Engineering Papers⌕ Search

SEARCH · Engineering Papers

Results for “Materials simulation”

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.

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 235 records · Page 13
All sourcesNASA NTRSDOE OSTI
DOE OSTI2021

Automated Parameterized CFD Simulations of Phase-Change Material Embedded Heat Exchangers

Thermal storage can be implemented using Phase-Change Materials (PCM), which absorb significant latent heat with a relatively small temperature change. PCM phase-change processes are transient and are driven by thermal diffusion and natural convection – the latter, especially for melting process. Modeling and simulation of PCM heat exchangers is typically computationally intensive due to the relative complex time-dependent underlying physics. This paper presents a study investigating a single straight tube with circular transverse fins in the vertical orientation, using PCM’s with 37oC nominal melting temperature, leveraging automated parametric CFD simulations. The computational domain is reduced to 2D axisymmetric for a segment of the HX comprising a region in between two fins with constant wall temperature as boundary condition. This approach allows for faster evaluations of the transient thermal characteristics for a given design space of interest. Correlations and reduced order models (ROM’s) are developed. Results indicate that the ROM’s reproduce the CFD simulations with high accuracy for designs from the training data set, however, designs from cross-validation and test sets do not always have good agreement. The limited number of designs in the training set is a possible cause for the lack of robustness of the ROM’s and thus additional training designs will be added in future work. The ROM’s solve the simulations on average 500,000 times faster than CFD.

25 ENERGY STORAGE↗
DOE OSTI2020

Benchmark Solutions for Radiation Transport in Stochastic Media with Inhomogeneous Material Statistics

Accurately solving implicit Monte Carlo (IMC) thermal photon transport problems with mixed material cells is important in realistic applications. The production IMC package at LLNL treats mixed material cells arising from ALE remap and hydrodynamics using the same approximate model. The new Imp IMC thermal photon transport package currently under development has both a material interface reconstruction (MIR) algorithm and a Levermore-Pomraning (LP) stochastic medium algorithm for treating mixed material cells. Existing stochastic medium algorithms for treating mixed material cells in IMC lack a complete theoretical basis. The IMC LP algorithm implementation has been demonstrated to reproduce published deterministic LP solutions for the particular case of spatially homogeneous material statistics. Realistic simulations will include spatially inhomogeneous material statistics (material mean chord lengths). In a previous investigation, the LP-model for transport in binary stochastic media in rod geometry was generalized to accommodate spatially varying material chord lengths, i.e., the mixing statistics were allowed to be nonhomogeneous. Analytical solutions were obtained and used to produce a verifi cation suite for the Imp IMC Levermore-Pomraning implementation for different spatial variations of the chord lengths. However, the accuracy of the LP model when the mixing statistics are nonhomogeneous has not been assessed and leaves open the question of whether local accuracy is improved or further degraded when chord lengths are not uniform. This shortcoming is rectifi ed here by developing benchmark analytic solutions for transport in binary Markovian stochastic mixtures in rod geometry with nonhomogeneous mixing statistics, using spatially varying chord lengths considered in the previous investigation based on the LP model. Methods for sampling a nonhomogeneous Poisson process (NHPP) are first described and used to construct individual realizations of the binary mixtures in rod geometry. Analytic solutions are then obtained for the forward and backward directed fluxes on a given realization, now viewed as a deterministic medium with alternating layers of the two materials with known interface locations. Finally, material averaged scalar fluxes are obtained using these sampling schemes with spatially linear and quadratic chord lengths and used to assess the accuracy of the previously obtained LP-model results.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗
DOE OSTI2019

Preface for focus issue on uncertainty quantification in materials modeling

This focus issue is motivated by the growing demand for rigorous uncertainty quantification (UQ) in materials modeling, which is driven by the need to use these tools, in conjunction with experiments, to support decision making in materials design, development, and deployment. Traditionally, predictive materials modeling has focused on gaining qualitative insight into the range of mechanisms that control material behavior and how those mechanisms interact to govern material properties and processes. In that context, quantitative evaluation of modeling uncertainty was not a priority. As materials modeling advances, there is increased impetus to employ it in the context of materials design and qualification. This trend is manifested in the establishment of integrated computational materials engineering (ICME) as a growing sub-discipline, as well as by initiatives such as the materials genome in the USA and similar efforts around the globe. Current practice and future needs are described in several recent reports including NASA's Vision 2040: A Roadmap for Integrated, Multiscale Modeling and Simulation of Materials and Systems. Invariably, these studies point out the need for the field to embrace the challenge of UQ.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Acoustic cloaking: Geometric transform, homogenization and a genetic algorithm

