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DOE OSTI2021

Mechanical analysis of heterogeneous materials with higher-order parameters

Abstract Even though heterogeneous porous materials are widely used in a variety of engineering and scientific fields, such as aerospace, energy-storage technology, and bio-engineering, the relationship between effective material properties of porous materials and their underlying morphology is still not fully understood. To contribute to this knowledge gap, this paper adopts a higher-order asymptotic homogenization method to numerically investigate the effect of complex micropore morphology on the effective mechanical properties of a porous system. Specifically, we use the second-order scheme that is an extension of the first-order computational homogenization framework, where a generalized continuum enables us to introduce length scale into the material constitutive law and capture both pore size and pore distribution. Through several numerical case studies with different combinations of porosity, pore shapes, and distributions, we systematically studied the relationship between the underlying morphology and effective mechanical properties. The results highlight the necessity of higher-order homogenization in understanding the mechanical properties and reveal that higher-order parameters are required to capture the role of realistic pore morphologies on effective mechanical properties. Furthermore, for specific pore shapes, higher-order parameters exhibit dominant influence over the first-order continuum.

42 ENGINEERING↗

DOE OSTI2024

A large deformation multiphase continuum mechanics model for shock loading of soft porous materials

A large deformation, coupled finite-element (FE) model is developed to simulate the multiphase response of soft porous materials subjected to high strain-rate loading. The approach is based on the theory of porous media (TPM) at large deformations. Simplifications to the one-dimensional regime studied in the numerical simulations follow. An overview of several different time integration schemes is presented for the purpose of solving the nonlinear dynamic coupled balance of momenta (mixture and fluid) and balance of mass of the mixture equations. Numerical examples are presented for (i) verification against closed-form analytical solutions assuming small loads, (ii) demonstrating large deformation effects at high strain-rate, and (iii) showing differences in deformations between a single-phase elastodynamics model with occluded compressible pore fluid and a multiphase poroelastodynamics model at high strain-rate. The multiphase model shows that the relative motion of the pore fluid significantly dampens the deformation response of the solid skeleton as compared to the single-phase model, and makes it possible to extract quantitative values for the stresses of the different constituents, thereby allowing one to form preliminary conclusions about the onset of damage in the solid skeleton. The novelty of the current work is developing a multiphase, large deformation, mixture theory numerical model for high strain-rate loading of soft porous materials. It was discovered that explicit, adaptive time-stepping Runge–Kutta schemes offer high accuracy at relatively low cost when compared to traditional implicit or explicit central difference time-stepping schemes for shock-like loadings. Here, shock viscosity is added to the mixture momentum balance equation to regularize the shock front, and a stabilization term is added to the mixture mass balance equation to stabilize equal order interpolation finite elements for the coupled finite element solution of multiphase materials.

Engineering↗

DOE OSTI2018

Influence of Welding Strength Matching Coefficient and Cold Stretching on Welding Residual Stress in Austenitic Stainless Steel

Austenitic stainless steel is widely used in pressure vessels for the storage and transportation of liquid gases such as liquid nitrogen, liquid oxygen, and liquid hydrogen. Cryogenic pressure vessel manufacturing uses cold stretching technology, which relies heavily on welding joint performance, to construct lightweight and thin-walled vessels. Residual stress from welding is a primary factor in cases of austenitic stainless steel pressure vessel failure. In this paper, on the basis of Visual Environment 10.0 finite element simulation technology, the residual stress resulting from different welding strength matching coefficients (0.8, 1, 1.2, 1.4) for two S30408 plates welded with three-pass butt welds is calculated according to thermal elastoplastic theory. In addition, the stress field was calculated under a loading as high as 410 MPa and after the load was released. Path 1 was set to analyze stress along the welding line, and path 2 was set to analyze stress normal to the welding line. The welding strength matching coefficient strongly affected both the longitudinal residual stress (center of path 1) and the transverse residual stress (both ends of path 1) after the welding was completed. However, the coefficient had little effect on the longitudinal and transverse residual stress of path 2. Under the loading of 410 MPa, the longitudinal and transverse stress decreased and the stress distribution, with different welding strength matching coefficients, was less diverse. After the load was released, longitudinal and transverse stress distribution for both path 1 and path 2 decreased to a low level. Cold stretching could reduce the effect of residual stress to various degrees. Transverse strain along the stretching direction was also taken into consideration. The experimental results validated the reliability of the partial simulation.

