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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.

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At least 1,135 records · Page 63
All sourcesNASA NTRSDOE OSTI
DOE OSTI2020

Constitutive modeling of δ-phase zircaloy hydride based on strain rate dependent nanoindentation and nano-scale impact dataset

In this work, a constitutive model for zircaloy-4 embedded with δ-phase hydride rim/blister structures (δ-phase zircaloy hydride) is presented. Nanoindentation and nano-scale impact experiments were performed on the δ-hydride blisters as a function of temperature in order to obtain strain rate dependent location specific constitutive response. A power law viscoplastic constitutive model was chosen to represent the strain rate dependent behavior. The strength coefficient and the strain hardening exponent in the power law relation were found to decrease with increase in temperature indicating softening behavior at higher temperatures. The strain rate exponent remained constant with increase in temperature indicating that the rate dependent ductility does not change significantly at higher temperatures. A finite element method based model was created to analyze the failure behavior and the ductile to brittle transition in zircaloy hydride. The model predicted that fracture strength of δ-phase zircaloy hydride decreases linearly with increase in temperature.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Weight function procedure for reduced order fracture analysis of arbitrary flaws in cylindrical pressure vessels

Fracture mechanics calculations using the finite element method can be computationally expensive, which makes them challenging to use in engineering evaluations of flaws in pressure vessels. The weight function (WF) technique is a reduced order fracture modeling method that is widely used to greatly reduce these computational costs. Its computational efficiency is essential for use in probabilistic fracture mechanics evaluations of embrittled nuclear reactor pressure vessels (RPVs), due to the large number of sampled flaws that must be evaluated. Although the WF technique is general, it is typically used only for axis-aligned flaws. Recent discoveries of off-axis flaws in operating nuclear reactors have necessitated detailed simulations of such flaws and the interactions between neighboring flaws. This paper presents a generalized WF approach applicable for analyzing arbitrary flaw geometries in thick-walled cylindrical vessels, including surface-breaking and subsurface flaws, which can either axis-aligned or off-axis, and can account for interactions with other flaws. Herein, this approach is demonstrated on representative simulations of multiple flaw geometries in a RPV subjected to transient loading conditions. In all cases, the WF technique gives good comparison with benchmark results from direct simulation with greatly reduced computational effort.

42 ENGINEERING↗
DOE OSTI2019

Assessing the reliability of fast Fourier transform-based crystal plasticity simulations of a polycrystalline material near a crack tip

Crystal plasticity simulations enable a physically-based description of the micromechanical fields associated with microstructural attributes in polycrystalline materials. Fast Fourier transforms implementation of crystal plasticity (CP-FFT) in periodic unit cells offers increased computational efficiency compared to traditional finite element methods (CP-FEM). Albeit, questions may arise concerning the accuracy of the CP-FFT approach given its underlying spectral framework, specifically in regards to: potential artifacts due to violating the traction-free conditions at internal free surface within the unit cell, Gibbs phenomenon near regions with sharp changes in local mechanical properties, and representation of free surfaces under the constraints imposed by the requirement of periodicity of the unit cell. This paper presents a custom massively parallelized implementation of CP-FFT. A direct comparison of simulation results for polycrystalline deformation near a crack in a Ti55531 alloy is presented between CP-FEM and CP-FFT. The micromechanical fields and slip system level values are quantified and are similar between the two methods. Up to 10% difference in the stress fields is reported at the crack tip and this value dissipates moving away from the crack tip after 5 voxels (7 µm). In conclusion, the results point towards the reliable use of CP-FFT simulations to model polycrystalline deformation with caveats based on the treatment of the discussed artifacts.

36 MATERIALS SCIENCE↗
DOE OSTI2022

A unified finite strain gradient-enhanced micropolar continuum approach for modeling quasi-brittle failure of cohesive-frictional materials

Here, in this work, a novel framework for modeling quasi-brittle crack propagation and shear band dominated failure of cohesive-frictional materials like concrete, mortar, rock, tough ceramics, energetic materials, but also granular materials like sands or powders in terms of a unified continuum approach is proposed. It is based on a combination of the gradient-enhanced continuum with gradients of internal variables for representing quasi-brittle cracking, and the micropolar continuum, accounting for the deformation of the microstructure. For developing the gradient-enhanced micropolar framework, the set of balance equations and the kinematic relations are derived, and the constitutive relations are established in a general manner. The framework is formulated in a geometrically exact setting, based on the thermodynamically sound theory of hyperelasto-plasticity, and the numerical implementation by means of the finite element method is discussed. For assessing the approach, realizations of this new approach in terms of constitutive models for particular materials are developed. They are applied to numerical benchmark examples, investigating various loading conditions, and the obtained results are validated by means of a comparison with experiments from the literature.