A general process is proposed to experimentally design anisotropic inhomogeneous metamaterials obtained through a change of coordinates in the Helmholtz equation. The method is applied to the case of a cylindrical transformation that allows cloaking to be performed. To approximate such complex metamaterials we apply results of the theory of homogenization and combine them with a genetic algorithm. To illustrate the power of our approach, we design three types of cloaks composed of isotropic concentric layers structured with three types of perforations: curved rectangles, split rings and crosses. These cloaks have parameters compatible with existing technology and they mimic the behavior of the transformed material. Numerical simulations have been performed to qualitatively and quantitatively study the cloaking efficiency of these metamaterials.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Quantum-classical embedding via ghost Gutzwiller approximation for enhanced simulations of correlated electron systems

Simulating correlated materials on present-day quantum hardware remains challenging due to limited quantum resources. Quantum embedding methods offer a promising route by reducing computational complexity through the mapping of bulk systems onto effective impurity models, allowing more feasible simulations on pre- and early-fault-tolerant quantum devices. Here, this work develops a quantum-classical embedding framework based on the ghost Gutzwiller approximation to enable quantum-enhanced simulations of ground-state properties and spectral functions of correlated electron systems. Circuit complexity is analyzed using an adaptive variational quantum algorithm on a statevector simulator, applied to the infinite-dimensional Hubbard model with increasing ghost mode numbers from 3 to 5, resulting in circuit depths growing from 16 to 104. Noise effects are examined using a realistic error model, revealing significant impact on the spectral weight of the Hubbard bands. To mitigate these effects, the Iceberg quantum error detection code is employed, achieving up to 40% error reduction in simulations. Finally, the accuracy of the density matrix estimation and the derived spectral function is benchmarked on IBM and Quantinuum quantum hardware, featuring distinct qubit-connectivity and employing multiple levels of error mitigation techniques.

Chen, I-Chi [Ames Laboratory (AMES), Ames, IA (Uni↗
DOE OSTI2020

The TRANSCEND University Consortium: Theme 2 - Site Decommissioning, Deconstruction and Remediation - 20329

This paper will discuss the aims, objectives and progress to-date under Theme 2 of the TRANSCEND consortium project: Site decommissioning, deconstruction and remediation. Decommissioning nuclear sites involves waste retrieval, decontamination, deconstruction and, where necessary, containment and/or remediation of the remaining structure and surrounding land. Critical to management of these processes is limiting radiation exposure for the workforce, restricting the spread of radionuclides in groundwater, surface water and airborne particulates, and minimising the volume of contaminated waste for disposal. The aim of Theme 2 research is to develop new technologies for monitoring, remediation and containment that serve to minimise the volume of radioactively contaminated waste for disposal, for application prior to, during and after retrieval, deconstruction and decontamination operations. Prior research, conducted under the previous DISTINCTIVE project, demonstrated that colloidal silica grout can penetrate low permeability materials (including cement) for hydraulic barrier formation, and improved sorption capacity. The silica grout can be injected at surface using extremely small (potentially gravity-driven) fluid pressures, without the need for borehole drilling. Current work is investigating the erodibility of silica-grouted soils for inhibition of airborne and water-borne particulates as well as enhancing the grout's sorption capacity by addition of other materials to provide a chemical, as well as hydraulic, barrier to subsurface migration. EK remediation uses low voltage DC current to control migration of contaminants in porous media as well as to remove or degrade them. Researchers in the consortium have already demonstrated that low-energy ex-situ EK techniques can be used to provide remediation and volume minimisation for AWE legacy wastes in the UK. Under the current project researchers are building EK test cells containing simulated site materials at laboratory and intermediate(m)-scales to: remove, focus or degrade contaminants (remediation or waste minimisation); and direct subsurface water, chemical and colloid flow (fencing/containment or forced migration). This lab-based research is being informed by numerical models of EK processes that can subsequently be used to design full-scale on-site applications by nuclear site holders. Research under theme 2 of TRANSCEND will ultimately combine novel non-invasive detection technologies with EK techniques and colloidal silica grout barriers, to optimise the containment of radionuclide contamination in soils. Thus, allowing us to detect in-situ contamination, mobilise it to a selected location and grout it in-situ, prior to the initiation of decommissioning and deconstruction operations. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2025

Materials Learning Algorithms (MALA): Scalable machine learning for electronic structure calculations in large-scale atomistic simulations