36 MATERIALS SCIENCE↗

DOE OSTI2019

Effect of Vertical Strut Arrangements on Compression Characteristics of 3D Printed Polymer Lattice Structures: Experimental and Computational Study

This paper discusses the behavior of the three-dimensional (3D) printed polymer lattice core structures during compressive deformation, by both physical testing and computer modeling. Four lattice configurations based on the body-centered cubic (BCC) unit cell were selected to investigate the effect of vertical strut arrangements on stiffness, failure load, and energy absorption per unit mass or the specific energy absorption (SEA). The basic BCC unit cell consists of struts connecting the body center to the corners of the cube. Three variations in the BCC configuration considered in this study are (1) BCCV, with vertical members connecting all nodes of the lattice, (2) BCCA, with vertical members in alternating layers of the lattice, and (3) BCCG, with a gradient in the number of vertical members increasing from none at the top layer to all vertical members at the bottom layer. The unit cell dimensions were 5 mm × 5 mm × 5 mm with strut diameter of 1 mm. The lattice was assembled with 5 cells in the x and y directions and 4 cells in the z direction. Specimens were first made by 3D printing by using a fused deposition modeling printer with acrylonitrile–butadiene–styrene thermoplastic. Specimens were then tested under compression in the z direction under quasi-static conditions. Finite element analysis was used to model the compressive behavior of the different lattice structures. Results from both experiments and finite element models show that the strength of the lattice structures is greater when vertical members are present, and the SEA depends on the lattice geometry and not its mass.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Modeling low cycle fatigue (LCF) of additively manufactured Hastelloy X using An accelerated crystal plasticity fatigue damage model

This paper presents a microstructure-based model for low cycle fatigue (LCF) behavior and life of Nickel-based alloy Hastelloy X manufactured using laser-powder bed fusion (L-PBF) additive manufacturing (AM). AM Hastelloy X, a solution-strengthened alloy, is tested at elevated temperature under fully reversed LCF conditions at different strain levels. A generalized plane strain finite element model is generated from electron backscatter diffraction (EBSD) characterization. The constitutive behavior of the material under fatigue is modeled using crystal plasticity and calibrated with both monotonic tensile and cyclic stress–strain data. The fatigue micro-crack initiation and propagation in the microstructure is modeled using a modified Chaboche fatigue damage model. An embedded boundary condition with a homogenous medium is used to apply the cyclic deformation and prevent numerically introduced over-constraints during fatigue simulation. A ‘cycle-jump’ method is used to accelerate the fatigue simulation and reduce the computational cost. The simulation results are compared to LCF experiments, showing satisfactory matches in cyclic stress behavior and number of cycles to macro-crack initiation for all applied strain ranges. In addition, the model illustrates the potential for quantifying microscale fatigue life impacting factors such as microstructure and surface roughness, which is needed to accurately quantify the reliability of AM components in service.

36 MATERIALS SCIENCE↗

DOE OSTI2018

A Review of Finite Element Method Models for Nuclear Graphite Applications

Graphite components serve as structural support and as a neutron moderator in multiple nuclear power stations and is also a prospective material in Generation IV reactor concepts. The environment (e.g. high temperature and intense radiation) within a graphite core changes the geometry, microstructure and material properties of the graphite components, that could limit the lifetime (i.e. safe operation) of a reactor. Some of the assessments made for graphite reactor core components include Finite Element Method (FEM) simulations. These simulations are used to estimate the stress state and strain state and probability of failure of irradiated graphite components. FEM also forms part of the validation of measurements or as a complementary technique to experimental procedures in graphite research. A comprehensive overview of FEM methodologies is provided in this review, including: FEM software, basics steps to set up a FEM model, and analytical solutions used to validate simulations for this field of study. In conclusion, the objective of this paper is to inform researchers in the different available FEM techniques and tools used in the research of nuclear graphite.

