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DOE OSTI2025

Role of Computational Parameters on Predicting Self-Consistent Residual Stress and Distortion during Wire Arc Additive Manufacturing

Production of three-dimensional metallic parts through integration of an articulated robot and gas metal arc welding, also known as wire arc additive manufacturing (WAAM), can produce large-scale components with moderate geometrical complexity. This technology is particularly appealing due to its high deposition rates, scalability, and cost-effective feedstock compared to other AM processes. Despite its advantages, WAAM adoption is hindered by challenges in ensuring geometric conformity without extensive distortion, defect-free structures, and consistent mechanical properties. Finite element analysis (FEA) is often used to address the challenge of geometrical conformity. As the size of parts increases, the best practices for mesh size and temporal resolution known in the literature become computationally unviable. This research examined the effects of mesh and time-step resolutions during transient FEA of a large-scale (248 layers) metallic part. The impact of computational parameters on the thermal history, displacement, and residual stress distributions were evaluated. The results showed that predicted distortion was consistent across resolutions, while time-step length significantly affected predicted thermal history, and mesh size influenced residual stress distributions. To investigate this relationship further, directionally biased meshes were considered and analyzed. The results indicated that increasing mesh resolution perpendicular to the welding path yielded stress predictions that aligned closely with higher-resolution models while offering substantial computational savings. In conclusion, the significances of this research are related to verification and validation of WAAM models for widespread industrial adoption and pragmatic guidelines for optimizing computation parameters for balancing computational efficiency and predictive accuracy of residual stress and distortion.

Solsbee, Brandon [Univ. of Tennessee, Knoxville, T↗

DOE OSTI2020

Self-consistent Color–Stellar Mass-to-light Ratio Relations for Low Surface Brightness Galaxies

The color–stellar mass-to-light ratio relation (CMLR) is a widely accepted tool for estimating the stellar mass (M {sub *}) of a galaxy. However, an individual CMLR tends to give distinct M {sub *} for a same galaxy when it is applied in different bands. Examining five representative CMLRs from the literature, we find that the difference in M {sub *} predicted in different bands from optical to near-infrared by a CMLR is 0.1 ∼ 0.3 dex. Based on a sample of low surface brightness galaxies that covers a wide range of color and luminosity, we therefore recalibrated each original CMLR in r, i, z, J, H, and K bands to give internally self-consistent M {sub *} for a same galaxy. The g–r is the primary color indicator in the recalibrated relations, which show little dependence on red (r–z) or near-infrared (J–K) colors. Additionally, the external discrepancies in the originally predicted γ {sub *} by the five independent CMLRs have been greatly reduced after recalibration, especially in the near-infrared bands, implying that the near-infrared luminosities are more robust in predicting γ {sub *}. For each CMLR, the recalibrated relations provided in this work could produce internally self-consistent M {sub *} from divergent photometric bands, and are extensions of the recalibrations from the Johnson–Cousin filter system by the pioneering work of McGaugh & Schombert to the filter system of the Sloan Digital Sky Survey.

79 ASTRONOMY AND ASTROPHYSICS↗

DOE OSTI2021

Reconstructing the Universe: Testing the Mutual Consistency of the Pantheon and SDSS/eBOSS BAO Data Sets with Gaussian Processes

We test the mutual consistency between the baryon acoustic oscillation measurements from the eBOSS SDSS final release and the Pantheon supernova compilation in a model-independent fashion using Gaussian process regression. We also test their joint consistency with the ΛCDM model in a model-independent fashion. We also use Gaussian process regression to reconstruct the expansion history that is preferred by these two data sets. While this methodology finds no significant preference for model flexibility beyond ΛCDM, we are able to generate a number of reconstructed expansion histories that fit the data better than the best-fit ΛCDM model. These example expansion histories may point the way toward modifications to ΛCDM. We also constrain the parameters Ω{sub k} and H {sub 0} r {sub d} both with ΛCDM and with Gaussian process regression. We find that H {sub 0} r {sub d} = 10,030 ± 130 km s{sup −1} and Ω{sub k} = 0.05 ± 0.10 for ΛCDM and that H {sub 0} r {sub d} = 10,040 ± 140 km s{sup −1} and Ω{sub k} = 0.02 ± 0.20 for the Gaussian process case.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗

DOE OSTI2020

Thermodynamic Consistent Neural Networks for Learning Material Interfacial Mechanics

