR↗

Design and characterization of “flow-cell” integrated-flow active cooling for high-average-power ceramic optics

We used COMSOL Multiphysics to design a prototype actively cooled “flow-cell” substrate targeted at high-average-power applications, fabricated the prototype from cordierite ceramic, and tested the substrate under load in our thermal loading test stand. Sub-aperture testing revealed average-power handling up to 3.88-W/cm 2 absorbed power density, in excellent agreement with model predictions. Gratings fabricated on 2-in.-diam cordierite coupons were subjected to laser-damage testing and showed a damage threshold of 250 mJ/cm 2 .

47 OTHER INSTRUMENTATION↗

Analytical Design and Performance Estimation Methods for Aircraft Permanent Magnet Synchronous Machines

The design of an electric motor drivetrain is a complex multiphysics problem. Low fidelity motor drivetrain sizing can be a key tool in the design cycle of an electric motor drivetrain and for system level studies of aircraft configurations. However, low fidelity sizing can lead to misleading results if all the physics involved in a motor design are not properly accounted for. This paper provides details on modeling approaches for initial design and sizing of permanent magnet synchronous electric machines. The goal of this paper is to provide the reader an understanding of the key principles of motor design and some modeling approaches to perform initial sizing of an electric motor and its inverter.

Thomas F. Tallerico↗