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Simunovic, Srdjan

Publications and source records attributed to Simunovic, Srdjan.

At least 73 records · Page 4
All sourcesNASA NTRSDOE OSTI
DOE OSTI2017

Process Modeling and Validation for Metal Big Area Additive Manufacturing

Metal Big Area Additive Manufacturing (mBAAM) is a new additive manufacturing (AM) technology based on the metal arc welding. A continuously fed metal wire is melted by an electric arc that forms between the wire and the substrate, and deposited in the form of a bead of molten metal along the predetermined path. Objects are manufactured one layer at a time starting from the base plate. The final properties of the manufactured object are dependent on its geometry and the metal deposition path, in addition to depending on the basic welding process parameters. Computational modeling can be used to accelerate the development of the mBAAM technology as well as a design and optimization tool for the actual manufacturing process. We have developed a finite element method simulation framework for mBAAM using the new features of software ABAQUS. The computational simulation of material deposition with heat transfer is performed first, followed by the structural analysis based on the temperature history for predicting the final deformation and stress state. In this formulation, we assume that two physics phenomena are coupled in only one direction, i.e. the temperatures are driving the deformation and internal stresses, but their feedback on the temperatures is negligible. The experiment instrumentation (measurement types, sensor types, sensor locations, sensor placements, measurement intervals) and the measurements are presented. The temperatures and distortions from the simulations show good correlation with experimental measurements. Ongoing modeling work is also briefly discussed.

Simunovic, Srdjan↗
DOE OSTI2017

Coupled Bison/Thermochimica Simulation of Hydride Formation in Zircalloy Cladding

The report describes implementation of the thermodynamics models for simulation of zirconium hydride formation in LWR fuel cladding. The current models for ZrH x formation are based on empirical rate models that must calibrated to materials and regimes of interest. The thermodynamic approach enables hydride formation calculations based on fundamental thermodynamics principles and material composition. Thermodynamic formulations and models were implemented in the Idaho National Laboratory fuel performance code Bison using Material, Kernel and AuxKernel methods. The results for the Material and Kernel implementation are shown in this report. The Material method implementation naturally fits the concept of modeling evolution of material state in the material models. Given the relatively high cost of thermodynamic computation, the advantage of the AuxKernel compared to Material implementation is the ability to control the execution and computational cost. The implemented formulations are illustrated on example problems which fit the experimental data and satisfy the computational requirements of conservation equations.

36 MATERIALS SCIENCE↗
DOE OSTI2017

Metal Big Area Additive Manufacturing: Process Modeling and Validation

Metal Big Area Additive Manufacturing (mBAAM) is a new additive manufacturing (AM) technology for printing large-scale 3D objects. mBAAM is based on the gas metal arc welding process and uses a continuous feed of welding wire to manufacture an object. An electric arc forms between the wire and the substrate, which melts the wire and deposits a bead of molten metal along the predetermined path. In general, the welding process parameters and local conditions determine the shape of the deposited bead. The sequence of the bead deposition and the corresponding thermal history of the manufactured object determine the long range effects, such as thermal-induced distortions and residual stresses. Therefore, the resulting performance or final properties of the manufactured object are dependent on its geometry and the deposition path, in addition to depending on the basic welding process parameters. Physical testing is critical for gaining the necessary knowledge for quality prints, but traversing the process parameter space in order to develop an optimized build strategy for each new design is impractical by pure experimental means. Computational modeling and optimization may accelerate development of a build process strategy and saves time and resources. Because computational modeling provides these opportunities, we have developed a physics-based Finite Element Method (FEM) simulation framework and numerical models to support the mBAAM process s development and design. In this paper, we performed a sequentially coupled heat transfer and stress analysis for predicting the final deformation of a small rectangular structure printed using the mild steel welding wire. Using the new simulation technologies, material was progressively added into the FEM simulation as the arc weld traversed the build path. In the sequentially coupled heat transfer and stress analysis, the heat transfer was performed to calculate the temperature evolution, which was used in a stress analysis to evaluate the residual stresses and distortions. In this formulation, we assume that physics is directionally coupled, i.e. the effect of stress of the component on the temperatures is negligible. The experiment instrumentation (measurement types, sensor types, sensor locations, sensor placements, measurement intervals) and the measurements are presented. The temperatures and distortions from the simulations show good correlation with experimental measurements. Ongoing modeling work is also briefly discussed.

