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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 19 records
All sourcesNASA NTRSDOE OSTI
NASA NTRS2004

Aerodynamic Shape Optimization Based on Free-form Deformation

This paper presents a free-form deformation technique suitable for aerodynamic shape optimization. Because the proposed technique is independent of grid topology, we can treat structured and unstructured computational fluid dynamics grids in the same manner. The proposed technique is an alternative shape parameterization technique to a trivariate volume technique. It retains the flexibility and freedom of trivariate volumes for CFD shape optimization, but it uses a bivariate surface representation. This reduces the number of design variables by an order of magnitude, and it provides much better control for surface shape changes. The proposed technique is simple, compact, and efficient. The analytical sensitivity derivatives are independent of the design variables and are easily computed for use in a gradient-based optimization. The paper includes the complete formulation and aerodynamics shape optimization results.

Samareh, Jamshid A.↗
DOE OSTI2023

Comparison of Shape Optimization Methods for Heat Exchanger Fins Using Computational Fluid Dynamics

Inverse design techniques are one way to leverage advances in 3D printing, artificial intelligence, and computational resources to achieve increased performance of heat exchangers. Two optimization techniques (genetic algorithm and particle swarm) and three geometry representations (binary level set, composite Bézier, and free form deformation) are used to increase the heat transfer and reduce the pressure drop of a heat exchanger fin. After running 210,810 OpenFOAM simulations, results indicate that a significant performance increase of the fin can be realized in less than 48 hrs, allowing for such a process to be integrated in traditional design processes. The best design increased the performance of the objective function, compared to the baseline rectangular geometry by 75%. A custom distributed infrastructure was built, allowing for all methods to reach 95% of the final objective values in a little over 4 hrs, handling 1674 OpenFoam simulations per hour.

42 ENGINEERING↗
NASA NTRS2015

Aerodynamic Shape Optimization of a Dual-Stream Supersonic Plug Nozzle

Aerodynamic shape optimization was performed on an isolated axisymmetric plug nozzle sized for a supersonic business jet. The dual-stream concept was tailored to attenuate nearfield pressure disturbances without compromising nozzle performance. Adjoint-based anisotropic mesh refinement was applied to resolve nearfield compression and expansion features in the baseline viscous grid. Deformed versions of the adapted grid were used for subsequent adjoint-driven shape optimization. For design, a nonlinear gradient-based optimizer was coupled to the discrete adjoint formulation of the Reynolds-averaged Navier- Stokes equations. All nozzle surfaces were parameterized using 3rd order B-spline interpolants and perturbed axisymmetrically via free-form deformation. Geometry deformations were performed using 20 design variables shared between the outer cowl, shroud and centerbody nozzle surfaces. Interior volume grid deformation during design was accomplished using linear elastic mesh morphing. The nozzle optimization was performed at a design cruise speed of Mach 1.6, assuming core and bypass pressure ratios of 6.19 and 3.24, respectively. Ambient flight conditions at design were commensurate with 45,000-ft standard day atmosphere.

