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At least 343 records · Page 19
All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

A Simple, Scalable Large Deformation Solid Mechanics Implementation in the MOOSE Framework

This article describes a large deformation solid mechanics solver implemented as part of the freely available and open source MOOSE finite element simulation framework. The article documents the choices made in developing the solid mechanics framework and describes novel formulations for the gradient operator and constitutive modeling framework made to simplify implementations of different coordinate systems, stabilized gradient operators, and different constitutive model inputs and outputs. In the process, the article describes a new formulation that casts objective integration of the Cauchy stress as a linear transformation of the small stress rate. Finally, the article presents key implementation details and examines the parallel efficiency of the solid mechanics solver implemented in MOOSE. The implementation retains a good weak scaling efficiency beyond 1,000 parallel processes. The article includes a discussion of the factors limiting the parallel efficiency of implicit, large deformation solid mechanics codes on current high-performance computers, with the main current limitation being the scalability of the algebraic multigrid methods used to solve the linearized equilibrium equations.

Applied computing → Computer-aided design↗
DOE OSTI2016

The PROMETRA program: plane strain tests on fresh and highly irradiated zircaloy-4, ZIRLO and M5 fuel claddings

In the framework of the PROMETRA program, clad hardening constitutive laws (stress-strain curves) have been already implemented in the SCANAIR code. These laws were derived from uniaxial hoop tensile tests performed on narrow machined ring samples. However, they do not reproduce the conditions of strain multi-axiality acting on cladding during a RIA (Reactivity-Initiated Accident) in a PWR. As a consequence, a new specimen called Plane Strain Tensile (PST) similar to the annular sample developed by Pennsylvania State University has been developed at CEA on a wider notched ring. It aims to accurately predict the cladding failure in more prototypical conditions, close to plane strain hoop tension in the middle of the gage section. This paper details the PST tests implementation and results in the framework of the PROMETRA program on fresh and irradiated claddings. The development of this test has led also to the development of a technique to measure local deformations in the gage section of the PST specimen using 2-D Digital Image Correlation (DIC). Tests performed on fresh Zircaloy-4 and on irradiated Zircaloy-4, M5 and ZIRLO specimens are analyzed relying of post-test examinations and finite element simulations. In the case of tests performed on irradiated Zry-4 and ZIRLO at 280 and 350 Celsius degrees, the presence of a hydride rim favors the crack nucleation on the outer surface. In this case, rupture nucleation occurs preferentially in the vicinity of notches. Such tests are not representative of the rupture of a cladding subjected to plane strain loading. Nevertheless, they give a good representation of the initiation of rupture observed during RIA on irradiated cladding, resulting in a hydride damage. Zry-4 specimens tested at 480 Celsius degrees and M5TM at 280 and 350 C. degrees result in a ductile fracture nucleation in the center of the specimen. This rupture is prototypical of a ductile rupture of an irradiated specimen subjected to a plane strain loading. However, the nucleation on inner surface by shear at the mandrel contact is not prototypical of a clad rupture during the PCMI (Pellet Clad Mechanical Interaction) phase of a RIA (membrane stresses in the clad thickness in RIA). An important lesson learned from this experimental approach is that the PST test is a particularly complex test, both in its implementation and interpretation.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2017

Reliable Thermoelectric Module Design under Opposing Requirements from Structural and Thermoelectric Considerations

Structural reliability of thermoelectric generation (TEG) systems still remains an issue especially for applications such as large scale industrial or automobile exhaust heat recovery where a TEG system is subject to dynamic loads and thermal cycling. Traditional thermoelectric (TE) system design and optimization techniques, focused on performance alone, could result in designs that may fail during operation as the geometric requirements for optimal performance (especially the power) are often in conflict with the requirements for mechanical reliability. This study focused on reducing the thermomechanical stresses in a TEG system without compromising the optimized system performance. Finite element simulations were carried out to study the effect of TE element (leg) geometry such as the leg length and cross-sectional shape under constrained material volume requirements. Results indicated that the element length has a major influence on the element stresses whereas the regular cross-sectional shapes have minor influence. Additionally, the impact of TE element stresses on the mechanical reliability is evaluated with the brittle material failure theory based on Weibull analysis. An alternate couple configuration that relies on the industry practice of redundant element design is investigated. Results showed that the alternate configuration considerably reduced the TE element and metallization stresses thereby enhancing the structural reliability with little trade-off in the optimized performance. The proposed alternate configuration could serve as a potential design modification for improving the reliability of systems optimized for thermoelectric performance.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Structural Reliability Evaluation of Thermoelectric Generator Modules: Influence of End Conditions, Leg Geometry, Metallization, and Processing Temperatures