36 MATERIALS SCIENCE↗
DOE OSTI2013

A Quantitative Comparison between C0 and C1 elements for Solving the Cahn-Hilliard Equation

The Cahn–Hilliard (CH) equation is a time-dependent fourth-order partial differential equation (PDE). When solving the CH equation via the finite element method (FEM), the domain is discretized by C1-continuous basis functions or the equation is split into a pair of second-order PDEs, and discretized via C0-continuous basis functions. In the current work, a quantitative comparison between C1 Hermite and C0 Lagrange elements is carried out using a continuous Galerkin FEM formulation. The different discretizations are evaluated using the method of manufactured solutions solved with Newton’s method and Jacobian-Free Newton Krylov. It is found that the use of linear Lagrange elements provides the fastest computation time for a given number of elements, while the use of cubic Hermite elements provides the lowest error. The results offer a set of benchmarks to consider when choosing basis functions to solve the CH equation. In addition, an example of microstructure evolution demonstrates the different types of elements for a traditional phase-field model.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2013

Three-dimensional simulation of unstable gravity-driven infiltration of water into a porous medium

Infiltration of water in dry porous media is subject to a powerful gravity-driven instability. Although the phenomenon of unstable infiltration is understood, its description using continuum mathematical models has posed a significant challenge for several decades. The classical model of water flow in the unsaturated flow, the Richards equation, is unable to reproduce the instability. In this work, we present a computational study of a model of unsaturated flow in porous media that extends the Richards equation and is capable of predicting the instability and captures the key features of gravity fingering quantitatively. The extended model is based on a phase-field formulation and is fourth-order in space. The new model poses a set of challenges for numerical discretizations, such as resolution of evolving interfaces, stiffness in space and time, treatment of singularly perturbed equations, and discretization of higher-order spatial partial–differential operators. We develop a numerical algorithm based on Isogeometric Analysis, a generalization of the finite element method that permits the use of globally-smooth basis functions, leading to a simple and efficient discretization of higher-order spatial operators in variational form. We highlight the accuracy, efficiency and robustness of our method with several examples in two and three dimensions in both homogeneous and strongly heterogeneous media. We simulate, for the first time, unstable gravity-driven infiltration in three dimensions, and confirm that the new theory reproduces the fundamental features of water infiltration into a porous medium. Our findings are consistent with classical experimental observations that demonstrate a transition from stable to unstable fronts depending on the infiltration flux.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
DOE OSTI2014

Parareal in time 3D numerical solver for the LWR Benchmark neutron diffusion transient model

In this paper we present a time-parallel algorithm for the 3D neutrons calculation of a transient model in a nuclear reactor core. The neutrons calculation consists in numerically solving the time dependent diffusion approximation equation, which is a simplified transport equation. The numerical resolution is done with finite elements method based on a tetrahedral meshing of the computational domain, representing the reactor core, and time discretization is achieved using a θ-scheme. The transient model presents moving control rods during the time of the reaction. Therefore, cross-sections (piecewise constants) are taken into account by interpolations with respect to the velocity of the control rods. The parallelism across the time is achieved by an adequate use of the parareal in time algorithm to the handled problem. This parallel method is a predictor corrector scheme that iteratively combines the use of two kinds of numerical propagators, one coarse and one fine. Our method is made efficient by means of a coarse solver defined with large time step and fixed position control rods model, while the fine propagator is assumed to be a high order numerical approximation of the full model. The parallel implementation of our method provides a good scalability of the algorithm. Numerical results show the efficiency of the parareal method on large light water reactor transient model corresponding to the Langenbuch–Maurer–Werner benchmark.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2016

Scalable algorithms for three-field mixed finite element coupled poromechanics

We introduce a class of block preconditioners for accelerating the iterative solution of coupled poromechanics equations based on a three-field formulation. The use of a displacement/velocity/pressure mixed finite-element method combined with a first order backward difference formula for the approximation of time derivatives produces a sequence of linear systems with a 3 x 3 unsymmetric and indefinite block matrix. The preconditioners are obtained by approximating the two-level Schur complement with the aid of physically-based arguments that can be also generalized in a purely algebraic approach. A theoretical and experimental analysis is presented that provides evidence of the robustness, efficiency and scalability of the proposed algorithm. In conclusion, the performance is also assessed for a real-world challenging consolidation experiment of a shallow formation.