shape optimization↗
NASA NTRSDate not supplied

Aerodynamic Design Optimization for Natural Laminar Flow Airfoils

Natural laminar flow technology is a passive laminar flow control (LFC) strategy that seeks to delay the onset of boundary-layer transition (BLT) through shape optimization to reduce the drag of the aerodynamic vehicle. Adjoint-based design optimization for LFC is proposed in an integrated multidisciplinary framework, which includes the computational fluid dynamics (CFD), geometry and grid deformation, and linear stability analysis (LSA) for transition prediction. In particular, the BLT location is predicted using the dual N-factor method that is based on a linear stability theory (LST) eigenvalue problem. The dual N-factor criterion accounts for the amplification of planar Tollmien-Schlichting (TS) and stationary crossflow (CF) boundary-layer instabilities to predict the transition location in three-dimensional boundary-layer flows. The adjoint-based shape optimization procedure is based on an iteratively coupled CFD and LSA methodology to converge the transition location and flow solutions, as well as to calculate the sensitivities of the aerodynamic metrics of interest with respect to the flow and shape design parameters. The RAE 2822 airfoil at 0 and 30 degrees yaw angles, an angle of attack of 0.72 degrees, and subsonic conditions (M∞ = 0.19, Rec = 5.6 × 106 ) are used as baseline configurations for design optimization. The angle of attack and the vertical displacement of free-form-deformation control points are used as design variables to reduce the drag coefficient while reaching a specified lift coefficient. The optimized unswept airfoil designs achieve a 30% drag reduction accompanied by a downstream shift of the transition locations over both suction and pressure sides of the airfoil. The initial design iterations for the swept case also show a favorable trend in the drag reduction with transition delay over both sides.

Transition↗
NASA NTRS1999

Engineering Overview of a Multidisciplinary HSCT Design Framework Using Medium-Fidelity Analysis Codes

An objective of the HPCC Program at NASA Langley has been to promote the use of advanced computing techniques to more rapidly solve the problem of multidisciplinary optimization of a supersonic transport configuration. As a result, a software system has been designed and is being implemented to integrate a set of existing discipline analysis codes, some of them CPU-intensive, into a distributed computational framework for the design of a High Speed Civil Transport (HSCT) configuration. The proposed paper will describe the engineering aspects of integrating these analysis codes and additional interface codes into an automated design system. The objective of the design problem is to optimize the aircraft weight for given mission conditions, range, and payload requirements, subject to aerodynamic, structural, and performance constraints. The design variables include both thicknesses of structural elements and geometric parameters that define the external aircraft shape. An optimization model has been adopted that uses the multidisciplinary analysis results and the derivatives of the solution with respect to the design variables to formulate a linearized model that provides input to the CONMIN optimization code, which outputs new values for the design variables. The analysis process begins by deriving the updated geometries and grids from the baseline geometries and grids using the new values for the design variables. This free-form deformation approach provides internal FEM (finite element method) grids that are consistent with aerodynamic surface grids. The next step involves using the derived FEM and section properties in a weights process to calculate detailed weights and the center of gravity location for specified flight conditions. The weights process computes the as-built weight, weight distribution, and weight sensitivities for given aircraft configurations at various mass cases. Currently, two mass cases are considered: cruise and gross take-off weight (GTOW). Weights information is obtained from correlations of data from three sources: 1) as-built initial structural and non-structural weights from an existing database, 2) theoretical FEM structural weights and sensitivities from Genesis, and 3) empirical as-built weight increments, non-structural weights, and weight sensitivities from FLOPS. For the aeroelastic analysis, a variable-fidelity aerodynamic analysis has been adopted. This approach uses infrequent CPU-intensive non-linear CFD to calculate a non-linear correction relative to a linear aero calculation for the same aerodynamic surface at an angle of attack that results in the same configuration lift. For efficiency, this nonlinear correction is applied after each subsequent linear aero solution during the iterations between the aerodynamic and structural analyses. Convergence is achieved when the vehicle shape being used for the aerodynamic calculations is consistent with the structural deformations caused by the aerodynamic loads. To make the structural analyses more efficient, a linearized structural deformation model has been adopted, in which a single stiffness matrix can be used to solve for the deformations under all the load conditions. Using the converged aerodynamic loads, a final set of structural analyses are performed to determine the stress distributions and the buckling conditions for constraint calculation. Performance constraints are obtained by running FLOPS using drag polars that are computed using results from non-linear corrections to the linear aero code plus several codes to provide drag increments due to skin friction, wave drag, and other miscellaneous drag contributions. The status of the integration effort will be presented in the proposed paper, and results will be provided that illustrate the degree of accuracy in the linearizations that have been employed.