Structural reliability of thermoelectric generators (TEGs) in medium to high temperature applications still remains a challenge. Currently there are no established standards for evaluating the thermomechanical reliability of TEGs during new material and module development phases in the industry. In this work we implemented a procedure for evaluating the reliability of brittle TE materials based on the common practice in the ceramics industry. The probabilistic thermomechanical reliability of TEG couples and modules is evaluated using Weibull analysis. Finite element simulations were carried out to study the influence of TEG couple parameters such as element geometry, dimensions, spacing, metallization thickness, and processing conditions on the stresses, and the structural reliability evaluations are conducted based on the TE element stresses. We report results showed that the boundary conditions and processing temperatures have significant influence on the element and metallization stresses and overall device reliability. The external compressive load significantly enhanced structural reliability. Results also showed that among geometrical parameters the element length has a dominating influence on the element stresses compared to the leg cross-sectional shapes. The cross-section geometry of legs showed considerable effect at shorter lengths and the influence diminished with increased lengths. The proposed approach for evaluating the structural reliability could be integrated with performance optimization techniques for developing optimal and reliable TEG devices.

36 MATERIALS SCIENCE↗
DOE OSTI2018

High-Temperature Sapphire Pressure Sensors for Harsh Environments

The project aimed to develop and characterize an optical pressure sensor capable of withstanding high temperatures, up to 1000 °C. Survivability in harsh environments was enabled using sapphire for both the substrate and the optical fibers, therefore mitigating thermal expansion mismatch. Such material cannot be machined through conventional microfabrication techniques, and unique additive and subtractive methods had to be studied and implemented. Subtractive methods included laser-machining the sapphire substrate using a picosecond laser machining tool. At first, the parameters of importance were theoretically and experimentally evaluated such that the fluence, the pulse spacing, and the number of passes were found to strongly influence the laser ablation process. A simulation tool was designed to predict the final pattern when inputting a set of parameters and a profile. This model was complemented with laser ablation material physics models and Bayesian uncertainty analysis for one dimensional and three dimensional ablation processes. An additive process called thermocompression bonding was studied in order to seal the diaphragm substrate to the back cavity. At first, bonding strength using this technique was examined using the chevron-notch method that allow to determine the fracture toughness of this bond. This parameter is independent of the geometry used and therefore can be extended to other geometries used in actual sensor bonding. A theoretical and experimental study of internal damage caused by the laser micromachining of the sapphire material was carried out. The research identified enhanced strength and fracture toughness along laser ablated surfaces. This was determined using bend bar specimens and Vicker’s microindentations. Softening of the plasticity behavior (as indicated by nanoindentation experiments) was also investigated using finite deformation plasticity modeling via a contact mechanics finite element simulation. Good correlations between experiments and the model were achieved to determine material parameters that can be used in future MEMS based sensor design and modeling to minimize sensor failure loads. The enhanced strength and fracture toughness was determined to be due to compressive residual stress near laser ablated surfaces. This was confirmed through x-ray spectra taken along different crystal structure planes in combination and Bayesian uncertainty analysis. The Bayesian analysis inferred the entire residual strain tensor (six components) and the residual stress tensor. The results illustrated compressive in-plane stress was the most likely cause of enhanced strength and toughness after laser machining. Due to major equipment failures, a parallel route for fabricating the sensor was taken, using commercially available sapphire removal method (subtractive) and ceramic adhesive bonding (additive). The fully-packaged sensor utilized laser micromachining for the sapphire substrate fabrication and was comprised only of high-temperature-compatible materials. Calibration tests of the sensor in both room-temperature and high-temperature plane-wave tubes showed good linearity and consistent frequency response, in the tested frequency range. The sensor also showed good thermal stability in tests up to 300 °C, proving the fiber-optic lever and its packaging process to be a promising approach for high-temperature measurements. The calibration from 23 °C to 300 °C gave a raw sensitivity of 3.9 × 10 -7 V/Pa and a normalized sensitivity of 9.8 × 10 -8 Pa -1 which were consistent within the temperature range. The sensor had a resonance at 16.3 kHz and a flat band (±3 dB) up to 10.3 kHz. The noise floor of the sensor at 1 kHz was 316 nV/Hz 1/2 , resulting in a MDP of 0.8 Pa. Previously, diaphragm delamination due to CTE mismatch was found at 500 °C, causing packaging failure. Unfortunately high temperature validation in hot jet environment could not be made in time. In the future, it is suggested that the two sapphire substrates be bonded by thermal compression bonding with an intermediate platinum layer instead of using an alumina-based adhesive, and therefore achieve higher temperature capacity up to 1000 °C.