For multilayer materials in thin substrate systems, interfacial failure is one of the most challenges. The traction-separation relations (TSR) quantitatively describe the mechanical behavior of a material interface undergoing openings, which is critical to understand and predict interfacial failures under complex loadings. However, existing theoretical models have limitations on enough complexity and flexibility to well learn the real-world TSR from experimental observations. A neural network can fit well along with the loading paths but often fails to obey the laws of physics, due to a lack of experimental data and understanding of the hidden physical mechanism. In this paper, we propose a thermodynamic consistent neural network (TCNN) approach to build a data-driven model of the TSR with sparse experimental data. The TCNN leverages recent advances in physics-informed neural networks (PINN) that encode prior physical information into the loss function and efficiently train the neural networks using automatic differentiation. We investigate three thermodynamic consistent principles, i.e., positive energy dissipation, steepest energy dissipation gradient, and energy conservative loading path. All of them are mathematically formulated and embedded into a neural network model with a novel defined loss function. A real-world experiment demonstrates the superior performance of TCNN, and we find that TCNN provides an accurate prediction of the whole TSR surface and significantly reduces the violated prediction against the laws of physics.

Zhang, Jiaxin↗

DOE OSTI2022

Global virtual address space consistency model

An approach is disclosed that maintains a consistent view of a virtual address by a local node which writes a first value to the virtual address and, after writing the first value, establishes a snapshot consistency state of the virtual address. The virtual address is shared amongst any number of processes and the processes includes a writing process and other processes that read from the virtual address. After writing the first value, the writing process writes a second value to the virtual address. Even after writing the second value, the first value is still visible to the other processes.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2023

On Practical Aspects of Variational Consistency in Contact Dynamics

Usage of contact mechanics methodologies is a pervasive modeling requirement in dynamic simulations. While for some trivial problems, solutions taken from analytical geometry are available, use of a finite element framework is common to achieve formulation generality. This work explores two dynamic contact formulations: one based on the traditional node-to-segment (NTS) approach, and a variationally consistent segment-to-segment (STS) mortar formulation. The NTS formulation employed here enforces the constraints kinematically (i.e., the interpenetration is enforced to the solver tolerance), whereas the mortar approach uses Lagrange multipliers to enforce the contact constraints. Both approaches are implemented in the open-source finite element framework Multiphysics Object-Oriented Simulation Environment (MOOSE). The results highlight two relevant contact-interface-related dynamic phenomena in finite element simulations. First, stabilization of contact constraints is discussed, taking into account the evolution of the total energy in a benchmark problem. Second, the influence of finite element discretization on both of the aforementioned contact formulations is analyzed by exercising a large-deformation example with continuous relative sliding. Variationally consistent contact approaches such as the mortar formulation lead to improved energy preservation and avoid spurious excitation of the system's frequencies. This is especially relevant in settings where inertia and vibrations are of importance.

42 ENGINEERING↗

DOE OSTI2023

Consistent Nuclear Data Evaluations for Criticality Safety

Evaluations of nuclear data are based on statistical analysis of available experimental data and their uncertainties plus model calculations and their uncertainties. As the models are currently rather limited, the evaluations are heavily biassed toward experimental data, with the caveat that a thorough analysis is also required to understand possible discrepancies between data sets. Hence, as new experimental data become available, they are incorporated into the evaluation procedure. Recent measurements of the 233 U capture to fission cross section ratio at the Los Alamos Neutron Science Center have prompted a re-evaluation of the capture cross section in the resonance and fast regions up to 250 keV. We will discuss the challenges of including the new fast neutron experimental data in an evaluation that is consistent with the resonance region. We will also discuss our consistent evaluation procedure based on the Hauser-Feshbach statistical model for nuclear reactions and its application to the evaluations of 239 Pu and 139 La neutron-induced reactions.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗

DOE OSTI2026

Self-consistent mean-field quantum approximate optimization

We introduce a self-consistent mean-field quantum optimization algorithm that approximates the ground state of classical Ising Hamiltonians. The algorithm decomposes the problem into independent subproblems and treats the interactions between them in a mean-field manner. These interactions are captured by a common environment, constructed self-consistently through a variational quantum circuit, and which modifies the subproblems to account for mutual influence while maintaining computational independence. Consequently, subproblems can be solved individually, avoiding the computational cost of the full problem. We explore the properties of the generated environment and assess the algorithm's performance through extensive numerical simulations on Sherrington-Kirkpatrick spin glasses. Furthermore, we apply it experimentally to a weighted maximum clique problem applied to molecular docking. This framework enables the solution of problems that would otherwise exceed the qubit and gate counts of current quantum hardware.