42 ENGINEERING↗
DOE OSTI2017

A scalable nonlinear fluid–structure interaction solver based on a Schwarz preconditioner with isogeometric unstructured coarse spaces in 3D

Nonlinear fluid-structure interaction (FSI) problems on unstructured meshes in 3D appear many applications in science and engineering, such as vibration analysis of aircrafts and patient-specific diagnosis of cardiovascular diseases. In this work, we develop a highly scalable, parallel algorithmic and software framework for FSI problems consisting of a nonlinear fluid system and a nonlinear solid system, that are coupled monolithically. The FSI system is discretized by a stabilized finite element method in space and a fully implicit backward difference scheme in time. To solve the large, sparse system of nonlinear algebraic equations at each time step, we propose an inexact Newton-Krylov method together with a multilevel, smoothed Schwarz preconditioner with isogeometric coarse meshes generated by a geometry preserving coarsening algorithm. Here ''geometry'' includes the boundary of the computational domain and the wet interface between the fluid and the solid. We show numerically that the proposed algorithm and implementation are highly scalable in terms of the number of linear and nonlinear iterations and the total compute time on a supercomputer with more than 10,000 processor cores for several problems with hundreds of millions of unknowns.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2017

Discontinuous Galerkin algorithms for fully kinetic plasmas

Here, we present a new algorithm for the discretization of the non-relativistic Vlasov–Maxwell system of equations for the study of plasmas in the kinetic regime. Using the discontinuous Galerkin finite element method for the spatial discretization, we obtain a high order accurate solution for the plasma's distribution function. Time stepping for the distribution function is done explicitly with a third order strong-stability preserving Runge–Kutta method. Since the Vlasov equation in the Vlasov–Maxwell system is a high dimensional transport equation, up to six dimensions plus time, we take special care to note various features we have implemented to reduce the cost while maintaining the integrity of the solution, including the use of a reduced high-order basis set. A series of benchmarks, from simple wave and shock calculations, to a five dimensional turbulence simulation, are presented to verify the efficacy of our set of numerical methods, as well as demonstrate the power of the implemented features.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2025

Evaluating the bond strength and fracture mechanisms of cold-sprayed zinc coating on AZ91 magnesium substrate via a combined experimental and computational approach

Magnesium (Mg) alloys are ideal candidates for automotive applications due to their high strength to weight ratio, castability, recyclability etc., however, they lack corrosion and oxidation resistance. Solid-state deposition techniques, such as cold spray, have been demonstrated to enhance their corrosion resistance as it relies on the severe plastic deformation of powder particles upon impact with the substrate to form a metallurgical bond with the substrate and within the coating. At cold sprayed interfaces, a heterogeneous microstructure is formed that includes some porosity, oxides and intermetallics which can significantly affect coating performance. Thus, establishing a direct correlation between the interface microstructure and its properties can aid in designing optimal cold spray parameters. In this study, we investigated the microstructure and mechanical properties of a zinc (Zn) coating deposited on a high pressure die cast (HPDC) AZ91 Mg substrate via high resolution scanning transmission electron microscopy, in situ micro-tensile testing, and finite element method (FEM) modeling. Micro-tensile pillars fabricated using the plasma focused ion beam (PFIB) successfully isolates the coating-substrate interface within the gauge length. The average bond strength of Zn-Mg interface was determined to be ∼140 MPa with failure occurring partially at the interface and mostly into the coatings. A detailed microstructural characterization revealed evidence of a strong metallurgical bonding at the Zn-Mg interface and formation of the C14 MgZn 2 laves phase interlayer resulting in a mixed mode of fracture during the micro-tensile experiments. FEM modeling reveals the stress distribution along the interfaces and suggests that a MgZn 2 layer thickness between 200–400 nm is optimum to increase the bond strength and minimize the triaxiality. Such a site-specific interfacial analysis with correlative computational modeling provides crucial insight into the overall performance of cold spray interfaces.

Bond strength↗
DOE OSTI2019

LaserOrigami (LO) of three-dimensional (3D) components: Experimental analysis and numerical modeling-part II

The present work explores how the choice of the scanning patterns can affect the final shapes of 3D components manufactured by laser-origami with a High-Power Diode Laser (HPDL). The experimental approach allowed the achievement of high bending angles, also avoiding any distortion on the surface of AISI 304 stainless steel workpiece. Optimization of the operational parameters led to the best prototype of the 3D components, with the closest respect of the strictest dimensional and geometrical tolerances. In addition, a thermo-mechanical model to predict the final shape of the 3D components was developed. The numerical model, implemented by Finite Element Method (FEM), was discovered to be a reliable tool in predicting the final shape of the prototypes, matching with a great deal of accuracy the experimental results. Specifically, the model allowed the estimation of the temperature distribution and nodal displacements of the components varying both the setting of the laser parameters and the choice of the scanning patterns.