We present the Materials Learning Algorithms (MALA) package, a scalable machine learning framework designed to accelerate density functional theory (DFT) calculations suitable for large-scale atomistic simulations. Using local descriptors of the atomic environment, MALA models efficiently predict key electronic observables, including local density of states, electronic density, density of states, and total energy. The package integrates data sampling, model training and scalable inference into a unified library, while ensuring compatibility with standard DFT and molecular dynamics codes. We demonstrate MALA's capabilities with examples including boron clusters, aluminum across its solid-liquid phase boundary, and predicting the electronic structure of a stacking fault in a large beryllium slab. Scaling analyses reveal MALA's computational efficiency and identify bottlenecks for future optimization. With its ability to model electronic structures at scales far beyond standard DFT, MALA is well suited for modeling complex material systems, making it a versatile tool for advanced materials research.

Density functional theory↗
DOE OSTI2025

A foundation model for atomistic materials chemistry

Atomistic simulations of matter, especially those that leverage first-principles (ab initio) electronic structure theory, provide a microscopic view of the world, underpinning much of our understanding of chemistry and materials science. Over the last decade or so, machine-learned force fields have transformed atomistic modeling by enabling simulations of ab initio quality over unprecedented time and length scales. However, early machine-learning (ML) force fields have largely been limited by (i) the substantial computational and human effort required to develop and validate potentials for each particular system of interest and (ii) a general lack of transferability from one chemical system to the next. Here, we show that it is possible to create a general-purpose atomistic ML model, trained on a public dataset of moderate size, that is capable of running stable molecular dynamics for a wide range of molecules and materials. We demonstrate the power of the MACE-MP-0 model-and its qualitative and at times quantitative accuracy-on a diverse set of problems in the physical sciences, including properties of solids, liquids, gases, chemical reactions, interfaces, and even the dynamics of a small protein. The model can be applied out of the box as a starting or "foundation" model for any atomistic system of interest and, when desired, can be fine-tuned on just a handful of application-specific data points to reach ab initio accuracy. Establishing that a stable force-field model can cover almost all materials changes atomistic modeling in a fundamental way: experienced users obtain reliable results much faster, and beginners face a lower barrier to entry. Foundation models thus represent a step toward democratizing the revolution in atomic-scale modeling that has been brought about by ML force fields.

Batatia, Ilyes↗
DOE OSTI2024

Energy-dependent implementation of secondary electron emission models in continuum kinetic sheath simulations

The plasma-material interactions present in multiple fusion and propulsion concepts between the flow of plasma through a channel and a material wall drive the emission of secondary electrons. This emission is capable of altering the fundamental structure of the sheath region, significantly changing the expected particle fluxes to the wall. The emission spectrum is separated into two major energy regimes, a peak of elastically backscattered primary electrons at the incoming energy, and cold secondary electrons inelastically emitted directly from the material. The ability of continuum kinetic simulations to accurately represent the secondary electron emission is limited by relevant models being formulated in terms of monoenergetic particle interactions which cannot be applied directly to the discrete distribution function. As a result, rigorous implementation of energy-dependent physics is often neglected in favor of simplified, constant models. We present here a novel implementation of semi-empirical models in the boundary of continuum kinetic simulations which allows the full range of this emission to be accurately captured in physically-relevant regimes.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2025

Accurate and efficient predictions of keyhole dynamics in laser materials processing using machine learning-aided simulations

The keyhole phenomenon has been widely observed in laser materials processing, including laser welding, remelting, cladding, drilling, and additive manufacturing. Keyhole-induced defects, primarily pores, dramatically affect the performance of final products, impeding the broad use of these laser-based technologies. The formation of these pores is typically associated with the dynamic behavior of the keyhole. So far, the accurate characterization and prediction of keyhole features, particularly keyhole depth, as a function of time, has been a challenging task. In situ characterization of keyhole dynamic behavior using the synchrotron X-ray technique is informative but complicated and expensive. Current simulations are generally hindered by their poor accuracy and generalization abilities in predicting keyhole depths due to the lack of accurate laser absorptance data. In this study, we develop a machine learning-aided simulation method that accurately predicts keyhole dynamics, especially in keyhole depth fluctuations, over a wide range of processing parameters. In two case studies involving titanium and aluminum alloys, we achieve keyhole depth prediction with a mean absolute percentage error of 10 %, surpassing those simulated using the ray-tracing method with an error margin of 30 %, while also reducing computational time. This exceptional fidelity and efficiency empower our model to serve as a cost-effective alternative to synchrotron experiments. Our machine learning-aided simulation method is affordable and readily deployable for a large variety of materials, opening new doors to eliminate or reduce defects for a wide range of laser materials processing techniques.