77 NANOSCIENCE AND NANOTECHNOLOGY↗
DOE OSTI2014

SU-E-J-102: Separation of Metabolic Supply and Demand: From Power Grid Economics to Cancer Metabolism

Purpose: To study a new model of glucose metabolism which is primarily governed by the timescale of the energetic demand and not by the oxygen level, and its implication on cancer metabolism (Warburg effect) Methods: 1) Metabolic profiling of membrane transporters activity in several cell lines, which represent the spectrum from normal breast epithelium to aggressive, metastatic cancer, using Seahorse XF reader.2) Spatial localization of oxidative and non-oxidative metabolic components using immunocytochemical imaging of the glycolytic ATP-producing enzyme, pyruvate kinase and mitochondria. 3) Finite element simulations of coupled partial differential equations using COMSOL and MATLAB. Results: Inhibition or activation of pumps on the cell membrane led to reduction or increase in aerobic glycolysis, respectively, while oxidative phosphorylation remained unchanged. These results were consistent with computational simulations of changes in short-timescale demand for energy by cell membrane processes. A specific model prediction was that the spatial distribution of ATP-producing enzymes in the glycolytic pathway must be primarily localized adjacent to the cell membrane, while mitochondria should be predominantly peri-nuclear. These predictions were confirmed experimentally. Conclusion: The results in this work support a new model for glucose metabolism in which glycolysis and oxidative phosphorylation supply different types of energy demand. Similar to power grid economics, optimal metabolic control requires the two pathways, even in normoxic conditions, to match two different types of energy demands. Cells use aerobic metabolism to meet baseline, steady energy demand and glycolytic metabolism to meet short-timescale energy demands, mainly from membrane transport activities, even in the presence of oxygen. This model provides a mechanism for the origin of the Warburg effect in cancer cells. Here, the Warburg effect emerges during carcinogenesis is a physiological response to an increase in energy demands from membrane transporters, required for cell division, growth, and migration. This work is supported by the NIH Physical Sciences in Oncology Center grant 1U54CA143970-03 and NIH R01 CA077575-10.

60 APPLIED LIFE SCIENCES↗
DOE OSTI2025

Monolithic optoelectronic circuit design for on-chip terahertz applications

We demonstrate a monolithic coplanar stripline platform for on-chip terahertz (THz) generation, transmission, and detection, addressing key challenges of mode purity, bandwidth, and referencing. Capacitive coupling of the photoconductive generator switch enforces pure odd-mode propagation, increases THz field strength, and extends the operational frequency range, achieving 0.05–1.4 THz. Our architecture enables fully monolithic fabrication with amorphous silicon switches, in situ field referencing, and galvanic isolation between generation and detection. Finite-element simulations and experiments confirm that suppressing parasitic modes improves signal integrity, providing a robust platform for high-fidelity THz spectroscopy, ultrafast electronics, and nanoscale quantum materials research.