Dupont, Maxime [Rigetti Computing] (ORCID:00000001↗

DOE OSTI2026

Self-consistent mean-field quantum approximate optimization

Dupont, Maxime [Rigetti Computing] (ORCID:00000001↗

DOE OSTI2026

Self-consistent mean-field quantum approximate optimization

Dupont, Maxime [Rigetti Computing] (ORCID:00000001↗

DOE OSTI2026

A LASER POWDER BED FUSION ADDITIVE MANUFACTURING CHARACTERIZATION APPROACH AND DATASET HIGHLIGHTING IMPLICATIONS FOR CROSS-PLATFORM PERFORMANCE CONSISTENCY

Additive Manufacturing (AM) has remained a rapidly growing technology over the past decade, which affords many benefits. However, there is one main hinderance to widespread adoption: Products produced on one Laser Powder Bed Fusion (LPBF) AM system can vary in mechanical performance from those produced on another system. This is due to the fact that while LPBF AM system is producing a product’s shape, it is also producing the product’s material. Due to the complex and dynamic nature of LPBF, items fabricated on one system can be different in terms of dimensions, microstructure and quality compared to items fabricated on a different make or model system. This lack of cross-platform performance consistency makes widespread adoption challenging. This work was created to help understand the variation between different Laser Powder Bed Fusion (LPBF) Additive Manufacturing (AM) systems across different manufacturers, models, and users, and to provide insight into how to ensure product consistency regardless of system selection.

36 MATERIALS SCIENCE↗

DOE OSTI2023

Correlated Dirac–Coulomb–Breit multiconfigurational self-consistent-field methods

The fully correlated frequency-independent Dirac–Coulomb–Breit Hamiltonian provides the most accurate description of electron–electron interaction before going to a genuine relativistic quantum electrodynamics theory of many-electron systems. In this work, we introduce a correlated Dirac–Coulomb–Breit multiconfigurational self-consistent-field method within the frameworks of complete active space and density matrix renormalization group. In this approach, the Dirac–Coulomb–Breit Hamiltonian is included variationally in both the mean-field and correlated electron treatment. Here, we also analyze the importance of the Breit operator in electron correlation and the rotation between the positive- and negative-orbital space in the no-virtual-pair approximation. Atomic fine-structure splittings and lanthanide contraction in diatomic fluorides are used as benchmark studies to understand the contribution from the Breit correlation.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2020

Nonlinear Multiobjective MPC-Based Optimal Operation of a High Consistency Refining System in Papermaking

As one of the most important unit in the papermaking industry, the high consistency (HC) refining system is confronted with challenges such as improving pulp quality, energy saving, and emissions reduction in its operation processes. Here in this correspondence, an optimal operation of HC refining system is presented using nonlinear multiobjective model predictive control strategies that aim at set-point tracking objective of pulp quality, economic objective, and specific energy (SE) consumption objective, respectively. First, a set of input and output data at different times are employed to construct the subprocess model of the state process model for the HC refining system, and then the Wiener-type model can be obtained through combining the mechanism model of Canadian Standard Freeness and the state process model that determines their structures based on Akaike information criterion. Second, the multiobjective optimization strategy that optimizes both the set-point tracking objective of pulp quality and SE consumption is proposed simultaneously, which uses NSGA-II approach to obtain the Pareto optimal set. Furthermore, targeting at the set-point tracking objective of pulp quality, economic objective, and SE consumption objective, the sequential quadratic programming method is utilized to produce the optimal predictive controllers. In conclusion, the simulation results demonstrate that the proposed methods can make the HC refining system provide a better performance of set-point tracking of pulp quality when these predictive controllers are employed. In addition, while the optimal predictive controllers orienting with comprehensive economic objective and SE consumption objective, it has been shown that they have significantly reduced the energy consumption.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2020

Solving Stochastic Inverse Problems for Property–Structure Linkages Using Data-Consistent Inversion and Machine Learning

