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Exploration of Shear-Dominated Geometries for Material Characterization and Model Calibration; Part 2: Calibration.
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Modeling Detonations in Materials With Non-Uniform Temperature
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Final Report (October 2024): University of Tennessee, Knoxville (UTK) contribution to: FusMatML: Machine Learning Atomistic Modeling for Fusion Materials Collaborative Project led by Dr. Aidan Thompson, Sandia National Laboratory
The rapid growth of the field of Machine Learning Inter-Atomic Potentials (MLIAP) has lead to a profusion of methods, all of which have some similarity to each other, but each also restricted to particular design choices, often arrived at in a rather ad hoc fashion. Beyond anecdotal evidence, and some benchmarking studies on specific problems, little progress has been made in developing design principles for MLIAPs. The goal of this project is to use machine learning, data science, and uncertainty quantification methods to optimize the design choices for MLIAP.
In-situ Measurements of Hydrogen-Titanium Plasma-Material Interactions for Model Validation
Final performance report for our DOE grant
Density estimation techniques for multiscale coupling of kinetic models of the plasma material interface
In this work we analyze two classes of Density-Estimation techniques which can be used to consistently couple different kinetic models of the plasma-material interface, intended as the region of plasma immediately interacting with the first surface layers of a material wall. In particular, we handle the general problem of interfacing a continuum multi-species Vlasov-Poisson-BGK plasma model to discrete surface erosion models. The continuum model solves for the energy-angle distributions of the particles striking the surface, which are then driving the surface response. A modification to the classical Binary-Collision Approximation (BCA) method is here utilized as a prototype discrete model of the surface, to provide boundary conditions and impurity distributions representative of the material behavior during plasma irradiation. The numerical tests revealed the superior convergence properties of Gaussian Mixture Models over Kernel Density Estimation methods, with Gaussian Mixtures and Epanechnikov-KDEs both being up to two orders of magnitude faster than Gaussian-KDEs. The methodology here presented allows a self-consistent treatment of the plasma-material interface in magnetic fusion devices, including both the near-surface plasma (plasma sheath and presheath) in magnetized conditions, and surface effects such as sputtering, back-scattering, and ion implantation. The same coupling techniques can also be utilized for other discrete material models such as Molecular Dynamics.
Solid and gas thermal conductivity models improvement and validation in various porous insulation materials
In the past few decades, significant efforts have been made to improve the theoretical understanding of thermal transport mechanisms in thermal insulation materials and push the thermal conductivity's lower limits. However, most works focused singularly on specific types of materials, and the models used for thermal conductivity predictions are diverse - a model that fits one material might not fit others. Here, we improve and unify the gas and solid thermal conductivity models for porous materials. Through experimental characterization of several different materials as well as literature data for other materials, these models are validated. Further, we have also found that the pressure-dependent gas thermal conductivity of most materials can be well fitted by using one or two pore sizes without using a complex pore size distribution. With the refined models, we decompose the effective thermal conductivity of several thermal insulation materials into gas, solid, and radiation contributions. For cellular (polystyrene and polyurethane) foams, the relative contributions from air, solid, and radiation are 58–75%, 3–11%, 16–38%, respectively. For granular porous materials (polyurethane and silica in this work), the contributions from air, solid, and radiation are 45–66%, 34–46%, and 0–8%, respectively. This work is expected to provide guidance on the design and optimization of the next generation of thermal insulation materials, for example, through the effort of reducing gas conduction and radiation in foams and suppressing gas and solid conduction in aerogels.