42 ENGINEERING↗

DOE OSTI2023

Finite temperature properties of uranium mononitride

Uranium mononitride (UN) is a promising nuclear fuel that combines the advantageous properties of readily used UO 2 and uranium alloys, such as high melting temperature and high uranium density, and thermal conductivity, respectively. A better understanding of UN behavior at operating temperatures can be obtained from finite temperature data, such as elastic properties. To get this information, ab initio molecular dynamics (AIMD) simulations were performed at five different temperatures using constant volume (NVT) and constant pressure (NPT) ensembles. Initially, the performance of PBE functional in reproducing experimental crystallographic properties and magnetic ordering is assessed. The finite temperature phonon dispersions are calculated using NVT simulation results, which show a softening of the phonon modes with increasing temperature. The NPT results are used to obtain the thermal expansion of UN and finite temperature electronic properties. The calculated thermal expansion is compared with our measurements using neutron diffraction. Additionally, the temperature dependent elastic properties of UN are evaluated using the strain-stress method in AIMD simulations, indicating that UN becomes softer and more compressible with increasing temperature. Also, the calculated Young’s modulus slope is in very good agreement with the experiment. The finite temperature heat capacity and electronic thermal conductivity are calculated from AIMD simulations, which are in better agreement with the experiment than the heat capacity and thermal conductivity calculated using the structures relaxed at 0K. Finally, the thermal diffusivity from AIMD has opposite temperature dependence compared to experimental results, which we argued comes from the underestimated electronic thermal conductivity.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2025

Lieb-Robinson Bounds with Exponential-in-Volume Tails

Lieb-Robinson bounds demonstrate the emergence of locality in many-body quantum systems. Intuitively, Lieb-Robinson bounds state that, with local or exponentially decaying interactions, the correlation that can be built up between two sites separated by distance 𝑟 after a time 𝑡 decays as exp (𝑣⁢𝑡 −𝑟), where 𝑣 is the emergent Lieb-Robinson velocity. In many problems, it is important to also capture how much of an operator grows to act on 𝑟 𝑑 sites in 𝑑 spatial dimensions. Perturbation theory and cluster expansion methods suggest that, at short times, these volume-filling operators are suppressed as exp (−𝑟 𝑑 ). We confirm this intuition, showing that, for 𝑟 >𝑣⁢𝑡, the volume-filling operator is suppressed by exp (−(𝑟−𝑣⁢𝑡) 𝑑 /(𝑣⁢𝑡) 𝑑−1 ). This closes a conceptual and practical gap between the cluster expansion and the Lieb-Robinson bound. We then present two very different applications of this new bound. Firstly, we obtain improved bounds on the classical computational resources necessary to simulate many-body dynamics with error tolerance 𝜀 for any finite time 𝑡: as 𝜀 becomes sufficiently small, only 𝜀 −O⁡(𝑡 𝑑−1 ) resources are needed. A protocol that likely saturates this bound is given. Secondly, we prove that disorder operators have volume-law suppression near the “solvable (Ising) point” in quantum phases with spontaneous symmetry breaking, which implies a new diagnostic for distinguishing many-body phases of quantum matter.