Capacitive coupling↗
DOE OSTI2023

Boosting Piezoelectricity by 3D Printing PVDF‐MoS 2 Composite as a Conformal and High‐Sensitivity Piezoelectric Sensor

Abstract Additively manufactured flexible and high‐performance piezoelectric devices are highly desirable for sensing and energy harvesting of 3D conformal structures. Herein, the study reports a significantly enhanced piezoelectricity in polyvinylidene fluoride (PVDF) achieved through the in situ dipole alignment of PVDF within PVDF‐2D molybdenum disulfide (2D MoS 2 ) composite by 3D printing. The shear stress‐induced dipole poling of PVDF and 2D MoS 2 alignment are harnessed during 3D printing to boost piezoelectricity without requiring a post‐poling process. The results show a remarkable, more than the eight‐fold increment in the piezoelectric coefficient ( d 33 ) for 3D printed PVDF‐8wt.% MoS 2 composite over cast neat PVDF. The underlying mechanism of piezoelectric property enhancement is attributed to the increased volume fraction of β phase in PVDF, filler fraction, heterogeneous strain distribution around PVDF‐MoS 2 interfaces, and strain transfer to the nanofillers as confirmed by microstructural analysis and finite element simulation. These results provide a promising route to design and fabricate high‐performance 3D piezoelectric devices via 3D printing for next‐generation sensors and mechanical–electronic conformal devices.

2D MoS2↗
DOE OSTI2024

Multilaminate Energy Storage Films from Entropy‐Driven Self‐Assembled Supramolecular Nanocomposites

Abstract Composite materials comprising polymers and inorganic nanoparticles (NPs) are promising for energy storage applications, though challenges in controlling NP dispersion often result in performance bottlenecks. Realizing nanocomposites with controlled NP locations and distributions within polymer microdomains is highly desirable for improving energy storage capabilities but is a persistent challenge, impeding the in‐depth understanding of the structure–performance relationship. In this study, a facile entropy‐driven self‐assembly approach is employed to fabricate block copolymer‐based supramolecular nanocomposite films with highly ordered lamellar structures, which are then used in electrostatic film capacitors. The oriented interfacial barriers and well‐distributed inorganic NPs within the self‐assembled multilaminate nanocomposites effectively suppress leakage current and mitigate the risk of breakdown, showing superior dielectric strength compared to their disordered counterparts. Consequently, the lamellar nanocomposite films with optimized composition exhibit high energy efficiency (>90% at 650 MV m −1 ), along with remarkable energy density and power density. Moreover, finite element simulations and statistical modeling have provided theoretical insights into the impact of the lamellar structure on electrical conduction, electric field distribution, and electrical tree propagation. This work marks a significant advancement in the design of organic–inorganic hybrids for energy storage, establishing a well‐defined correlation between microstructure and performance.

Li, He↗
DOE OSTI2021

Kinetic Limitations in Single‐Crystal High‐Nickel Cathodes

Abstract High‐nickel cathodes attract immense interest for use in lithium‐ion batteries to boost Li‐storage capacity while reducing cost. For overcoming the intergranular‐cracking issue in polycrystals, single‐crystals are considered an appealing alternative, but aggravating concerns on compromising the ionic transport and kinetic properties. We report here a quantitative assessment of redox reaction in single‐crystal LiNi 0.8 Mn 0.1 Co 0.1 O 2 using operando hard X‐ray microscopy/spectroscopy, revealing a strong dependence of redox kinetics on the state of charge (SOC). Specifically, the redox is sluggish at low SOC but increases rapidly as SOC increases, both in bulk electrodes and individual particles. The observation is corroborated by transport measurements and finite‐element simulation, indicating that the sluggish kinetics in single‐crystals is governed by ionic transport at low SOC and may be alleviated through synergistic interaction with polycrystals integrated into a same electrode.