47 OTHER INSTRUMENTATION↗
DOE OSTI2018

Coupled elasticity, plastic slip, and twinning in single crystal titanium loaded by split-Hopkinson pressure bar

Here coupled elasticity, plastic slip, and twinning in high-purity single crystal titanium loaded by split-Hopkinson pressure bar (SHPB) are investigated, in the framework of large deformation and by utilizing the finite element method (FEM). A thermodynamically consistent system of equations for combined plastic slip and twinning is formulated. Novel kinematics is proposed to develop the driving forces for slip and twinning processes and to consider plastic slip in twins. Dislocation based crystal plasticity is proposed, with an emphasis on the interactions among all slip modes in multi-variant/multiphase heterogeneous materials. A mechanism for dislocation density evolution during twinning is proposed. The impact loading along the [0001] and [1$0\bar{1}$1] directions of single crystal high purity titanium is investigated. The evolution of stress-strain field, dislocation density, and volume fraction for each variant in the sample during the entire loading process are obtained and discussed in detail. Results in simulations show that for the [0001] specimen due to the existence of six symmetry primary twin variants with respect to the loading direction and fifteen different slip systems in each variant, the fields of stress and dislocation density are very homogenous in the sample. The simulation results are compared with experimental data for the [0001] and [1$0\bar{1}$1] specimens. The experimental results are explained and interpreted for both specimens, which include the pole figures, the stress-strain curves, and volume fraction of variants. The simulation results provide an important insight into mechanical responses of high-purity single crystal titanium under high rate loading, and this paper advances the mesoscale modeling and simulations in coupled plastic slip and twinning.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Micro-mechanical investigation of the thermo-mechanical properties of micro-architectured tungsten coatings

The thermo-mechanical response of micro-architectured tungsten coatings is characterized in the temperature range of 293 to 673 K using both in situ micro-compression experiments inside a scanning electron microscope (SEM) as well as image-based crystal plasticity finite element method (CPFEM) simulations. The experiments were conducted on micropillar-like specimens that were focus ion beam milled into the coatings, while the simulations were conducted on columnar-grained micropillar simulation cells constructed based on the statistics of the coating’s microstructure. The experimental results show that the stress–strain response and deformation mode exhibit a strong temperature-dependence. At room temperature, catastrophic failure is observed shortly after yield and is manifested in the form of intergranular fracture and buckling of individual columnar grains. With increasing temperature, this catastrophic failure is gradually suppressed and the material exhibits a steadier strain hardening response at 693 K. The CPFEM simulations are also shown to be in good agreement with the experimental results, and these simulations indicate that the material response is strongly influenced by the local crystallographic anisotropy and microstructure inhomogeneity. Furthermore, the simulations capture the underlying mechanisms that control the temperature-dependent transition in deformation mode. The current results highlight that the micro-architectured microstructure offers a great combination of excellent mechanical strength and structural integrity at elevated temperatures, which is of importance for high temperature applications.

36 MATERIALS SCIENCE↗
DOE OSTI2022

A concurrent irradiation-mechanics multiscale coupling model

The vast majority of our current knowledge regarding the basic mechanisms controlling irradiation effect on mechanical properties is based almost entirely on the results of post-irradiation experiments or theoretical models. However, the concurrent effects of irradiation, mechanical stress, and thermal damage on the failure phenomena of materials and components remain largely unexplored due to its internal multiscale-multiphysics coupling nature. Here, we present here a concurrent irradiation-mechanics multiscale coupling model. The concurrent evolutions of nanoscale irradiation defect clusters, microscale dislocation configurations, and mechanical responses are well captured based on coupling cluster dynamics, discrete dislocation dynamics, and the finite element methods using an effective time marching scheme. Model predictions of defect densities and size are in general agreement with experimental observations. Irradiation hardening is shown to take place also in samples undergoing concurrent irradiation-mechanical loading, similar to samples tested post-irradiation. However, the occurrence of plastic flow localization and dislocation channel formation is not accompanied with apparent yield drop (softening) under concurrent irradiation-mechanical loading conditions, which is different from the post-irradiation case.

