Search NASA⌕ Search

SEARCH · Search NASA

Results for “finite element problems”

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.

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

At least 1,009 records · Page 56
All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

An MPMD approach coupling electromagnetic continuum mechanics approximations in ALEGRA

In this work, two complementary approximations for describing aspects of continuum electromagnetics in moving media are discussed: electroquasistatic and magnetoquasistatic. Each has been implemented in the finite element shock code ALEGRA for modeling dynamic electromechanical phenomena on typical engineering time scales, with fully integrated circuit coupling. The approximations can be obtained by consistent asymptotic balancing of Maxwell’s equations relative to timescales associated with magnetic diffusion, charge relaxation, and electromagnetic wave propagation. In ALEGRA, the electroquasistatic approximation is used for ferroelectric (FE) modeling, while the magnetoquasistatic approximation is used for magnetohydrodynamic (MHD) modeling. In this paper we introduce for the first time a detailed derivation of a useful quasi-steady “low-R m ” variant of the MHD approximation applicable for cases, such as with detonators, where the thermodynamic pressure arising from Joule heating dominates over magnetic forces. An additional purpose of this paper is to present a coupling mode using Multiple Program-Multiple Data (MPMD) message passing communication that allows the user to run 3D FE problems together with 2D and/or 3D MHD problems with the respective simulation domains coupled through a common circuit equation. The MPMD coupling capability is used here to model the dynamic coupling of a notional ferroelectric generator with an RP-87 exploding bridgewire detonator. The simulated bridgewire heats up and bursts under current generated by simulated depoling of the ferroelectric generator, as a demonstration of the MPMD capability.

42 ENGINEERING↗
DOE OSTI2020

A linearity preserving nodal variation limiting algorithm for continuous Galerkin discretization of ideal MHD equations

A stabilized continuous Galerkin (CG) method for magnetohydrodynamics (MHD) is presented herein. Ideal, compressible inviscid MHD equations are discretized in space on unstructured meshes using piecewise linear or bilinear finite element bases to get a semi-discrete scheme. Stabilization is then introduced to the semi-discrete method in a strategy that follows the algebraic flux correction paradigm. This involves adding some artificial diffusion to the high order, semi-discrete method and mass lumping in the time derivative term. The result is a low order method that provides local extremum diminishing properties for hyperbolic systems. The difference between the low order method and the high order method is scaled element-wise using a limiter and added to the low order scheme. The limiter is solution dependent and computed via an iterative linearity preserving nodal variation limiting strategy. The stabilization also involves an optional consistent background high order dissipation that reduces phase errors. The resulting stabilized scheme is a semi-discrete method that can be applied to inviscid shock MHD problems and may be even extended to resistive and viscous MHD problems. To satisfy the divergence free constraint of the MHD equations, we add parabolic divergence cleaning to the system. Various time integration methods can be used to discretize the scheme in time. We demonstrate the robustness of the scheme by solving several shock MHD problems.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
DOE OSTI2019

Compact feature-aware Hermite-style high-order surface reconstruction

High-order surface reconstruction is now a commonly used technique for mesh generation and adaptation, geometric and physical modeling, and high-order numerical methods for solving partial differential equations (PDEs). However, surface reconstruction from a relatively coarse mesh remained a challenging problem, especially for surfaces with sharp features. Here in this paper, we introduce a new method to address this challenge by improving the previous state of the art, including continuous moving frames (CMF) and weighted averaging of local fittings (WALF) (Eng Comput 28 (2012)), in two aspects. First, we significantly improve the robustness of reconstruction from coarse meshes using a Hermite-style least squares approximation to incorporate normals of the surface and tangents of the feature curves. Second, we ensure both G 0 continuity and high-order accuracy of the reconstruction near sharp features by generating parametric surface elements with an iterative feature-aware parameterization. We present the theoretical framework of our method and compare it against point-based methods in terms of accuracy and stability. We demonstrate the use of the proposed technique in generating high-order meshes for finite element methods, and show that it enables nearly identical solutions as using the meshes generated from exact geometry, while allowing additional flexibility.