Weston, R. P.↗
NASA NTRS1999

Practical Aerodynamic Design Optimization Based on the Navier-Stokes Equations and a Discrete Adjoint Method

Compressible and incompressible versions of a three-dimensional unstructured mesh Reynolds-averaged Navier-Stokes flow solver have been differentiated and resulting derivatives have been verified by comparisons with finite differences and a complex-variable approach. In this implementation, the turbulence model is fully coupled with the flow equations in order to achieve this consistency. The accuracy demonstrated in the current work represents the first time that such an approach has been successfully implemented. The accuracy of a number of simplifying approximations to the linearizations of the residual have been examined. A first-order approximation to the dependent variables in both the adjoint and design equations has been investigated. The effects of a "frozen" eddy viscosity and the ramifications of neglecting some mesh sensitivity terms were also examined. It has been found that none of the approximations yielded derivatives of acceptable accuracy and were often of incorrect sign. However, numerical experiments indicate that an incomplete convergence of the adjoint system often yield sufficiently accurate derivatives, thereby significantly lowering the time required for computing sensitivity information. The convergence rate of the adjoint solver relative to the flow solver has been examined. Inviscid adjoint solutions typically require one to four times the cost of a flow solution, while for turbulent adjoint computations, this ratio can reach as high as eight to ten. Numerical experiments have shown that the adjoint solver can stall before converging the solution to machine accuracy, particularly for viscous cases. A possible remedy for this phenomenon would be to include the complete higher-order linearization in the preconditioning step, or to employ a simple form of mesh sequencing to obtain better approximations to the solution through the use of coarser meshes. An efficient surface parameterization based on a free-form deformation technique has been utilized and the resulting codes have been integrated with an optimization package. Lastly, sample optimizations have been shown for inviscid and turbulent flow over an ONERA M6 wing. Drag reductions have been demonstrated by reducing shock strengths across the span of the wing. In order for large scale optimization to become routine, the benefits of parallel architectures should be exploited. Although the flow solver has been parallelized using compiler directives. The parallel efficiency is under 50 percent. Clearly, parallel versions of the codes will have an immediate impact on the ability to design realistic configurations on fine meshes, and this effort is currently underway.

Grossman, Bernard↗
NASA NTRS1999

Practical Aerodynamic Design Optimization Based on the Navier-Stokes Equations and a Discrete Adjoint Method

The technical details are summarized below: Compressible and incompressible versions of a three-dimensional unstructured mesh Reynolds-averaged Navier-Stokes flow solver have been differentiated and resulting derivatives have been verified by comparisons with finite differences and a complex-variable approach. In this implementation, the turbulence model is fully coupled with the flow equations in order to achieve this consistency. The accuracy demonstrated in the current work represents the first time that such an approach has been successfully implemented. The accuracy of a number of simplifying approximations to the linearizations of the residual have been examined. A first-order approximation to the dependent variables in both the adjoint and design equations has been investigated. The effects of a "frozen" eddy viscosity and the ramifications of neglecting some mesh sensitivity terms were also examined. It has been found that none of the approximations yielded derivatives of acceptable accuracy and were often of incorrect sign. However, numerical experiments indicate that an incomplete convergence of the adjoint system often yield sufficiently accurate derivatives, thereby significantly lowering the time required for computing sensitivity information. The convergence rate of the adjoint solver relative to the flow solver has been examined. Inviscid adjoint solutions typically require one to four times the cost of a flow solution, while for turbulent adjoint computations, this ratio can reach as high as eight to ten. Numerical experiments have shown that the adjoint solver can stall before converging the solution to machine accuracy, particularly for viscous cases. A possible remedy for this phenomenon would be to include the complete higher-order linearization in the preconditioning step, or to employ a simple form of mesh sequencing to obtain better approximations to the solution through the use of coarser meshes. . An efficient surface parameterization based on a free-form deformation technique has been utilized and the resulting codes have been integrated with an optimization package. Lastly, sample optimizations have been shown for inviscid and turbulent flow over an ONERA M6 wing. Drag reductions have been demonstrated by reducing shock strengths across the span of the wing.