Ge, Mingyuan↗
DOE OSTI2020

Kinetic Limitations in Single-Crystal High-Nickel Cathodes

High-nickel cathodes attract immense interest for use in lithium-ion batteries, to boost Li-storage capacity while reducing cost. For overcoming the intergranular-cracking issue in polycrystals, single-crystals are considered an appealing alternative, but aggravating concerns on compromising the electrochemical kinetics of electrodes. We report here a quantitative assessment of electrochemical reaction in single-crystal LiNi 0.8 Mn 0.1 Co 0.8 O 2 using operando hard X-ray microscopy/spectroscopy, revealing a strong dependence of redox kinetics on the state of charge (SOC) - being sluggish at low SOC while increasing rapidly as SOC increases both in the bulk electrode and individual particles. The observation is corroborated by transport measurements and finite-element simulation, indicating that the sluggish kinetics in single-crystals is governed by ionic transport at low SOC and may be alleviated through synergistic interaction with polycrystals integrated into a same electrode. Finally, with the elucidated mechanistic origin and alleviation solution of kinetic limitations in single-crystal high-Ni cathodes, this work constitutes a step forward in enabling their practical deployment.

25 ENERGY STORAGE↗
DOE OSTI2016

Cell migration and organization in three-dimensional in vitro culture driven by stiffness gradient: Cell Migration Driven by Stiffness Gradient

Durotaxis, a phenomenon that cells move according to changes in stiffness of the extra cellular matrix, has emerged as a crucial parameter controlling cell migration behavior. The current study provides a simple method to generate three-dimensional continuous stiffness variations without changing other physical characteristics of the extra cellular environment. Using Finite Element simulations, the stiffness and the stiffness gradient variations are evaluated quantitatively, leading to an analysis of the dependence of cell migration behavior on the substrate stiffness parameters. We tested various cell lines on several 3-D environments. In this work, the durotaxis results show that the cell migration velocity does not have any consistency with the stiffness of the substrate, rather it is more related to the stiffness gradient of the substrate. This finding suggests a new mechanism underlying the durotaxis phenomenon, highlighting the importance of the substrate stiffness gradient, rather than the stiffness itself.

36 MATERIALS SCIENCE↗
DOE OSTI2017

A performance spectrum for parallel computational frameworks that solve PDEs

Summary Important computational physics problems are often large‐scale in nature, and it is highly desirable to have robust and high performing computational frameworks that can quickly address these problems. However, it is no trivial task to determine whether a computational framework is performing efficiently or is scalable. The aim of this paper is to present various strategies for better understanding the performance of any parallel computational frameworks for solving PDEs. Important performance issues that negatively impact time‐to‐solution are discussed, and we propose a performance spectrum analysis that can enhance one's understanding of critical aforementioned performance issues. As proof of concept, we examine commonly used finite element simulation packages and software and apply the performance spectrum to quickly analyze the performance and scalability across various hardware platforms, software implementations, and numerical discretizations. It is shown that the proposed performance spectrum is a versatile performance model that is not only extendable to more complex PDEs such as hydrostatic ice sheet flow equations but also useful for understanding hardware performance in a massively parallel computing environment. Potential applications and future extensions of this work are also discussed.

Chang, J.↗
DOE OSTI2023

Modeling of the effectiveness of novel edge seal designs for fast, low‐Cap‐Ex manufacturing

Abstract In the manufacturing of photovoltaic (PV) modules, the lamination process can take up to 20 min to complete. In this work, new lamination processes are being developed, and have been prototyped, which hope to be able to cut this time down to as little as 30 s. This could provide significant savings in the cost of lamination equipment, floor space, and energy. PV modules are expected to have a lifespan exceeding 20 to 30 years. For moisture‐sensitive PV technologies, the edge seal between the two layers of glass can be the weakest point of its reliability. There is an inherent challenge when evaluating edge seal materials due to their low permeation rates. As part of Colorado State University's Photovoltaic Research and Development 2, work at the National Renewable Energy Laboratory has developed models to evaluate edge seal configurations in glass‐glass PV modules. Here, this new manufacturing process is evaluated for long‐term moisture durability. Different edge seal design options within glass–glass PV modules are explored. Most of these designs are targeting a superstrate on glass configuration, e.g CdTe, but some designs could be used on conventional crystalline Si cells. Using COMSOL finite element simulation software, we investigated the edge seal and interlayer design configurations containing silicone perimeter edge adhesive, desiccated polyisobutylene‐based edge seal, air, and polyolefin while integrating climate conditions equivalent to a hot and humid environment such as Miami, Florida. We found optimized configurations that will allow the module to prevent moisture ingress over 50 years minimizing the amount of time and material used while utilizing polymers that are easily dispensed.