Additive Manufacturing↗
DOE OSTI2016

Progressive mechanical indentation of large-format Li-ion cells

We used large format Li-ion cells to study the mechanical responses of single cells of thickness 6.5 mm and stacks of three cells under compressive loading. We carried out various sequences of increasing depth indentations using a 1.0 inch (25.4 mm) diameter steel ball with steel plate as a rigid support surface. The indentation depths were between 0.025 and 0.250 with main indentation increments tests of 0.025 steps. Increment steps of 0.100 and 0.005 were used to pinpoint the onset of internal-short that occurred between 0.245 and 0.250 . The indented cells were disassembled and inspected for internal damage. Load vs. time curves were compared with the developed computer models. Separator thinning leading to the short circuit was simulated using both isotropic and anisotropic mechanical properties. This study show that separators behave differently when tested as a single layer vs. a stack in a typical pouch cell. The collective responses of the multiple layers must be taken into account in failure analysis. A model that resolves the details of the individual internal cell components was able to simulate the internal deformation of the large format cells and the onset of failure assumed to coincide with the onset of internal short circuit.

25 ENERGY STORAGE↗
DOE OSTI2016

Virtual Integrated Battery Environment (VIBE): Version 1.2 Release Documentation

As part of the CAEBAT (Computer Aided Engineering for Batteries) activities, ORNL developed a flexible, robust, and computationally scalable open-architecture framework that integrates multi-physics and multi-scale battery models. The physics phenomena of interest include charge and thermal transport, electrochemical reactions, and mechanical stresses. They operate and interact across the porous 3D structure of the electrodes (cathodes an d anodes), the solid or liquid electrolyte system and the other battery components. The underlying lower-length processes are accounted for through closure equations and sub-models that are based on resolved quantities.

25 ENERGY STORAGE↗
DOE OSTI2016

Communication—indentation of Li-ion pouch cell: Effect of material homogenization on prediction of internal short circuit

We performed finite element simulations of spherical indentation of Li-ion pouch cells. Our model fully resolves different layers in the cell. The results of the layer resolved models were compared to the models available in the literature that treat the cell as an equivalent homogenized continuum material. Simulations were carried out for different sizes of the spherical indenter. Here, we show that calibration of a failure criterion for the cell in the homogenized model depends on the indenter size, whereas in the layer-resoled model, such dependency is greatly diminished.

25 ENERGY STORAGE↗
DOE OSTI2016

Crashworthiness Models for Automotive Batteries - Report on Project 2088-A031-15 for DOT/NHTSA

Safety is a key element of any device designed to store energy, in particular electrochemical batteries, which convert energy of chemical reactions to electrical energy. Safety considerations are especially important when applied to large automotive batteries designed for propulsion of electric vehicles (EV). The high amount of energy stored in EV battery packs translates to higher probability of fire in case of severe deformation of battery compartment due to automotive crash or impact caused by road debris. While such demand for safety has resulted in heavier protection of battery enclosure, the mechanisms leading to internal short circuit due to deformation of the battery are not well understood even on the level of a single electrochemical cell. Moreover, not all internal shorts result in thermal runaway, and thus a criterion for catastrophic failure needs to be developed. This report summarizes the effort to pinpoint the critical deformation necessary to trigger a short via experimental study on large format automotive Li-ion cells in a rigid spherical indentation configuration. Cases of single cells and cell stacks undergoing indentation were investigated. Mechanical properties of cell components were determined via experimental testing and served as input for constitutive models of Finite Element (FE) analysis. The ability of the model to predict the behavior of cell(s) under spherical indentation and to predict failure leading to internal short circuit was validated against experiments. The necessity of resolving pairs of negative and positive electrodes in the FE formulation is clearly demonstrated by comparing layer-resolved simulations with simulations involving batteries with homogenized material properties. Finally, a coupled solution of electrochemical-electrical-thermal (EET) problem on a Nissan Leaf battery module was demonstrated towards the goal of extending the simulations to module level.