Characterization of Nonlinear Rate Dependent Response of Shape Memory Polymers
Shape Memory Polymers (SMPs) are a class of polymers, which can undergo deformation in a flexible state at elevated temperatures, and when cooled below the glass transition temperature, while retaining their deformed shape, will enter and remain in a rigid state. Upon heating above the glass transition temperature, the shape memory polymer will return to its original, unaltered shape. SMPs have been reported to recover strains of over 400%. It is important to understand the stress and strain recovery behavior of SMPs to better develop constitutive models which predict material behavior. Initial modeling efforts did not account for large deformations beyond 25% strain. However, a model under current development is capable of describing large deformations of the material. This model considers the coexisting active (rubber) and frozen (glass) phases of the polymer, as well as the transitions between the material phases. The constitutive equations at the continuum level are established with internal state variables to describe the microstructural changes associated with the phase transitions. For small deformations, the model reduces to a linear model that agrees with those reported in the literature. Thermomechanical characterization is necessary for the development, calibration, and validation of a constitutive model. The experimental data reported in this paper will assist in model development by providing a better understanding of the stress and strain recovery behavior of the material. This paper presents the testing techniques used to characterize the thermomechanical material properties of a shape memory polymer (SMP) and also presents the resulting data. An innovative visual-photographic apparatus, known as a Vision Image Correlation (VIC) system was used to measure the strain. The details of this technique will also be presented in this paper. A series of tensile tests were performed on specimens such that strain levels of 10, 25, 50, and 100% were applied to the material while it was above its glass transition temperature. After deforming the material to a specified applied strain, the material was then cooled to below the glass transition temperature (Tg) while retaining the deformed shape. Finally, the specimen was heated again to above the transition temperature, and the resulting shape recovery profile was measured. Results show that strain recovery occurs at a nonlinear rate with respect to time. Results also indicate that the ratio of recoverable strain/applied strain increases as the applied strain increases.
Hot Isostatic Pressing for Reduction of Defects in Additively Manufactured Inconel-718 Preliminary Simulation Approach and Results
Selective laser melting (SLM) of Inconel-718 (IN718) is a promising advanced manufacturing technology; however, challenges exist for fracture-critical parts where pores induced during the manufacturing process reduce fatigue life of the material. Hot isostatic pressing (HIP) is a common post processing technique used to reduce the part porosity by exposing parts to high temperature and pressures. Pore closure depends on the pore shape, trapped gas, and HIP parameters, and the process can only be optimized by understanding the effect of these variables. An analysis capability is described to better understand the conditions necessary for pore closure, and the effect of several variables on porosity are explored and compared to a baseline case. The importance of valid material response models is identified as a significant factor in model accuracy; especially the creep material response model which, in the baseline case, predicts that creep strain accounts for 87.7% of the total strain at the conclusion of the HIP cycle. Lessons learned are described, in addition to future work including model validation.
Evaluation of Three Constitutive Models for the Prediction of Hastelloy X Elevated Temperature Cyclic Response
The approach for the method development assumes that, for a thermally loaded structure, the overall strain history is defined by linear elastic analysis. The local stress history at a fatigue critical location is then determined from a one dimensional material behavior model and the local strain and temperature conditions. Three material models are currently being evaluated to assess their ability to predict relevant high temperature cyclic material response characteristics. They are: a time independent classical plasticity and creep representation, a time dependent viscoplastic model capable of predicting combined creep and plasticity effects, and an approximate elastic analysis approach that uses a series of stress-strain curves and a cyclic hardening model to determine reverse plasticity.
A computer program for predicting nonlinear uniaxial material responses using viscoplastic models
A computer program was developed for predicting nonlinear uniaxial material responses using viscoplastic constitutive models. Four specific models, i.e., those due to Miller, Walker, Krieg-Swearengen-Rhode, and Robinson, are included. Any other unified model is easily implemented into the program in the form of subroutines. Analysis features include stress-strain cycling, creep response, stress relaxation, thermomechanical fatigue loop, or any combination of these responses. An outline is given on the theoretical background of uniaxial constitutive models, analysis procedure, and numerical integration methods for solving the nonlinear constitutive equations. In addition, a discussion on the computer program implementation is also given. Finally, seven numerical examples are included to demonstrate the versatility of the computer program developed.