42 ENGINEERING↗
DOE OSTI2017

CEED-MS8:Initial Integration of CEED Software in ECP Applications

Key components of CEED software development involve fast finite element operator storage and evaluation, architecture optimizations, performant algorithms for all orders, global kernels for finite element operators, efficient use of the memory sub-system, optimal data locality and motion, enhanced scalability and parallelism, and fast tensor contractions. As ultimate goals of the project, CEED is exploring and identifying the best algorithms for the full range of discretizations and applying algorithmic and software development to support ECP applications’ needs. In this milestone we report on the initial integration of CEED software in the selected first-wave ECP/CEED apps and the continued exploration of other ECP applications as second-wave (milestone CEED-MS23) and third-wave (milestone CEED-MS35) ECP/CEED application candidates. An extensive evaluation of various approaches for GPU acceleration of the CEED computational motives is also a major focus of the report, both in the settings of CEED’s Nekbone and Laghos miniapps, as well as versions of CEED’s bake-off problems (introduced in milestone CEED-MS6). The first-wave ECP applications targeted for coupling with CEED software include the ExaSMR and MARBL applications. We also report on near-term collaboration with the seed-funded Urban Systems project, as well as engagements with ACME, ExaAM, GEOS and the Application Assessment and Proxy App projects. The ExaSMR project involves coupled thermal-hydraulics/neutronics, with the latter based on Monte Carlo methods and the former based on high-order discretizations of the Navier-Stokes and energy equations for accurate simulation of turbulent transport. The project requires fast and efficient turbulence simulation capabilities that will scale to exascale platforms. Work within CEED will ensure that all aspects of the Nek5000 workflow scale to the target problem space, which involves > 10 10 degrees of freedom in typical production runs. CEED’s goal is to provide implementations that perform with maximum attainable efficiency and deliver low turn-around times. A deliverable for this milestone is beta-release of the GPU-based variant of Nek5000. MARBL is targeting high-energy-density physics problems, including single fluid multi-material hydrodynamics and radiation/magnetic diffusion simulation, with applications in inertial confined fusion, pulsed power experiments, and equation of state/material strength analysis. The code uses high-order methods based arbitrary Lagrangian-Eulerian, direct Eulerian, and unstructured adaptive mesh refinement. A deliverable for this milestone is collaboration with MARBL for improved performance based on partially-assembled operators. The Urban exascale project is planning to couple real-time data with high performance simulations to study particulate transport in cities. Nek5000 will be used for large eddy and RANS (Reynolds-averaged Navier-Stokes) simulations of turbulent transport in these domains. Areas where the CEED team is aiding the Urban Canyon group include creating high-order meshes for urban geometries and developing boundary conditions appropriate for simulations close to real-life urban conditions. The software artifacts delivered as part of this milestone include GPU-enabled versions of the Nekbone and Laghos miniapps, which are provided through the CEED website, http://ceed.exascaleproject.org and the CEED GitHub organization, http://github.com/ceed. In addition to details and results from the above R&D efforts, in this document we are also reporting on other project-wide activities performed in Q4 of FY17, including: the CEED first annual meeting and participation of CEED researchers in a variety of outreach activities.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2017

HPC Institutional Computing Project: W15_lesreactiveflow KIVA-hpFE Development: A Robust and Accurate Engine Modeling Software

KIVA-hpFE is a high performance computer software for solving the physics of multi-species and multiphase turbulent reactive flow in complex geometries having immersed moving parts. The code is written in Fortran 90/95 and can be used on any computer platform with any popular complier. The code is in two versions, a serial version and a parallel version utilizing MPICH2 type Message Passing Interface (MPI or Intel MPI) for solving distributed domains. The parallel version is at least 30x faster than the serial version and much faster than our previous generation of parallel engine modeling software, by many factors. The 5th generation algorithm construction is a Galerkin type Finite Element Method (FEM) solving conservative momentum, species, and energy transport equations along with two-equation turbulent model k-ω Reynolds Averaged Navier-Stokes (RANS) model and a Vreman type dynamic Large Eddy Simulation (LES) method. The LES method is capable modeling transitional flow from laminar to fully turbulent; therefore, this LES method does not require special hybrid or blending to walls. The FEM projection method also uses a Petrov-Galerkin (P-G) stabilization along with pressure stabilization. We employ hierarchical basis sets, constructed on the fly with enrichment in areas associated with relatively larger error as determined by error estimation methods. In addition, when not using the hp-adaptive module, the code employs Lagrangian basis or shape functions. The shape functions are constructed for hexahedral, prismatic and tetrahedral elements. The software is designed to solve many types of reactive flow problems, from burners to internal combustion engines and turbines. In addition, the formulation allows for direct integration of solid bodies (conjugate heat transfer), as in heat transfer through housings, parts, cylinders. It can also easily be extended to stress modeling of solids, used in fluid structure interactions problems, solidification, porous media modeling and magneto hydrodynamics.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2026