computational complexity↗

DOE OSTI2018

Degradation of ILW Drums Due to Internal Metallic Corrosion - 18036

Within the British nuclear inventory, metallic Intermediate Level Waste (ILW) is encapsulated in grout and stored in stainless steel drums. Based on recent inspections held in the relevant storage facilities (Sellafield, Cumbria), a proportion of these drums have exhibited considerable distortion, raising concerns about the long-term safety of the packages. Distortion may be caused by the generation of voluminous and potentially flammable substances resulting from metallic corrosion occurring within the drums' core. Potential oxygen influx in the event of steel fracture and consequently drum's failure could potentially cause release or even ignition of the encapsulated radioactive material. The mechanical degradation of the encapsulants (stainless steel and grout) induced from the progressive corrosion of the encapsulated metallic components (and the associated volume expansion) was investigated using both Finite Element Modelling (FEM) techniques as well as experimental trials. A parametric study using simplified 3D FE models was performed to determine their structural integrity under different scenarios. Synchrotron X-Ray tomography (XRT) was used to monitor the behaviour of miniaturized ILW drum-simulants, whilst the latter were subjected to controlled accelerated corrosion in situ. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2017

Declamped Piezoelectric Coefficients in Patterned 70/30 Lead Magnesium Niobate–Lead Titanate Thin Films

Lateral subdivision of blanket piezoelectric thin films increases the functional properties through both increased domain wall mobility and declamping of the intrinsic response. This work presents the local effects of substrate declamping on the piezoelectric coefficient d 33,f of 300 nm thick, rhombohedral, {001}-oriented lead magnesium niobate–lead titanate thin films at the 70/30 composition (70PMN–30PT). Films grown by chemical solution deposition on platinized Si substrates are patterned into strip structures ranging from 0.75 to 9 µm in width. The longitudinal piezoelectric coefficient, d 33,f , is interrogated as a function of position across the patterned structures by three approaches: finite element modeling, piezoresponse force microscopy, and nanoprobe synchrotron X-ray diffraction. It is found that d 33,f increases from the clamped value of 40–50 to ≈160 pm V -1 at the free sidewall under 200 kV cm -1 excitation. The sidewalls partially declamp the piezoelectric response 500–600 nm into the patterned structure, raising the piezoelectric response at the center of features with lateral dimensions less than 1 µm (3:1 width to thickness aspect ratio). The normalized data from all three methods are in excellent agreement, with quantitative differences providing insight to the field dependence of the piezoelectric coefficient and its declamping behavior.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Simulated effect of defect volume and location on very high cycle fatigue of laser beam powder bed fused AlSi10Mg

This study quantifies the interaction between volumetric defect location and size on the very high cycle fatigue (VHCF) of laser beam powder bed fused (LB-PBF) AlSi10Mg. Crystal plasticity finite element method (CPFEM) simulations were used to investigate the effects of defect location and size on the driving force for crack initiation. The CPFEM model was calibrated against uniaxial and cyclic experimental data of LB-PBF AlSi10Mg. Defect characteristics were informed by experimental data from the specimens produced in various geometries to create realistic representative volume elements (RVEs) with equivalent volume fractions of defects. By embedding defects of varying sizes and locations within the RVEs, fatigue indicator parameters (FIPs) were calculated to analyze the impact of defects’ characteristics on fatigue performance. Different combinations of defect volume and locations were generated for various microstructure instantiations, providing insight into extreme value fatigue responses. Larger defect volumes located on free surfaces consistently generated the highest FIPs, suggesting defect size and boundary proximity intensify stress concentration effects. RVEs with multiple smaller defects produced lower FIPs than those with single large critical defects. These findings underscore the critical role of defect characteristics on fatigue life, providing a foundation for future predictive modeling in fatigue-sensitive AM applications.