25 ENERGY STORAGE↗
DOE OSTI2016

Numerical modeling of heat-transfer and the influence of process parameters on tailoring the grain morphology of IN718 in electron beam additive manufacturing

The fabrication of 3-D parts from CAD models by additive manufacturing (AM) is a disruptive technology that is transforming the metal manufacturing industry. The correlation between solidification microstructure and mechanical properties has been well understood in the casting and welding processes over the years. This paper focuses on extending these principles to additive manufacturing to understand the transient phenomena of repeated melting and solidification during electron beam powder melting process to achieve site-specific microstructure control within a fabricated component. In this paper, we have developed a novel melt scan strategy for electron beam melting of nickel-base superalloy (Inconel 718) and also analyzed 3-D heat transfer conditions using a parallel numerical solidification code (Truchas) developed at Los Alamos National Laboratory. The spatial and temporal variations of temperature gradient (G) and growth velocity (R) at the liquid-solid interface of the melt pool were calculated as a function of electron beam parameters. By manipulating the relative number of voxels that lie in the columnar or equiaxed region, the crystallographic texture of the components can be controlled to an extent. The analysis of the parameters provided optimum processing conditions that will result in columnar to equiaxed transition (CET) during the solidification. Furthermore, the results from the numerical simulations were validated by experimental processing and characterization thereby proving the potential of additive manufacturing process to achieve site-specific crystallographic texture control within a fabricated component.

43 PARTICLE ACCELERATORS↗
DOE OSTI2016

Material mechanical characterization method for multiple strains and strain rates

A specimen for measuring a material under multiple strains and strain rates. The specimen including a body having first and second ends and a gage region disposed between the first and second ends, wherein the body has a central, longitudinal axis passing through the first and second ends. The gage region includes a first gage section and a second gage section, wherein the first gage section defines a first cross-sectional area that is defined by a first plane that extends through the first gage section and is perpendicular to the central, longitudinal axis. The second gage section defines a second cross-sectional area that is defined by a second plane that extends through the second gage section and is perpendicular to the central, longitudinal axis and wherein the first cross-sectional area is different in size than the second cross-sectional area.

42 ENGINEERING↗
DOE OSTI2016

Internal configuration of prismatic lithium-ion cells at the onset of mechanically induced short circuit

The response of Li-ion cells to mechanically induced internal electrical shorts is an important safety performance metric design. We assume that the battery internal configuration at the onset of electrical short influences the subsequent response and can be used to gauge the safety risk. We subjected a series of prismatic Li-ion cells to lateral pinching using 0.25", 0.5", 1", 2" and 3" diameter steel balls until the onset of internal short. The external aluminum enclosure froze the internal cell configuration at the onset of short and enabled us to cross-section the cells, and take the cross-section images. The images indicate that an internal electric short is preceded by extensive strain partitioning in the cells, fracturing and tearing of the current collectors, and cracking and slipping of the electrode layers with multiple fault lines across multiple layers. These observations are at odds with a common notion of homogeneous deformation across the layers and strain hardening of electrodes that eventually punch through the separator and short the cell. The faults are akin to tectonic movements of multiple layers that are characteristic of granular materials and bonded aggregates. As a result, the short circuits occur after extensive internal faulting, which implies significant stretching and tearing of separators.

25 ENERGY STORAGE↗
DOE OSTI2016

Applying Reduced Generator Models in the Coarse Solver of Parareal in Time Parallel Power System Simulation

The development of high-performance computing techniques and platforms has provided many opportunities for real-time or even faster-than-real-time implementation of power system simulations. One approach uses the Parareal in time framework. The Parareal algorithm has shown promising theoretical simulation speedups by temporal decomposing a simulation run into a coarse simulation on the entire simulation interval and fine simulations on sequential sub-intervals linked through the coarse simulation. However, it has been found that the time cost of the coarse solver needs to be reduced to fully exploit the potentials of the Parareal algorithm. This paper studies a Parareal implementation using reduced generator models for the coarse solver and reports the testing results on the IEEE 39-bus system and a 327-generator 2383-bus Polish system model.

High-performance computing↗
DOE OSTI2016

Numeric Modified Adomian Decomposition Method for Power System Simulations

This paper investigates the applicability of numeric Wazwaz El Sayed modified Adomian Decomposition Method (WES-ADM) for time domain simulation of power systems. WESADM is a numerical method based on a modified Adomian decomposition (ADM) technique. WES-ADM is a numerical approximation method for the solution of nonlinear ordinary differential equations. The non-linear terms in the differential equations are approximated using Adomian polynomials. In this paper WES-ADM is applied to time domain simulations of multimachine power systems. WECC 3-generator, 9-bus system and IEEE 10-generator, 39-bus system have been used to test the applicability of the approach. Several fault scenarios have been tested. It has been found that the proposed approach is faster than the trapezoidal method with comparable accuracy.