Enhanced accuracy through ensembling of randomly initialized auto-regressive models for dynamical systems

Computational mechanics simulations using traditional finite element methods (FEM) require prohibitively expensive computational resources for real-time engineering applications, design optimization, and digital twin implementations. While machine learning (ML) surrogate models offer significant computational speedups, autoregressive ML models for time-dependent mechanical systems suffer from error accumulation that compromises long-term prediction reliability - a critical concern for engineering applications where accuracy over extended time horizons is essential for safety and performance assessments. Here, we propose a deep ensemble framework specifically designed to address this challenge in computational mechanics applications, where multiple ML surrogate models with random weight initializations are trained in parallel and their predictions aggregated during inference. This approach leverages statistical diversity to maximize information gain from a fixed set of training data and to mitigate error propagation, while maintaining the computational efficiency that makes ML surrogates attractive for engineering practice. We validate the framework on three representative problems spanning critical areas of computational mechanics: stress field evolution in heterogeneous microstructures under complex loading (relevant to advanced materials design and composite analysis), planetary-scale shallow water dynamics (applicable to environmental and geotechnical engineering), and Gray-Scott reaction-diffusion systems (relevant to mass transport and chemical process engineering). Across all test cases, the ensemble approach demonstrates consistent error reduction of 15-33% compared to individual models. The codes for this work are available on GitHub (https://github.com/Graham-Brady-Research-Group/AutoregressiveEnsemble_SpatioTemporal_Evolution).

autoregressive prediction↗
DOE OSTI2025

Gradient flow based phase-field modeling using separable neural networks

Allen–Cahn equation is a reaction–diffusion equation and is widely used for modeling phase separation. Machine learning methods for solving the Allen–Cahn equation in its strong form suffer from inaccuracies in collocation techniques, errors in computing higher-order spatial derivatives, and the large system size required by the space–time approach. To overcome these challenges, we propose solving the gradient flow of the Ginzburg–Landau free energy functional, which is equivalent to the Allen–Cahn equation, thereby avoiding the second-order spatial derivatives associated with the Allen–Cahn equation. A minimizing movement scheme is employed to solve the gradient flow problem, eliminating the complexities of a space–time approach. We utilize a separable neural network that efficiently represents the phase field through low-rank tensor decomposition. As we use the minimizing movement scheme to numerically solve the gradient flow problem, we thus, refer to the proposed method as the Separable Deep Minimizing Movement (SDMM) method. The evaluation of the functional in the minimizing movement scheme using the Gauss quadrature technique bypasses the inaccuracies associated with collocation techniques traditionally used to solve partial differential equations. A hyperbolic tangent transformation is introduced on the phase field prior to the evaluation of the functional to ensure that it remains strictly bounded within the values of the two phases. For this transformation, theoretical guarantee for energy stability of the minimizing movement scheme is established. Our results suggest that this transformation helps to improve the accuracy and efficiency significantly. The proposed method resolves the challenges faced by state-of-the-art machine learning techniques, outperforming them in both accuracy and efficiency. It is also the first machine learning method to achieve an order of magnitude speed improvement over the finite element method. In addition to its formulation and computational implementation, several case studies illustrate the applicability of the proposed method.

42 ENGINEERING↗
DOE OSTI2018

Reducing spurious mesh motion in Lagrangian finite volume and discontinuous Galerkin hydrodynamic methods

The Lagrangian finite volume (FV) cell-centered hydrodynamic (CCH) method and the Lagrangian discontinuous Galerkin (DG) CCH method have been demonstrated to be quite stable and capable of producing very accurate solutions on many mesh topologies. However, some challenges can arise with higher-order elements and polygonal elements that have many deformational degrees of freedom. With these types of meshes, elements can deform in unphysical ways and the mesh can tangle. In this study, we present methods for obtaining more robust Lagrangian solutions on polygonal and higher-order elements. The robustness is achieved by (1) incorporating a new iterative method that modifies the velocity reconstructions in the corners of the elements, and (2) a new multidirectional approximate Riemann solver that, when coupled with the iterative method, reduces spurious mesh motion. Lastly, the details of the numerical methods are discussed and their utility is demonstrated on a diverse suite of test problems using higher-order and polygonal elements.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
DOE OSTI2015