Computational fluid dynamics↗
DOE OSTI2024

Qualitative Conditions for Reasonable Estimates of Kerma Using Total and Kerma Cross Section Attenuation of Photons

Performing a full adjoint simulation in the Integrated Tiger Series (ITS) can be time consuming to obtain statistically significant results. The ray-trace capability in ITS allows for rapid scoping calculations of the uncollided kerma from photon sources without needing to run a full adjoint simulation. However, the uncollided estimate will always underestimate the full-physics kerma since it neglects scattered radiation, and under certain conditions, the result from the capability may not provide a sufficiently accurate estimate of the full-physics kerma. To exemplify the conditions in which the capability provides reasonable estimates, two problem geometries with different materials are simulated using the full adjoint capability as well as the ray-trace capability with a total cross section treatment and a new kerma-attenuation cross-section treatment. The results are then compared to show under which conditions the estimates are accurate. Reasonable estimates are provided from the ray-trace feature when there is minimal scattering into a region of interest occurring, such as with low-Z material and when the photons travel through small amounts of material.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗
DOE OSTI2020

Report Summarizing Boiling Transition (Dryout) Testing of FeCrAl Cladding

Nuclear fuel and cladding in a light water reactor must maintain integrity under all normal operational and anticipated operational occurrences. In a Boiling Water Reactor (BWR) some Anticipated Operational Occurrences (AOOs) and Anticipated Transients Without SCRAM (ATWS) events have been known to result in cladding damage due to dryout with conventional Zircaloy-2 claddings. This work presents an assessment of commercially-fabricated, accident tolerant iron-chromium-aluminum (FeCrAl) alloy C26M cladding in such events with regard to the ballooning failure mode for unirradiated cladding In the severe accident test station (SATS), an experiment has been developed to gauge accident tolerance of fuel cladding materials under simulated cyclic dryout conditions. Thermal cycling from 300°C to 650°C was implemented on C26M and Zircaloy-2 tubes. The C26M tube did not fail after 54 cycles. The Zircaloy- 2 tube run under the same parameters as the C26M tube failed during the fourth cycle, consistent with expectations from the literature. Due to thermal gradients present in the furnace, both tubes experienced a maximum temperature at ~780°C. Due to differences in tube geometry, the hoop stress of the C26M tube was significantly higher than that of the Zircaloy-2 tube, 76 MPa at the maximum peak temperature compared to 55 MPa at burst, respectively. The cyclic dryout experiments show an increased performance of C26M over Zircaloy-2 under simulated conditions, an indication of C26M possessing superior high temperature oxidation resistance, mechanical properties and potentially resistance to fatigue.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2026

Scaling kinetic Monte-Carlo simulations of grain growth with combined convolutional and graph neural networks

Graph neural networks (GNN) have emerged as a promising machine learning method for microstructure simulations such as grain growth. However, accurate modeling of realistic grain boundary networks requires large simulation cells, which GNN has difficulty scaling up to. To alleviate the computational costs and memory footprint of GNN, we suggest a hybrid architecture combining a convolutional neural network (CNN) based bijective autoencoder to compress the spatial dimensions, and a GNN that evolves the microstructure in the latent space of reduced spatial sizes. Our results demonstrate that the new design significantly reduces computational costs with using fewer message passing layer (from 12 down to 3) compared with GNN alone. The reduction in computational cost becomes more pronounced as the spatial size increases, indicating strong computational scalability. For the largest mesh evaluated (160 3 ), our method reduces memory usage and runtime in inference by 117× and 115×, respectively, compared with GNN-only baseline. More importantly, it shows higher accuracy and stronger spatiotemporal capability than the GNN-only baseline, especially in long-term testing. Such combination of scalability and accuracy is essential for simulating realistic material microstructures over extended time scales. The improvements can be attributed to the bijective autoencoder’s ability to compress information losslessly from spatial domain into a high dimensional feature space, thereby producing more expressive latent features for the GNN to learn from, while also contributing its own spatiotemporal modeling capability. Training data are generated from stochastic grain growth simulations, providing realistic variability for learning robust microstructure evolution. Comprehensive system validation confirms that the model is accurate, robust, and scalable.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Development & Experimental Validation of a Generalized Resistance-Capacitance Model for Numerical Simulation of Phase-Change Material Embedded Heat Exchangers