Adomian Decomposition↗
DOE OSTI2015

Multiscale modeling and characterization for performance and safety of lithium-ion batteries

Lithium-ion batteries are highly complex electrochemical systems whose performance and safety are governed by coupled nonlinear electrochemical-electrical-thermal-mechanical processes over a range of spatiotemporal scales. Gaining an understanding of the role of these processes as well as development of predictive capabilities for design of better performing batteries requires synergy between theory, modeling, and simulation, and fundamental experimental work to support the models. This paper presents the overview of the work performed by the authors aligned with both experimental and computational efforts. In this paper, we describe a new, open source computational environment for battery simulations with an initial focus on lithium-ion systems but designed to support a variety of model types and formulations. This system has been used to create a three-dimensional cell and battery pack models that explicitly simulate all the battery components (current collectors, electrodes, and separator). The models are used to predict battery performance under normal operations and to study thermal and mechanical safety aspects under adverse conditions. This paper also provides an overview of the experimental techniques to obtain crucial validation data to benchmark the simulations at various scales for performance as well as abuse. We detail some initial validation using characterization experiments such as infrared and neutron imaging and micro-Raman mapping. In addition, we identify opportunities for future integration of theory, modeling, and experiments.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
DOE OSTI2015

Numerical Simulation of Big Area Additive Manufacturing (3D Printing) of a Full Size Car

Distortion and buildup of residual stresses are common design problems in structures manufactured using additive manufacturing techniques, popularly known as 3D printing. These problems lead to poor product quality, which often is improved by trial and error, where the sensitivity of different manufacturing configurations to product quality are experimentally determined. With the introduction of Big Area Additive Manufacturing (BAAM), where significant amount of material is deposited per unit time, trial and error philosophy reduces the economical efficiency of the process. In this work, a numerical simulation methodology based on Finite Element Method (FEM), multi-scale damage mechanics and fracture mechanics is introduced to simulate the BAAM process for determining product quality in terms of distortions, material damage and interface fracture due to manufacturing. In addition, this tool can be used to obtain the sensitivities of the manufacturing configurations with respect to product quality in an economically efficient manner compared to the trial and error philosophy. Computational tools providing a fully coupled thermo-mechanical solution of polymer additive manufacturing with chopped fiber reinforced plastics are presented.

42 ENGINEERING↗
DOE OSTI2015

Coupling of Thermochemistry Solver THERMOCHIMICA with MOOSE/BISON

THERMOCHIMICA is a computational library for chemical thermodynamics. It determines a unique combination of phases and their compositions for a prescribed chemical composition, temperature and pressure. The solver and the underlying thermodynamic models can be used to estimate the chemical state and various constitutive and transport properties necessary for nuclear fuel performance modeling. Our NEAMS research project focuses on the development of nuclear fuel thermodynamics models and computational thermodynamics equilibrium solvers, and their implementation into Idaho National Laboratory (INL) nuclear fuel performance simulation system MOOSE/BISON. This report documents the software integration of THERMOCHIMICA with MOOSE/BISON using the current INL development framework GitLab. The THERMOCHIMICA implementation is demonstrated on modeling oxygen related phenomena in irradiated fuel, such as calculation of oxygen to metal ratio in the fluorite phase, oxygen partial pressure, oxygen chemical potential and oxygen transport. Experimental measurements from the open literature were used to validate the implemented models and illustrate functionality of the developed thermodynamics module. The calculations are based on chemical element inventory provided by neutronics, isotopic depletion, transmutation and decay calculations in the SCALE system. The burnup calculation in BISON can also be used for elemental composition although it provides only a limited set. Coupling of THERMOCHIMICA with other codes that can provide chemical composition of irradiated fuel for BISON simulations is currently being explored.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2015

CAEBAT OAS/VIBE Production Release v1.1

The objective of the project is to develop a mathematical and computational infrastructure, and modeling framework that will enable seamless multi-scale and multi-physics simulations of battery performance and safety. The modeling framework will transfer the information between models in a physically consistent and mathematically rigorous fashion for both spatial and temporal variations. The end result will be a verified, computationally scalable, portable, and flexible (extensible and easily-modified) framework that can integrate models from the other CAEBAT tasks and industrial partners. The framework will be used to validate models and modeling approaches against experiments and to support rapid prototyping of advanced battery concepts. Fig. 2 shows different parts of CAEBAT VIBE simulation environment that work together to provide user with flexibility in the problem setup, solution formulation and simulation launch. Each of the parts is discussed in subsequent sections with corresponding examples.

25 ENERGY STORAGE↗