Determining process–structure–property linkages is one of the key objectives in material science, and uncertainty quantification plays a critical role in understanding both process–structure and structure–property linkages. In this work, we seek to learn a distribution of microstructure parameters that are consistent in the sense that the forward propagation of this distribution through a crystal plasticity finite element model matches a target distribution on materials properties. This stochastic inversion formulation infers a distribution of acceptable/consistent microstructures, as opposed to a deterministic solution, which expands the range of feasible designs in a probabilistic manner. Furthermore, to solve this stochastic inverse problem, we employ a recently developed uncertainty quantification framework based on push-forward probability measures, which combines techniques from measure theory and Bayes’ rule to define a unique and numerically stable solution. This approach requires making an initial prediction using an initial guess for the distribution on model inputs and solving a stochastic forward problem. To reduce the computational burden in solving both stochastic forward and stochastic inverse problems, we combine this approach with a machine learning Bayesian regression model based on Gaussian processes and demonstrate the proposed methodology on two representative case studies in structure–property linkages.

36 MATERIALS SCIENCE↗

DOE OSTI2020

Self-consistent GW method: O(N) algorithm for polarizability and self energy

In this work, an efficient implementation of the self-consistent GW method in the FlapwMBPT code [1] is presented. It features the evaluation of polarizability and self-energy which scales linearly with respect to the system size. Altogether the computational time scaling was measured to be be-tween linear and quadratic in the applications to silicon supercells with up to 72 atoms. Application to such materials as paracostibite CoSbS, supercells of La 2 CuO 4 (up to 56 atoms) and SmB 6 , illustrate the potential of the approach in computational material science.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗

DOE OSTI2020

An analytical expression for temperature in a thermodynamically consistent model with a Mie-Gruneisen equation for pressure

The objective of this paper is to develop an analytical expression for temperature in a thermodynamically consistent model with a Mie-Gruneisen equation for pressure. This expression for the temperature is obtained for both constant and variable specific heat models and can be used in common models for the material yield strength that include thermal softening due to increase in temperature. Additionally, the material parameters in the model can easily be calibrated to match known experimental data and the model has been used to determine the value of the shock pressure at the onset of melting during shock loading.

42 ENGINEERING↗

DOE OSTI2021

Self-interaction-corrected Kohn–Sham effective potentials using the density-consistent effective potential method

Density functional theory (DFT) and beyond-DFT methods are often used in combination with photoelectron spectroscopy to obtain physical insights into the electronic structure of molecules and solids. The Kohn–Sham eigenvalues are not electron removal energies except for the highest occupied orbital. The eigenvalues of the highest occupied molecular orbitals often underestimate the electron removal or ionization energies due to the self-interaction (SI) errors in approximate density functionals. Here, we adapt and implement the density-consistent effective potential method of Kohut, Ryabinkin, and Staroverov (2014) to obtain SI-corrected local effective potentials from the SI-corrected Fermi–Löwdin orbitals and density in the Fermi–Löwdin orbital self-interaction correction scheme. The implementation is used to obtain the density of states (photoelectron spectra) and HOMO–LUMO gaps for a set of molecules and polyacenes. Good agreement with experimental values is obtained compared to a range of SI uncorrected density functional approximations.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2023

Self-consistent implementation of locally scaled self-interaction-correction method

Recently proposed local self-interaction correction (LSIC) method is a one-electron self-interaction-correction (SIC) method that uses an iso-orbital indicator to apply the SIC at each point in space by scaling the exchange–correlation and Coulomb energy densities. The LSIC method is exact for the one-electron densities, also recovers the uniform electron gas limit of the uncorrected density functional approximation, and reduces to the well-known Perdew–Zunger SIC (PZSIC) method as a special case. This article presents the self-consistent implementation of the LSIC method using the ratio of Weizsäcker and Kohn–Sham kinetic energy densities as an iso-orbital indicator. The atomic forces as well as the forces on the Fermi-Löwdin orbitals are also implemented for the LSIC energy functional. Results show that LSIC with the simplest local spin density functional predicts atomization energies of the AE6 dataset better than some of the most widely used generalized-gradient-approximation (GGA) functional and barrier heights of the BH6 database better than some of the most widely used hybrid functionals. The LSIC method [a mean absolute error (MAE) of 0.008 Å] predicts bond lengths of a small set of molecules better than the PZSIC-LSDA (MAE 0.042 Å) and LSDA (0.011 Å). Furthermore, this work shows that accurate results can be obtained from the simplest density functional by removing the self-interaction-errors using an appropriately designed SIC method.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