AlSi10Mg↗

DOE OSTI2020

Superfluid condensate fraction and pairing wave function of the unitary Fermi gas

The unitary Fermi gas is a many-body system of two-component fermions with zero-range interactions tuned to infinite scattering length. Despite much activity and interest in unitary Fermi gas and its universal properties, there have been great difficulties in performing accurate calculations of the superfluid condensate fraction and pairing wave function. In this paper, we present auxiliary-field lattice Monte Carlo simulations using a lattice interaction which accelerates the approach to the continuum limit, thereby allowing for robust calculations of these difficult observables. As a benchmark test, we compute the ground-state energy of 33 spin-up and 33 spin-down particles. As a fraction of the free Fermi gas energy $E_{\text{FG}}$, we find $E_0/E_{\text{FG}}$ = 0.369(2), 0.372(2), using two different definitions of the finite-system energy ratio, in agreement with the latest theoretical and experimental results. We then determine the condensate fraction by measuring off-diagonal long-range order in the two-body density matrix. We find that the fraction of condensed pairs is α = 0.43(2). Further, we also extract the pairing wave function and find the pair correlation length to be $ζ_pk_F$ = 1.8(3)ℏ, where $k_F$ is the Fermi momentum. Provided that the simulations can be performed without severe sign oscillations, the methods we present here can be applied to superfluid neutron matter as well as more exotic $\textit{P}$-wave and $\textit{D}$-wave superfluids.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗

DOE OSTI2024

Efficient real space formalism for hybrid density functionals

We present an efficient real space formalism for hybrid exchange-correlation functionals in generalized Kohn–Sham density functional theory (DFT). In particular, we develop an efficient representation for any function of the real space finite-difference Laplacian matrix by leveraging its Kronecker product structure, thereby enabling the time to solution of associated linear systems to be highly competitive with the fast Fourier transform scheme while not imposing any restrictions on the boundary conditions. We implement this formalism for both the unscreened and range-separated variants of hybrid functionals. We verify its accuracy and efficiency through comparisons with established planewave codes for isolated as well as bulk systems. In particular, we demonstrate up to an order-of-magnitude speedup in time to solution for the real space method. We also apply the framework to study the structure of liquid water using ab initio molecular dynamics, where we find good agreement with the literature. Overall, the current formalism provides an avenue for efficient real-space DFT calculations with hybrid density functionals.

Chemistry↗

DOE OSTI2021

Damage development in neutron-irradiated concrete in a test reactor: Hygro-thermal and mechanical simulations

This paper reports the development of a 3D mesoscale hygro-thermal-mechanical simulation approach to predict damage in concrete irradiated in a test reactor. This framework, developed in MOOSE, considers the effects of elevated temperature, moisture content, and high neutron fluence (energy threshold, E > 0.1 MeV) on the mortar and aggregates separately. The first-stage simulation implements hygro-thermal analysis to determine the temperature and RH inside the specimen as a function of imposed radiation energy. These are used as inputs to the second stage, which considers radiation-induced volumetric expansion (RIVE) of aggregates, and creep, shrinkage, and stress-strain response of mortar to predict the expansion, stresses, and damage in specimens made using different coarse aggregates and subjected to different irradiation times. The irradiation time-dependent damage in the mortar is expressed using an isotropic damage parameter. This multi-physics model serves as a predictive tool for damage quantification in concrete due to neutron irradiation.

36 MATERIALS SCIENCE↗

DOE OSTI2019

Numerical Simulation of Critical Factors Controlling Heat Extraction from Geothermal Systems Using a Closed-Loop Heat Exchange Method