Grossman, Bernard↗
NASA NTRS2001

Deriving the Coronal Magnetic Field Using Parametric Transformation Analysis

When plasma-beta greater than 1 then the gas pressure dominates over the magnetic pressure. This ratio as a function along the coronal magnetic field lines varies from beta greater than 1 in the photosphere at the base of the field lines, to beta much less than 1 in the mid-corona, to beta greater than 1 in the upper corona. Almost all magnetic field extrapolations do not or cannot take into account the full range of beta. They essentially assume beta much less than 1, since the full boundary conditions do not exist in the beta greater than 1 regions. We use a basic parametric representation of the magnetic field lines such that the field lines can be manipulated to match linear features in the EUV and SXR coronal images in a least squares sense. This research employs free-form deformation mathematics to generate the associated coronal magnetic field. In our research program, the complex magnetic field topology uses Parametric Transformation Analysis (PTA) which is a new and innovative method to describe the coronal fields that we are developing. In this technique the field lines can be viewed as being embedded in a plastic medium, the frozen-in-field-line concept. As the medium is deformed the field lines are similarly deformed. However the advantage of the PTA method is that the field line movement represents a transformation of one magnetic field solution into another magnetic field solution. When fully implemented, this method will allow the resulting magnetic field solution to fully match the magnetic field lines with EUV/SXR coronal loops by minimizing the differences in direction and dispersion of a collection of PTA magnetic field lines and observed field lines. The derived magnetic field will then allow beta greater than 1 regions to be included, the electric currents to be calculated, and the Lorentz force to be determined. The advantage of this technique is that the solution is: (1) independent of the upper and side boundary conditions, (2) allows non-vanishing magnetic forces, and (3) provides a global magnetic field solution, which contains high- and low-beta regimes and maximizes the similarity between the field lines structure and all the coronal images of the region. The coronal image analysis is crucial to the investigation and for the first time these images can be exploited to derive the coronal magnetic field in a well-posed mathematical formulation. This program is an outgrowth of an investigation in which an extrapolated potential field was required to be "inflated" in order to have the field lines match the Yohkoh/SXT images. The field lines were radially stretched resulting in a better match to the coronal loops of an active region. The PTA method of radial and non-radial deformations of field lines to provide a match to the EUV/SXR images will be presented.

Gary, G. Allen↗
NASA NTRS2003

Parametric Transformation Analysis

Because twisted coronal features are important proxies for predicting solar eruptive events, and, yet not clearly understood, we present new results to resolve the complex, non-potential magnetic field configurations of active regions. This research uses free-form deformation mathematics to generate the associated coronal magnetic field. We use a parametric representation of the magnetic field lines such that the field lines can be manipulated to match the structure of EUV and SXR coronal loops. The objective is to derive sigmoidal magnetic field solutions which allows the beta greater than 1 regions to be included, aligned and non-aligned electric currents to be calculated, and the Lorentz force to be determined. The advantage of our technique is that the solution is independent of the unknown upper and side boundary conditions, allows non-vanishing magnetic forces, and provides a global magnetic field solution, which contains high- and low-beta regimes and is consistent with all the coronal images of the region. We show that the mathematical description is unique and physical.

Gary, G. Allan↗
DOE OSTI2024

Interacting chiral form field theories and $$ T\overline{T} $$-like flows in six and higher dimensions

Abstract In this paper we initiate the study of six-dimensional non-linear chiral two-form gauge theories as deformations of free chiral two-form gauge theories driven by stress-tensor$$ T\overline{T} $$ T T ¯ -like flows. To lay the background for this study, we elaborate on the relationship between different Lagrangian formulations of duality-invariantp-form theories and corresponding$$ T\overline{T} $$ T T ¯ -like flows in various dimensions. To this end we propose a new formulation which (i) is a generalization of the four-dimensional construction by Ivanov, Nurmagambetov and Zupnik (INZ) and (ii) turns into the PST formulation upon integrating out an auxiliary self-dual field. We elucidate space-time covariant properties of the PST formulation by clarifying and making use of its relation to the INZ-type formulation and to a so-called “clone” construction.