Nuclear Forensics for Irradiated Materials using Kernel Regression Models
The ultimate purpose of nuclear forensics is to locate the origin of nuclear and other radioactive materials out of regulatory control used in nuclear security events such as classical forensics. For this purpose, some specific characteristics of interdicted materials (referred to as 'signatures') should be defined to compare the known sample database. In some cases, involved with irradiated material, the signatures could be specific amount of fission product inventory depending on reactor operational histories such as reactor type, initial enrichment, burn up rate of nuclear fuel and cooling period after irradiation in the reactor. In order to make inference model for irradiated material for nuclear forensics, we suggested 3 ways as follows; (i) analyzing ORIGEN produced nuclear substances for the fission product inventory, (ii) classifying the range of reactor type, (iii) predicting the operational history from the fission product inventory. In terms of nuclear substance analysis, the construction of spent fuel database has been internationally carried out since ITWG (Nuclear Smuggling International Technical Working Group) was established in 1995. However, enough sample data cannot be obtained in Korea to determine reactor type and operational histories because analyzing nuclear substances have been limited due to the international regulation. Thus, this study does not mention how to obtain mass or ratios of nuclides for the spent fuel. We just have generated simulation sample data as a fission product inventory using ORIGEN to construct spent fuel database. When unidentified radioactive materials are discovered, it is assumed that mass or ratios of the nuclides are analyzed by certain methods which are available in Korea as well as other countries. Then, a reactor type is determined, and finally, regression model can locate the origin or source of the radioactive materials by inferring operational histories using the fission product inventory. There are some studies on the classification of reactor type using statistical methods. As a part of predicting the operational history, this paper focuses on the development of spent fuel inference algorithm for nuclear forensics to estimate reactor operational histories that reflect characteristics of a reactor from the fission product inventory. The spent fuel inference algorithm for nuclear forensics has been developed on the basis of Kernel Regression (KR) which can conditionally generate the estimated output data by giving weight depending on geometric distance between sample data and input data. Also the KR which comprises Auto-Associative KR and Inferential KR have some benefits that can estimate only using data without assumption for specific physical model and re-learning process. Auto-associative KR (AAKR) was used to sort out outliers of input data and Inferential KR (IKR) was carried out to predict the operational histories for spent fuel. All of regression algorithms were performed in R programming tool. From the validation of both AAKR and IKR, it is expected that kernel regression has enough accuracy to be applied to nuclear forensics for spent fuel. Once the nuclear substance is measured to fill the fission product inventory with a certain reactor type, this kernel regression algorithm would predict the operational histories of spent fuel with high accuracy. Finally, this information is expected to be useful to find the origin of irradiated materials. (authors)
Self-consistent clustering analysis: an efficient multiscale scheme for inelastic heterogeneous materials
A predictive computational theory is shown for modeling complex, hierarchical materials ranging from metal alloys to polymer nanocomposites. The theory can capture complex mechanisms such as plasticity and failure that span across multiple length scales. This general multiscale material modeling theory relies on sound principles of mathematics and mechanics, and a cutting-edge reduced order modeling method named self-consistent clustering analysis (SCA) [Zeliang Liu, M.A. Bessa, Wing Kam Liu, “Self-consistent clustering analysis: An efficient multi-scale scheme for inelastic heterogeneous materials,” Comput. Methods Appl. Mech. Engrg. 306 (2016) 319–341]. SCA reduces by several orders of magnitude the computational cost of micromechanical and concurrent multiscale simulations, while retaining the microstructure information. This remarkable increase in efficiency is achieved with a data-driven clustering method. Computationally expensive operations are performed in the so-called offline stage, where degrees of freedom (DOFs) are agglomerated into clusters. The interaction tensor of these clusters is computed. In the online or predictive stage, the Lippmann-Schwinger integral equation is solved cluster-wise using a self-consistent scheme to ensure solution accuracy and avoid path dependence. To construct a concurrent multiscale model, this scheme is applied at each material point in a macroscale structure, replacing a conventional constitutive model with the average response computed from the microscale model using just the SCA online stage. A regularized damage theory is incorporated in the microscale that avoids the mesh and RVE size dependence that commonly plagues microscale damage calculations. The SCA method is illustrated with two cases: a carbon fiber reinforced polymer (CFRP) structure with the concurrent multiscale model and an application to fatigue prediction for additively manufactured metals. For the CFRP problem, a speed up estimated to be about 43,000 is achieved by using the SCA method, as opposed to FE2, enabling the solution of an otherwise computationally intractable problem. The second example uses a crystal plasticity constitutive law and computes the fatigue potency of extrinsic microscale features such as voids. This shows that local stress and strain are capture sufficiently well by SCA. This model has been incorporated in a process-structure-properties prediction framework for process design in additive manufacturing.
