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DOE OSTI2022

Prediction of local concentration fields in porous media with chemical reaction using a multi scale convolutional neural network

The study of solute transport in porous media is of interest in many chemical engineering systems. Some example applications include packed bed catalytic reactors, filtration devices, and batteries. The pore scale modeling of these systems is time consuming and may require large computing resources, for this reason computational fluid dynamics (CFD) simulations are not practical if a large number of simulations is required, like in multiscale modeling, where a model at a large scale calls for pore scale simulations. It has been shown that neural networks can be trained with a dataset of flow simulations and then predict fields orders of magnitude faster, and with less computational resources, in new domains. However, it is crucial to provide the neural network with an effective description of the domain and the undergoing operating conditions to be able to train models that generalize accurately in unseen samples. Therefore, research is needed to employ neural networks in new complex systems. The appropriate training of a network for predicting coupled flow and solute transport processes is an outstanding problem due to the complex interplay between geometry and operating conditions. In this work, we train a multi scale convolutional neural network (MSNet) with a diverse dataset of simulations of transport and chemical reaction in porous media to predict the local concentration fields in images of porous media. Our dataset contains a wide diversity of sphere pack arrangements under different operating conditions (Péclet and Reynolds numbers). Further, we train a robust model by employing different input descriptors that represent the medium and the different operating conditions of each system. Our trained model is able to provide nearly instantaneous predictions, compared to around twenty hours of the CFD workflow, with less than 3.5% error on new geometries and transport conditions. Thus the model could be easily integrated in a multiscale workflow where fast response is needed.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

NASA NTRS2018

2040 Vision: A Roadmap for Integrated, Multiscale Materials and System Modeling and Simulation

Over the last few decades, advances in high-performance computing, new materials characterization methods, and, more recently, an emphasis on integrated computational materials engineering (ICME) and additive manufacturing have been a catalyst for multiscale modeling and simulation-based design of materials and structures in the aerospace industry. While these advances have driven significant progress in the development of aerospace components and systems, that progress has been limited by persistent technology and infrastructure challenges that must be overcome to realize the full potential of integrated materials and systems design and simulation modeling throughout the supply chain. As a result, NASA's Transformational Tools and Technology (TTT) Project sponsored a study (performed by a team led by Pratt & Whitney) to define the potential 25-year future state required for integrated multiscale modeling of materials and systems (e.g., load-bearing structures) to accelerate the pace and reduce the expense of innovation in future aerospace and aeronautical systems. This talk will describe the findings of this 2040 Vision study (e.g., the 2040 vision state; the required interdependent core technical work areas, Key Element (KE); associated critical gaps and actions to close those gaps; and major recommendations). This roadmap is a community consensus document and is a result of over 450 professionals input obtain via: i) four society workshops (AIAA, NAFEMS, and two TMS), ii) community-wide survey, and iii) the establishment of 9 expert panels (one per key element) consisting on average 10 non-team members from academia, government and industry to review, update content, and prioritize gaps and actions. It is NASA's hope and desire that this roadmap provides the strategic guidance to both public and private research and development decision makers to make the proposed 2040 vision state a reality and thereby provide a significant advancement in the United States global competitiveness.

Multiscale Modeling↗

NASA NTRS2009

A Method for Combining Experimentation and Molecular Dynamics Simulation to Improve Cohesive Zone Models for Metallic Microstructures

Fracture processes within a material begin at the nanometer length scale at which the formation, propagation, and interaction of fundamental damage mechanisms occur. Physics-based modeling of these atomic processes quickly becomes computationally intractable as the system size increases. Thus, a multiscale modeling method, based on the aggregation of fundamental damage processes occurring at the nanoscale within a cohesive zone model, is under development and will enable computationally feasible and physically meaningful microscale fracture simulation in polycrystalline metals. This method employs atomistic simulation to provide an optimization loop with an initial prediction of a cohesive zone model (CZM). This initial CZM is then applied at the crack front region within a finite element model. The optimization procedure iterates upon the CZM until the finite element model acceptably reproduces the near-crack-front displacement fields obtained from experimental observation. With this approach, a comparison can be made between the original CZM predicted by atomistic simulation and the converged CZM that is based on experimental observation. Comparison of the two CZMs gives insight into how atomistic simulation scales.