Closed-loop heat exchange for geothermal energy production involves injecting working fluid down a well that extends through the geothermal resource over a significant length to absorb heat by conduction through the well pipe. The well then needs to return to the surface for energy recovery and fluid re-injection to complete the cycle. We have carried out mixed convective-conductive fluid-flow modeling using a wellbore flow model for TOUGH2 called T2Well to investigate the critical factors that control closed-loop geothermal energy recovery. T2Well solves a mixed explicit-implicit set of momentum equations for flow in the pipe with full coupling to the implicit three-dimensional integral finite difference equations for Darcy flow in the porous medium. T2Well has the option of modeling conductive heat flow from the porous medium to the pipe by means of a semi-analytical solution which makes the computation very efficient because the porous medium does not have to be discretized. When the fully three-dimensional option is chosen, the porous medium is discretized and heat flow to the pipe is by conduction and convection, depending on reservoir permeability and other factors. Simulations of the closed-loop system for a variety of parameter values have been carried out to elucidate the heat recovery process. To the extent that convection may occur to aid in heat delivery to the pipe, the permeability of the geothermal reservoir, whether natural or stimulated, is an important property in heat extraction. The injection temperature and flow rate of the working fluid strongly control the ultimate energy recovery. Pipe diameter also plays a strong role in heat extraction, but is correlated with flow rate. Similarly, the choice of working fluid plays an important role, with water showing better heat extraction than CO2 for certain flow rates, while the CO2 has higher pressure at the production wellhead which can aid in surface energy recovery. In general, we find complex interactions between the critical factors that will require advanced computational approaches to fully optimize.

Oldenburg, Curtis↗

DOE OSTI2018

Modeling the diffusion of heat energy within composites of homogeneous materials using the uncertainty principle

The goal of this paper is to develop a highly accurate and efficient numerical method for the solution of a time-dependent partial differential equation with a piecewise constant coefficient, on a finite interval with periodic boundary conditions. The resulting algorithm can be used, for example, to model the diffusion of heat energy in one space dimension, in the case where the spatial domain represents a medium consisting of two homogeneous materials. The resulting model has, to our knowledge, not yet been solved in closed form through analytical methods, and is difficult to solve using existing numerical methods, thus suggesting an alternative approach. The approach presented in this paper is to represent the solution as a linear combination of wave functions that change frequencies at the interfaces between different materials. It is demonstrated through numerical experiments that using the Uncertainty Principle to construct a basis of such functions, in conjunction with a spectral method, a mathematical model for heat diffusion through different materials can be solved much more efficiently than with conventional time-stepping methods.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2026

Determining Stability Margins in Adiabatic Superconducting Magnets with 3-D Finite Element Analysis

Superconducting magnets play a key role in the development of experiments at Fermilab; understanding the operating stability of these can allow us to utilize more potent magnets for future experiments (like the proposed Muon Collider), optimize the design of magnets in more immediate experiments (like Mu2e), and research the future use of more exotic materials (like high-temperature superconductors). This summer, I developed a 3-D parametric FEA program in ANSYS Mechanical APDL that simulates quench in superconducting magnets, and I also developed a parametric MATLAB program that predicts thermal behavior in magnet quench using the MIITS method. These programs can provide useful quenching parameters (like minimum quench energy and normal zone propagation velocity) for different cases of quench, leading to the previously mentioned objective of magnet design optimization. To test the programs, preliminary cases were run and the data produced was compared and analyzed. The results of these analyses, as well as the program operating methods, are discussed in this project.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗

DOE OSTI2021

Incorporating point defect generation due to jog formation into the vector density-based continuum dislocation dynamics approach

During plastic deformation of crystalline materials, point defects such as vacancies and interstitials are generated by jogs on moving dislocations. A detailed model for jog formation and transport during plastic deformation was developed within the vector density-based continuum dislocation dynamics framework. Here as a part of this model, point defect generation associated with jog transport was formulated in terms of the volume change due to the non-conservative motion of jogs. Balance equations for the vacancies and interstitials including their rate of generation due to jog transport were also formulated. A two-way coupling between point defects and dislocation dynamics was then completed by including the stress contributed by the eigen-strain of point defects. A jog drag stress was further introduced into the mobility law of dislocations to account for the energy dissipation during point defects generation. A number of test problems and a fully coupled simulation of dislocation dynamics and point defects generation and diffusion were performed. The results show that there is an asymmetry of vacancy and interstitial generation due to the different formation energies of the two types of defects. The results also show that a higher hardening rate and a higher dislocation density are obtained when the point defect generation mechanism is coupled to dislocation dynamics.

36 MATERIALS SCIENCE↗