In-space production of large space systems from extraterrestrial materials: A program implementation model
A program implementation model is presented which covers the in-space construction of certain large space systems from extraterrestrial materials. The model includes descriptions of major program elements and subelements and their operational requirements and technology readiness requirements. It provides a structure for future analysis and development.
Development of a moderately sized finite element program for nonlinear structural analysis
AGGIE 1 is a computer program for predicting the linear and nonlinear, static and dynamic structural response of two- and three-dimensional continuum solids. The program is based on isoparametric finite elements and allows for 2-D plane stress, plane strain, and axisymmetric analyses and general 3-D analyses. Large strain kinematics is based on the total Lagrangian formulation. Materially nonlinear models include several elastic-plastic work-hardening models as well as an incompressible Mooney-Rivlin model. Included in this report is a brief description of the theoretical bases of the program, the material models used, the element library and the overall program organization. Instructions for data input preparation are given in detail. Several sample problems are given along with the required program input and program generated solutions.
Modular machine learning-based elastoplasticity: Generalization in the context of limited data
The development of highly accurate constitutive models for materials that undergo path-dependent processes continues to be a complex challenge in computational solid mechanics. Challenges arise both in considering the appropriate model assumptions and from the viewpoint of data availability, verification, and validation. Recently, data-driven modeling approaches have been proposed that aim to establish stress-evolution laws that avoid user-chosen functional forms by relying on machine learning representations and algorithms. However, these approaches not only require a significant amount of data but also need data that probes the full stress space with a variety of complex loading paths. Furthermore, they rarely enforce all necessary thermodynamic principles as hard constraints. Hence, they are in particular not suitable for low-data or limited-data regimes, where the first arises from the cost of obtaining the data and the latter from the experimental limitations of obtaining labeled data, which is commonly the case in engineering applications. In this work, we discuss a hybrid framework that can work on a variable amount of data by relying on the modularity of the elastoplasticity formulation where each component of the model can be chosen to be either a classical phenomenological or a data-driven model depending on the amount of available information and the complexity of the response. The method is tested on synthetic uniaxial data coming from simulations as well as cyclic experimental data for structural materials. The discovered material models are found to not only interpolate well but also allow for accurate extrapolation in a thermodynamically consistent manner far outside the domain of the training data. This ability to extrapolate from limited data was the main reason for the early and continued success of phenomenological models and the main shortcoming in machine learning-enabled constitutive modeling approaches. Training aspects and details of the implementation of these models into Finite Element simulations are discussed and analyzed.
Solid State Ionics: Materials Development by Multiscale Modeling and Advanced Manufacturing Techniques
Solid-state ionic materials are an important enabling technology for energy conversion and storage. Solid-state batteries would be a safer and higher energy density alternative to commercially available lithium ion batteries (LIB), however their implementation requires ion conduction in solids at room temperature to occur on the same level as the current generation of liquid electrolytes. Microstructural modifications have been demonstrated to play a major role on ion transport through the control of grain boundary interfaces, which traditionally serve as “blocking” layers. Ultimately, these materials will be fabricated in thin films form as electrolytes in order to minimize ohmic losses in electrochemical devices. This work uses advanced manufacturing techniques in combination with theoretical modeling to implement a science-based approach in the deposition of thin films ion conductors with controlled microstructures used in ceramic energy conversion and storage devices.
Eigenstrain Modeling of Laser–Shock Processing of Materials
Finite-element modeling of classical one-time and repeated laser–shock processing of materials by the eigenstrain method is considered. The distribution of the residual compressive stress in the surface layers is analyzed.