14 SOLAR ENERGY↗
DOE OSTI2016

Anomalous Oxidative Diffusion in Titanium Pyrotechnic Powders

It has long been observed that oxidation processes in metals tend to follow a parabolic rate law associated with the growth of a surface oxide layer. Here we observe that for certain titanium powders, the expected parabolic law (∝t 1/2 ) is recovered, yet for others, the exponent differs significantly. One explanation for this non-parabolic, anomalous diffusion arises from fractal geometry. Theoretical considerations indicate that the time response of diffusion-limited processes in an object closely follow a power-law in time (t n ) with n=(E–D)/2, where E is the object's Euclidean dimension and D is its boundary's Hausdorff dimension. Non-integer, (fractal) values of D will result in n≠1/2. Finite element simulations of several canonical fractal objects were performed to verify the application of this theory; the results matched the theory well. Two different types of titanium powder were tested in isothermal thermogravimetric tests under dilute oxygen. Time-dependent mass uptake data were fit with power-law forms and the associated exponents were used to determine an equivalent fractal dimension. One Ti powder type has an implied surface dimension of ca. 2.3 to 2.5, suggesting fractal geometry may be operative. Finally, the other has a dimension near 2.0, indicating it behaves like traditional material.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Grain Orientation Dependence of the Residual Lattice Strain in a Cold Rolled Interstitial-Free Steel

The experimentally measured grain-orientation-dependent residual lattice strains, evolved in an interstitia-free steel after 70% cold rolling reduction, are studied by means of crystal elastic visco-plastic finite element simulations, which provides a very satisfactory prediction of deformation texture. The calculated residual lattice strain pole figure matches well with the experimentally measured counterpart within the highest density regions of major texture components observed. Both experimental evidence and results of modeling clearly indicate that the residual lattice strain is orientation dependent, based on comprehensive information on the evolution of residual lattice strain in various crystallographic orientations during plastic deformation. It appears that in a cold rolled material, there is a general correlation between the stresses developed just prior to unloading and the residual lattice strains in particular directions. Here, it is also shown that the cumulative plastic shear does not reveal a clear correlation with the components of residual lattice strain while presented in the normal correlation plot, however, this relationship can be better understood by means of the orientation distribution function of residual lattice strain, which can be derived from the neutron or X-ray diffraction experiments.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Input specific neural networks

Neural networks have emerged as powerful tools for mapping between inputs and outputs. However, their black-box nature limits the ability to encode or impose specific structural relationships between inputs and outputs. Many scientific and engineering problems, such as constitutive modeling in solid mechanics, require networks that can enforce convexity, monotonicity, or other structural constraints to ensure physical consistency. Here, we introduce the Input Specific Neural Network (ISNN), a new architecture that enables multiple, distinct constraints to be imposed on different input subsets for scalar-valued outputs. This framework unifies convex, monotone–convex, monotone, and arbitrary mappings within a single network for the first time. Two ISNN architectures with analytical first- and second-order derivatives are developed. We demonstrate the performance on synthetic toy problems, inverse problems in isotropic hyperelasticity, and finite element simulations. ISNNs achieve improved extrapolation behavior, require fewer invariant inputs than standard input convex networks for polyconvex potentials, and enable significant computational savings via manual differentiation. We also show how ISNNs can be used to learn structural relationships between inputs and outputs via a binary gating mechanism. Particularly, ISNNs are employed to model a homogenized anisotropic free energy potential in a decoupled multiscale setting. The network learns whether or not the potential should be modeled as polyconvex and retains only the relevant layers while using the minimum number of inputs. ISNNs provide a flexible foundation for embedding structural priors into neural networks, enhancing both interpretability and stability. They are broadly applicable across computational mechanics and other scientific domains requiring constrained functional relationships.

Jadoon, Asghar A. [Univ. of Texas, Austin, TX (Uni↗