Comparison of multigrid algorithms for high‐order continuous finite element discretizations

Summary We present a comparison of different multigrid approaches for the solution of systems arising from high‐order continuous finite element discretizations of elliptic partial differential equations on complex geometries. We consider the pointwise Jacobi, the Chebyshev‐accelerated Jacobi, and the symmetric successive over‐relaxation smoothers, as well as elementwise block Jacobi smoothing. Three approaches for the multigrid hierarchy are compared: (1) high‐order h ‐multigrid, which uses high‐order interpolation and restriction between geometrically coarsened meshes; (2) p ‐multigrid, in which the polynomial order is reduced while the mesh remains unchanged, and the interpolation and restriction incorporate the different‐order basis functions; and (3) a first‐order approximation multigrid preconditioner constructed using the nodes of the high‐order discretization. This latter approach is often combined with algebraic multigrid for the low‐order operator and is attractive for high‐order discretizations on unstructured meshes, where geometric coarsening is difficult. Based on a simple performance model, we compare the computational cost of the different approaches. Using scalar test problems in two and three dimensions with constant and varying coefficients, we compare the performance of the different multigrid approaches for polynomial orders up to 16. Overall, both h ‐multigrid and p ‐multigrid work well; the first‐order approximation is less efficient. For constant coefficients, all smoothers work well. For variable coefficients, Chebyshev and symmetric successive over‐relaxation smoothing outperform Jacobi smoothing. While all of the tested methods converge in a mesh‐independent number of iterations, none of them behaves completely independent of the polynomial order. When multigrid is used as a preconditioner in a Krylov method, the iteration number decreases significantly compared with using multigrid as a solver. Copyright © 2015 John Wiley & Sons, Ltd.

Sundar, Hari↗
DOE OSTI2025

PIAFS: A 2D nonlinear hydrodynamics code to model gaseous optics

The survivability of final optics is expected to be a major challenge for all future inertial fusion energy concepts. Due to their higher damage threshold, gaseous optics have been identified as a promising solution to this problem. Gaseous optics can be created through the photoabsorption of spatially modulated UV light, which induces various chemical processes that heat the gas. This heating leads to a pressure perturbation, which in turn launches a density perturbation that can imprint a refractive index modulation such as a grating. In this article, we introduce a parallel C/C++ code to simulate gaseous optics. PIAFS2D is a high-order conservative finite-difference code to solve the compressible Navier–Stokes equations along with the photochemical heating sources on Cartesian grids. The simulations are validated by the linear theory derived in a previous paper [Michel et al., Phys. Rev. Appl. 22, 024014 (2024)]. For larger perturbations, the behavior of the system—particularly the evolution of the generated acoustic wave—demonstrates strong nonlinearity. PIAFS2D allows the study of nonlinear behaviors and can be used for the design of high-efficiency gaseous optics elements in realistic experimental conditions.

Oudin, A. [Lawrence Livermore National Laboratory ↗
DOE OSTI2021

srMO-BO-3GP: A sequential regularized multi-objective Bayesian optimization for constrained design applications using an uncertain Pareto classifier

Bayesian optimization (BO) is an efficient and flexible global optimization framework that is applicable to a very wide range of engineering applications. To leverage the capability of the classical BO, many extensions, including multi-objective, multi-fidelity, parallelization, and latent-variable modeling, have been proposed to address the limitations of the classical BO framework. In this work, we propose a novel multi-objective BO formalism, called srMO-BO-3GP, to solve multi-objective optimization problems in a sequential setting. Three different Gaussian processes (GPs) are stacked together, where each of the GPs is assigned with a different task. The first GP is used to approximate a single-objective computed from the multi-objective definition, the second GP is used to learn the unknown constraints, and the third one is used to learn the uncertain Pareto frontier. At each iteration, a multi-objective augmented Tchebycheff function is adopted to convert multi-objective to single-objective, where the regularization with a regularized ridge term is also introduced to smooth the single-objective function. Finally, we couple the third GP along with the classical BO framework to explore the convergence and diversity of the Pareto frontier by the acquisition function for exploitation and exploration. The proposed framework is demonstrated using several numerical benchmark functions, as well as a thermomechanical finite element model for flip-chip package design optimization.