42 ENGINEERING↗
DOE OSTI2024

A multiscale model to understand the interface chemistry, contacts, and dynamics during lithium stripping

A reversible Li-metal electrode, paired with a solid electrolyte, is critical for attaining higher energy density and safer batteries beyond the current lithium-ion cells. A stable stripping process may be even harder to attain as the stripping process will remove Li-atoms from the surface, and naturally reduce surface contact area, if not self-corrected by other mechanisms, such as diffusion and plastic deformation under an applied external stack pressure. Here, we capture these mechanisms occurring at multiple length- and time- scales, i.e., interface interactions, vacancy hopping, and plastic deformation, by integrating density functional theory (DFT) simulations, kinetic Monte Carlo (KMC), and continuum finite element method (FEM). By assuming the self-affine nature of multiscale contacts, we predict the steady-state contact area as a function of stripping current density, interface wettability, and stack pressure. We further estimate the exponential increase of overpotential due to contact area loss to maintain the same stripping current density. We demonstrate that a lithiophilic interface requires less stack pressure to reach the same steady-state contact area fraction than a lithiophobic interface. A “tolerable steady-state” contact area loss for maintaining stable stripping is estimated at 20 %, corresponding to a 10 % increase in overpotential. To constrain contact loss within the tolerance, the required stack pressure is 0.1, 0.5, and 2 times the yield strength of lithium metal for three distinct interfaces, lithiophilic Li/lithium oxide(Li2O), Li/lithium lanthanum zirconium oxide(LLZO), and lithiophoblic Li/lithium fluoride(LiF), respectively. The modeling results agree with experiments on the impact of the stack pressure quantitatively, while the discrepancy in stripping rate sensitivity is attributed to the simplifying interface interaction in our simulations. Overall, this multiscale simulation framework demonstrates the importance of electrochemical-mechanical coupling in understanding the dynamics of the Li/SE interface during stripping.

Feng, Min↗
DOE OSTI2022

A level set approach for the computational study of a yield stress fluid filling a thin mold

Many important engineering and scientific applications such as cement slurries, foams, crude oil, and granular avalanches involve the concept of yield stress. Therefore, modeling yield stress fluids in different flow configurations, including the accurate prediction of the yield surface, is important. In this paper, we present a computational model based on the finite element method to study the flow of yield stress fluids in a thin mold and compare the results with data from flow visualization experiments. Here, we use the level set method to describe the interface between the filling fluid and air. We use polypropylene glycol as a model Newtonian fluid and Carbopol for the model yield stress fluid, as the Carbopol solution demonstrates yielding without thixotropy. To describe the yielding and shear-thinning behavior, we use a generalized Newtonian constitutive equation with a Bingham–Carreau–Yasuda form. We compare the results obtained from the mold filling experiments with the results from the three-dimensional (3D) model and from a reduced-order Hele-Shaw (HS) model that is two-dimensional, including the effect of shear-thinning along the thin direction only approximately. We show that both the 3D and the HS model can capture the experimental meniscus shape reasonably well for all the fluids considered at three different flow rates. This indicates that the shape evolution is insensitive to the dimensionality of the model. However, the viscosity and yield surfaces predicted by the 3D and HS models are different. The HS model underestimates the high viscosity and unyielded regions compared to the estimation by the 3D model.

42 ENGINEERING↗
DOE OSTI2017

A nanomechanical Raman spectroscopy based assessment of stress distribution in irradiated and corroded SiC

Silicon carbide (SiC) composites are under consideration for cladding and structural materials in various types of reactors. The effects of ion irradiation and corrosion on stress distribution due to mechanical loading on chemical vapor deposited (CVD) SiC were investigated here in this paper by using nanomechanical Raman spectroscopy (NMRS). The stress distribution was analyzed as a function of the oxide formation on a corroded specimen and as a function of ion-induced irradiation damage in an irradiated specimen. A finite element method (FEM) based model was developed based on local mechanical properties measured using nanoindentation to predict the NMRS measured stress distribution. The stress distribution was also predicted theoretically by using a stress concentration factor, which is a function of sample geometry and boundary conditions. The maximum stress obtained theoretically was in good agreement with the FEM model and NMRS based measurements. FEM results captured the stress variation trends and maximum stress value in the analyzed samples. NMRS measurements predicted that corrosion had a greater influence on increasing the maximum value of stress in comparison to ion irradiation. The increase in stress attributed to corrosion in comparison to ion irradiated samples was approximately 10%–20%.

36 MATERIALS SCIENCE↗