Physics↗
DOE OSTI2023

Effect of free surfaces on localized plastic deformation in single-crystal nickel containing helium bubbles and radiation-induced self-interstitial atom clusters

This paper presents molecular dynamics (MD) simulations of plastic deformation in single-crystal Ni models containing internal distributions of helium (He) bubbles and self-interstitial atom (SIA) clusters corresponding to experimental characterization of ex-service Inconel X-750 components. Here, we simulate single crystals with and without free surfaces at room temperature and 588K, the latter temperature corresponding to the Inconel X-750 service conditions. Both models are deformed under multiple slip to a maximum deviatoric strain of ~10 %. A dislocation slip band forms in the model without free surfaces, but not in the model with free surfaces. However, the latter exhibits nano-twin nucleation from surfaces. Helium (He) bubbles that overlap with a slip band or a nano-twinned region deform more severely than other bubbles in the model. Nevertheless, the bubbles do not link up and do not form configurations that resemble incipient cracks.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Variationally consistent Maxwell stress in flexoelectric structures under finite deformation and immersed in free space

Maxwell stress refers to the mechanical stress exerted on a dielectric material due to the presence of electric fields. It plays a significant role in the interaction between a dielectric material and the surrounding free space under finite deformation. Previous research on finite deformation of flexoelectricity mainly adopted a modified form of Maxwell stress, potentially not able to correctly capture some physical phenomena, such as the compression of a dielectric droplet in an electric field. In this work, we propose a consistent and complete variational principle for flexoelectricity, in which the Maxwell stress emerges naturally from the derivation, without introducing additional assumptions. An Isogeometric analysis-based numerical framework is developed accordingly and verified by both linear and nonlinear benchmark cases compared with experimental results. The present framework successfully captures and quantifies the behaviors of conductive liquids and soft dielectric solids subjected to an external electric field. Finally, a novel scenario is investigated in which a flexoelectric beam immersed in free space is analyzed, showing the interesting distribution of Maxwell stress-induced tractions at opposing boundaries. The test demonstrates that a higher dielectric constant can effectively enhance the material's stiffness in response to the external electric loading.

36 MATERIALS SCIENCE↗
NASA NTRS1996

Deformation of Fluid Column by Action of Axial Vibration and Some Aspects of High-Rate Thermocapillary Convection

The deformation of the fluid column by an action of a low-frequency vibration is considered. It is shown that behavior of the free fluid surface depends on the frequency of applied vibration and its amplitude. In the area of very low frequencies when fluid has time to comment on travel of bounding solid walls limiting column, the harmonical oscillations of free surface with given frequency are observed. With increase of vibration frequency the steady-state relief on free fluid surface is formed. If the amplitude of vibration is very small and the frequency corresponding to the first peak in the vibration spectrum on the Mir orbital station, the deformation of free surface tends to zero. Fluid flow induced thermocapillary effect on deformed free surface is more unstable as in the case of smooth cylindrical surface. It was shown that width of heating zone affects very essentially the flow pattern and transition to oscillatory regime of thermocapillary convection.