42 ENGINEERING↗
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↗
DOE OSTI2018

Simple effective conservative treatment of uncertainty from sparse samples of random functions

This paper examines the variability of predicted responses when multiple stress-strain curves (reflecting variability from replicate material tests) are propagated through a finite element model of a ductile steel can being slowly crushed. Over 140 response quantities of interest (including displacements, stresses, strains, and calculated measures of material damage) are tracked in the simulations. Each response quantity’s behavior varies according to the particular stress-strain curves used for the materials in the model. We desire to estimate response variability when only a few stress-strain curve samples are available from material testing. Propagation of just a few samples will usually result in significantly underestimated response uncertainty relative to propagation of a much larger population that adequately samples the presiding random-function source. A simple classical statistical method, Tolerance Intervals, is tested for effectively treating sparse stress-strain curve data. The method is found to perform well on the highly nonlinear input-to-output response mappings and non-standard response distributions in the can-crush problem. The results and discussion in this paper support a proposition that the method will apply similarly well for other sparsely sampled random variable or function data, whether from experiments or models. Finally, the simple Tolerance Interval method is also demonstrated to be very economical.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Resonance form factors from finite-volume correlation functions with the external field method

A novel method for the extraction of form factors of unstable particles on the lattice is proposed. The approach is based on the study of two-particle scattering in a static, spatially periodic external field by using a generalization of the Lüscher method in the presence of such a field. It is shown that the resonance form factor is given by the derivative of the resonance pole position in the complex plane with respect to the coupling constant to the external field. Unlike the standard approach, this proposal does not suffer from problems caused by the presence of the triangle diagram.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗
DOE OSTI2023

Additive Polynomial Time Integrators, Part I: Framework and Fully Implicit-Explicit Collocation Methods

In this paper we generalize the polynomial time integration framework to additively partitioned initial value problems. The framework we present is general and enables the construction of many new families of additive integrators with arbitrary order-of-accuracy and varying degree of implicitness. In this first work, we focus on a new class of implicit-explicit polynomial block methods that are based on fully implicit Runge–Kutta methods with Radau nodes and that possess high stage order. Here, we show that the new fully implicit-explicit (FIMEX) integrators have improved stability compared to existing IMEX Runge–Kutta methods, while also being more computationally efficient due to recent developments in preconditioning techniques for solving the associated systems of nonlinear equations. For PDEs on periodic domains where the implicit component is trivial to invert, we will show how parallelization of the right-hand side evaluations can be exploited to obtain significant speedup compared to existing serial IMEX Runge–Kutta methods. For parallel (in space) finite element discretizations, the new methods can achieve orders of magnitude better accuracy than existing IMEX Runge–Kutta methods and/or achieve a given accuracy several times times faster in terms of computational runtime.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2015

Albany/FELIX: A parallel, scalable and robust, finite element, first-order Stokes approximation ice sheet solver built for advanced analysis

This paper describes a new parallel, scalable and robust finite element based solver for the first-order Stokes momentum balance equations for ice flow. The solver, known as Albany/FELIX , is constructed using the component-based approach to building application codes, in which mature, modular libraries developed as a part of the Trilinos project are combined using abstract interfaces and template-based generic programming, resulting in a final code with access to dozens of algorithmic and advanced analysis capabilities. Following an overview of the relevant partial differential equations and boundary conditions, the numerical methods chosen to discretize the ice flow equations are described, along with their implementation. The results of several verification studies of the model accuracy are presented using (1) new test cases for simplified two-dimensional (2-D) versions of the governing equations derived using the method of manufactured solutions, and (2) canonical ice sheet modeling benchmarks. Model accuracy and convergence with respect to mesh resolution are then studied on problems involving a realistic Greenland ice sheet geometry discretized using hexahedral and tetrahedral meshes. Also explored as a part of this study is the effect of vertical mesh resolution on the solution accuracy and solver performance. The robustness and scalability of our solver on these problems is demonstrated. Lastly, we show that good scalability can be achieved by preconditioning the iterative linear solver using a new algebraic multilevel preconditioner, constructed based on the idea of semi-coarsening.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2022