Latent heat thermal energy storage (LHTES) using phase change material (PCM) has attracted increased attention as a viable solution for overcoming the mismatch between energy supply and demand for renewable energy-based systems. PCM-embedded heat exchangers (PCM-HX) have the potential to significantly improve thermal performance due to high storage capacity and low temperature variation during the phase change process. Most models for simulating LHTES heat transfer use Computational Fluid Dynamics (CFD) simulations, which have high computational costs resulting from considering the complex and time-dependent physics relevant to PCM-HXs. In this paper, a Generalized Resistance Capacitance-based Model (GRCM) was developed to predict the thermal performance of arbitrary PCM-HXs in a computationally efficient manner without compromising modeling accuracy. The GRCM is exercised for three case studies: (i) verification for a single-slabbed finned PCM-HX, (ii) verification and validation for a copper foam/paraffin composite PCM-HX, and (iii) validation for a straight tube annular finned PCM-HX. The copper foam PCM-HX uses an electric heater at the top of HX, while the other two configurations utilize water as heat transfer fluid. For the single-slabbed finned PCM-HX melting case, the mean deviation in average PCM temperature predicted by the GRCM compared to the CFD model was between 0.56 – 0.73 K, with maximum temperature deviation of 2.68 K. For the HTF outlet temperature, the validation results showed that GRCM prediction matches very well with experimental data, with mean temperature deviation of 0.24 K during melting case, while for solidification case was 0.34 K. These results showcase the GRCM’s capability for accurately reproducing the thermal characteristics of PCM-HXs with considerably lower computational effort.

42 ENGINEERING↗
DOE OSTI2022

Extending and Smoothing Two-dimension Equation of State Simulation Data

The Multiphase Equation of State (MEOS) project works to produce high quality equation of state tables which are used in computationally intensive simulations of materials in different conditions. An equation of state table describes the state of matter under certain physical conditions such as pressure, volume, temperature, or internal energy. MEOS uses many different models and combinations thereof to produce accurate tables consisting of continuous smooth data, derivatives, and higher-order derivatives. Accurate and smooth data are important factors in producing precise simulations. This report focuses on improving the electron tables produced from Purgatorio and Thomas-Fermi data. Purgatorio data is extremely accurate but often jagged and discontinuous in the lower temperature and density region. Thomas-Fermi is a model that provides smooth data throughout. Together, this produces an EOS data table that is both accurate and smooth. This report describes the implementation of a new feature that allows users to define more detailed regions in the Purgatorio table to be replaced with Thomas-Fermi. As a result, MEOS can generate a table that is both more smooth and still accurate.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2025

Strong Correlation DMRG and DFT

This project developed new ways to improve computer simulations of materials where electrons interact strongly with each other, a challenge for today’s most widely used method, density functional theory (DFT). We used an exact numerical method, the density matrix renormalization group (DMRG), to create highly accurate reference results for simple model systems, and used these to test DFT, prove when it will converge, and even train machine-learned functionals. We also invented new kinds of localized basis functions (“gausslets” and “multi-sliced gausslets”) and a “sliced-basis” approach that make high-accuracy simulations faster and more practical. These methods were applied to extended hydrogen systems, enabling the direct derivation of accurate low-energy models from first-principles calculations. We also introduced a new formalism, Conditional-Probability DFT, which could bypass traditional approximations. The tools and results from this work, including open-source software releases, will help scientists design and understand complex quantum materials.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2021

A fourth-order Lagrangian discontinuous Galerkin method using a hierarchical orthogonal basis on curvilinear grids

The existing high-order Lagrangian discontinuous Galerkin (DG) hydrodynamic methods are restricted to using quadratic meshes with quadratic polynomials (P2), which in turn, yield up to third-order accuracy. Additionally, these existing DG hydrodynamic schemes, when extended to work with cubic meshes and cubic polynomials (P3), can be unstable on strong-shock problems. Therefore, this paper presents a new Lagrangian discontinuous Galerkin (DG) hydrodynamic method to simulate compressible material dynamics ( e.g., gasses, fluids, and solids) with strong-shocks using cubic meshes and cubic polynomials, and delivers up to fourth-order accuracy on smooth flows. The stability on shock problems is achieved using new hierarchical orthogonal basis functions and a new subcell mesh stabilization (SMS) scheme for cubic meshes. The accuracy and robustness of the new high-order accurate Lagrangian DG hydrodynamic method is demonstrated by simulating a diverse suite of challenging test problems covering gas and solid dynamic problems on curvilinear meshes.

97 MATHEMATICS AND COMPUTING↗