Feonychev, Alexander I.↗
DOE OSTI2026

Proliferation transitions from a topological phase in 2+1 dimensions

We consider phase transitions out of a general topological phase in 2+1 dimensions. We assume that the transition is triggered by a single Abelian anyon, which becomes light near the transition and whose worldlines proliferate after the transition. (This proliferation is often referred to as “condensation.”) We describe the transition using a continuum field theory obtained by coupling the corresponding topological quantum field theory (TQFT) to a single complex scalar field associated with this anyon. With these assumptions, we find the most general relativistic field theory for such a transition. Even though for a given TQFT and a choice of anyon, there are infinitely many such field theories, the transition theory depends on only a single additional integer parameter. We analyze all these theories, their global symmetries, and their phases. In generic cases, the theory after the transition can be related to the original one via an Abelian hierarchy construction. In special cases, the theory after the transition is gapless, and with a particular deformation, it is related to the original TQFT by gauging an anomaly-free one-form global symmetry. We also explore the enrichment of this setup by a global U⁡(1) symmetry. In some cases, enriching the original TQFT is incompatible with the full transition theory. Lastly, we demonstrate our construction with many specific examples.

Anyons↗
NASA NTRS1996

Mechanism of unassisted ion transport across membrane bilayers

To establish how charged species move from water to the nonpolar membrane interior and to determine the energetic and structural effects accompanying this process, we performed molecular dynamics simulations of the transport of Na+ and Cl- across a lipid bilayer located between two water lamellae. The total length of molecular dynamics trajectories generated for each ion was 10 ns. Our simulations demonstrate that permeation of ions into the membrane is accompanied by the formation of deep, asymmetric thinning defects in the bilayer, whereby polar lipid head groups and water penetrate the nonpolar membrane interior. Once the ion crosses the midplane of the bilayer the deformation "switches sides"; the initial defect slowly relaxes, and a defect forms in the outgoing side of the bilayer. As a result, the ion remains well solvated during the process; the total number of oxygen atoms from water and lipid head groups in the first solvation shell remains constant. A similar membrane deformation is formed when the ion is instantaneously inserted into the interior of the bilayer. The formation of defects considerably lowers the free energy barrier to transfer of the ion across the bilayer and, consequently, increases the permeabilities of the membrane to ions, compared to the rigid, planar structure, by approximately 14 orders of magnitude. Our results have implications for drug delivery using liposomes and peptide insertion into membranes.

NASA Discipline Exobiology↗
NASA NTRS2001

Restraint of Liquid Jets by Surface Tension in Microgravity Modeled

Tension in Microgravity Modeled Microgravity poses many challenges to the designer of spacecraft tanks. Chief among these are the lack of phase separation and the need to supply vapor-free liquid or liquidfree vapor to the spacecraft processes that require fluid. One of the principal problems of phase separation is the creation of liquid jets. A jet can be created by liquid filling, settling of the fluid to one end of the tank, or even closing a valve to stop the liquid flow. Anyone who has seen a fountain knows that jets occur in normal gravity also. However, in normal gravity, the gravity controls and restricts the jet flow. In microgravity, with gravity largely absent, jets must be contained by surface tension forces. Recent NASA experiments in microgravity (Tank Pressure Control Experiment, TPCE, and Vented Tank Pressure Experiment, VTRE) resulted in a wealth of data about jet behavior in microgravity. VTRE was surprising in that, although it contained a complex geometry of baffles and vanes, the limit on liquid inflow was the emergence of a liquid jet from the top of the vane structure. Clearly understanding the restraint of liquid jets by surface tension is key to managing fluids in low gravity. To model this phenomenon, we need a numerical method that can track the fluid motion and the surface tension forces. The fluid motion is modeled with the Navier-Stokes equation formulated for low-speed incompressible flows. The quantities of velocity and pressure are placed on a staggered grid, with velocity being tracked at cell faces and pressure at cell centers. The free surface is tracked via the introduction of a color function that tracks liquid as 1/2 and gas as -1/2. A phase model developed by Jacqmin is used. This model converts the discrete surface tension force into a barrier function that peaks at the free surface and decays rapidly. Previous attempts at this formulation have been criticized for smearing the interface. However, by sharpening the phase function, double gridding the fluid function, and using a higher order solution for the fluid function, interface smearing is avoided. These equations can be rewritten as two coupled Poisson equations that also include the velocity. The method of solution is as follows: first, the phase equations are solved from this solution, a velocity field is generated, then a successive overrelaxation scheme is used to solve for a pressure field consistent with the velocity solution. After the code was implemented in axisymmetric form and verified by several test cases, the drop tower runs of Aydelott were modeled. The model handed the free-surface deformation quite nicely, even to the point of modeling geyser growth in the regime where the free surface was no longer restrained. A representative run is shown.