An E and B gyrokinetic simulation model for kinetic Alfvén waves in tokamak plasmas

The gyrokinetic particle simulation is a powerful tool for studies of transport, nonlinear phenomenon, and energetic particle physics in tokamak plasmas. While most gyrokinetic simulations make use of the scalar and vector potentials, a new model (GK-E&B) has been developed by using the E and B field in a general form and has been implemented in simulating kinetic Alfvén waves in uniform plasma. In our work, the Chen et al. GK-E&B model has been expressed, in general, tokamak geometry using the local orthogonal coordinates and general tokamak coordinates. Its reduction for uniform plasma is verified, and the numerical results show good agreement with the original work. The theoretical dispersion relation and numerical results in the local model in screw pinch geometry are also in excellent agreement. Numerical results show excellent performance in a realistic parameter regime of burning plasmas with high values of β/(M e k$^{2}_{⊥}$ρ$^{2}_{i}$), which is a challenge for traditional methods due to the “cancellation” problem. As one application, the GK-E&B model is implemented with kinetic electrons in the local single flux surface limit. With the matched International Tokamak Physics Activity-Toroidicity-induced Alfvén Eigenmodes parameters adopted, numerical results show the capability of the GK-E&B in treating the parallel electron Landau damping for realistic tokamak plasma parameters. As another application, the global GK-E&B model has been implemented with the dominant electron contribution in the cold electron limit. Its capability in simulating the finite E || due to the finite electron mass is demonstrated.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2016

Thermal Testing Quality Assurance of 24LCC & 3LCC Electronic Packages

The purpose of this project is to experimentally validate the thermal fatigue life of solder interconnects for a variety of surface mount electronic packages. Over the years, there has been a significant amount of research and analysis in the fracture of solder joints on printed circuit boards. Solder is important in the mechanical and electronic functionality of the component. It is important throughout the life of the product that the solder remains crack and fracture free. The specific type of solder used in this experiment is a 63Sn37Pb eutectic alloy. Each package was manufactured with conformal coating along with and without an underfill material below the device. Conformal coating helps protect the board from environments such as electrostatic discharge and humidity. It is commonly used in broad types of engineering disciplines such as commercial, military, research and development, etc. Conformal coating can also pose a risk for the life of the board because of its high thermal expansion coefficient. This can greatly decrease the life of the product if it regularly sees high temperature variations. This leads to a shorter fatigue life of the solder. The fatigue life is a common mechanical problem in the field of electronic devices. Adding underfill can help increase the fatigue life of the solder. However, applying underfill adds time to manufacturing and production. This ultimately increases the cost per unit. The study of conformal coated printed circuit boards with and without underfill was done on two different surface mount electronic packages. The electronic packages studied were 24 and 3 contact Leadless Ceramic Chips packages. When the package was not underfilled, the coating was allowed to flow underneath. The assembly was analyzed and tested to obtain the best available combination of conformal coating, underfill, and potting to design the most robust and reliable circuit board while keeping in mind certain factors such as cost, manufacturing time, and need. Different types of conformal coatings were considered with and without underfill for each device. 29 of each component were manufactured to have a large sample size and for the sake of individual defects and imperfections. Finite Element Analysis (FEA) was performed by an engineer at Sandia National Laboratories for both Leadless Ceramic Chips. From the FEA results, a test acceleration profile was derived and the number of temperature cycles to fail the solder interconnects were found for three different cases. Experimentation was done as a secondary measure to validate this data to show confidence in the theoretical analysis. Accelerated testing functions as a quality check for the product. Accelerated testing is extremely useful in the research and development phase of engineering. It can save money from the potential of early life defects and the costs that come along with warranties. Accelerated testing makes a weaker design more robust and checks the reliability of a strong design in a shorter period of time. It is extremely helpful in a world where deliverables are in high demand and scheduling is tight. Accelerated testing helps the engineer gain an understanding of what needs to be improved and what works well. There are many different types of accelerated tests. Our circuit boards were accelerated inside a closed thermal chamber because of the high number of use cycles. The ultimate goal of this experimentation is to help identify what will prevent any premature cracking or fracturing in the solder alloy. It is important to understand that underfilling each component may or may not be needed. If underfill is not needed, there are several production benefits.

42 ENGINEERING↗