Chato, David J.↗
NASA NTRS2015

Multiscale and Multiphysics Modeling of Additive Manufacturing of Advanced Materials

The objective of this proposed project is to research and develop a prediction tool for advanced additive manufacturing (AAM) processes for advanced materials and develop experimental methods to provide fundamental properties and establish validation data. Aircraft structures and engines demand materials that are stronger, useable at much higher temperatures, provide less acoustic transmission, and enable more aeroelastic tailoring than those currently used. Significant improvements in properties can only be achieved by processing the materials under nonequilibrium conditions, such as AAM processes. AAM processes encompass a class of processes that use a focused heat source to create a melt pool on a substrate. Examples include Electron Beam Freeform Fabrication and Direct Metal Deposition. These types of additive processes enable fabrication of parts directly from CAD drawings. To achieve the desired material properties and geometries of the final structure, assessing the impact of process parameters and predicting optimized conditions with numerical modeling as an effective prediction tool is necessary. The targets for the processing are multiple and at different spatial scales, and the physical phenomena associated occur in multiphysics and multiscale. In this project, the research work has been developed to model AAM processes in a multiscale and multiphysics approach. A macroscale model was developed to investigate the residual stresses and distortion in AAM processes. A sequentially coupled, thermomechanical, finite element model was developed and validated experimentally. The results showed the temperature distribution, residual stress, and deformation within the formed deposits and substrates. A mesoscale model was developed to include heat transfer, phase change with mushy zone, incompressible free surface flow, solute redistribution, and surface tension. Because of excessive computing time needed, a parallel computing approach was also tested. In addition, after investigating various methods, a Smoothed Particle Hydrodynamics Model (SPH Model) was developed to model wire feeding process. Its computational efficiency and simple architecture makes it more robust and flexible than other models. More research on material properties may be needed to realistically model the AAM processes. A microscale model was developed to investigate heterogeneous nucleation, dendritic grain growth, epitaxial growth of columnar grains, columnar-to-equiaxed transition, grain transport in melt, and other properties. The orientations of the columnar grains were almost perpendicular to the laser motion's direction. Compared to the similar studies in the literature, the multiple grain morphology modeling result is in the same order of magnitude as optical morphologies in the experiment. Experimental work was conducted to validate different models. An infrared camera was incorporated as a process monitoring and validating tool to identify the solidus and mushy zones during deposition. The images were successfully processed to identify these regions. This research project has investigated multiscale and multiphysics of the complex AAM processes thus leading to advanced understanding of these processes. The project has also developed several modeling tools and experimental validation tools that will be very critical in the future of AAM process qualification and certification.

Liou, Frank↗
DOE OSTI2025

A hereditary integral, transient network approach to modeling permanent set and viscoelastic response in polymers

An efficient numerical framework is presented for modeling viscoelasticity and permanent set of polymers. It is based on the hereditary integral form of transient network theory, in which polymer chains belong to distinct networks each with different natural equilibrium states. Chains continually detach from previously formed networks and reattach to new networks in a state of zero stress. The free energy of these networks is given in terms of the deformation gradient relative to the configuration at which the network was born . A decomposition of the kernel for various free energies allows for a recurrence relationship to be established, bypassing the need to integrate over all time history. The technique is established for both highly compressible and nearly incompressible materials through the use of neo-Hookean, Blatz–Ko, Yeoh, and Ogden-Hill material models. Multiple examples are presented showing the ability to handle rate-dependent response and residual strains under complex loading histories.

Finite element method↗