Hochhalter, J. D.↗

DOE OSTI2023

Evaluation of present-day extreme precipitation over the United States: an inter-comparison of convection and dynamic permitting configurations of E3SMv1

Abstract Accurate simulation of the present-day characteristics of mean and extreme precipitation at regional scales remains a challenge for Earth system models, which is due in part to deficiencies in model physics such as convective parameterization (CP), and coarse resolution. High horizontal resolution (HR, ∼25 km) and multiscale modeling framework (MMF, i.e. replacing conventional CP with embedded km-scale cloud-resolving models) are two promising directions that could help improve the interaction between subgrid-scale physical processes and large-scale climate. Here, we evaluate simulated extreme precipitation over the United States (US) across three configurations (i.e. low-resolution [LR], HR, and MMF) of the Energy Exascale Earth System Model (E3SMv1) and intercompare them against two gridded observation datasets (climate prediction center daily US precipitation and integrated multi-satellite retrievals for global precipitation measurement). We assess the model’s ability to simulate very heavy seasonal precipitation (illustrated by the difference between the 99th and 90th percentile values) as well as the spatial distributions of several extreme precipitation indices defined by the expert team on climate change detection and indices. Our results show that both the dry (i.e. consecutive dry days (CDD)) and wet (i.e. consecutive wet days, maximum 5 day precipitation, and very wet days) extremes evaluated herein show some improvement as well as degradation with MMF and HR relative to LR. These results vary across seasons and US subregions. For instance, only the very heavy precipitation of winter is improved with MMF and HR. Both configurations alleviate the well-known drizzling bias evident in LR across both winter and summer in many parts of the US, largely due to the overall improvement in intensity and frequency of precipitation. Additionally, our results suggest that while E3SMv1-MMF has higher intensity rates when it does rain, it has too many CDD during the summer, contributing to a low mean precipitation bias.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2020

A Quantum-Based Approach to Predict Primary Radiation Damage in Polymeric Networks

Initial atomistic-level radiation damage in chemically reactive materials is thought to induce reaction cascades that can result in undesirable degradation of macroscale properties. Ensembles of quantum-based molecular dynamics (QMD) simulations can accurately predict these cascades, but extracting chemical insights from the many underlying trajectories is a labor-intensive process that can require substantial a priori intuition. We develop here a general and automated graph-based approach to extract all chemically distinct structures sampled in QMD simulations and apply our approach to predict primary radiation damage of polydimethylsiloxane (PDMS), the main constituent of silicones. A postprocessing protocol is developed to identify underlying polymer backbone structures as connected components in QMD trajectories. Furthermore, these backbones form a repository of radiation-damaged structures. A scheme for extracting and updating a library of isomorphically distinct structures is proposed to identify the spanning set and aid chemical interpretation of the repository. The analyses are applied to ensembles of cascade QMD simulations in which the four element types in PDMS are selectively excited in primary knock-on atom events. Our approach reveals a much higher degree of combinatorial complexity in this system than was inferred through radiolysis experiments. Probabilities are extracted for radiation-induced network changes including formation of branch points, carbon linkages, cycles, bond scissions, and carbon uptake into the Si–O siloxane backbone network. The general analysis framework presented here is readily extendable to modeling chemical degradation of other polymers and molecular materials and provides a basis for future quantum-informed multiscale modeling of radiation damage.

36 MATERIALS SCIENCE↗

DOE OSTI2025

The Capacity Expansion Regional Feasibility (CERF) Model: High-Resolution Power Plant Siting

Abstract This presentation gives an overview of the geospatial power plant siting model CERF. CERF (Capacity Expansion Regional Feasibility) is an open source Python package developed under the Integrated Multisector Multiscale Modeling (IM3) Project at PNNL. This presentation covers an overview of how the CERF model works, walks through various power plant siting analyses, and discusses future research opportunities for the model. The CERF model can be accessed at https://github.com/IMMM-SFA/cerf. PNNL Information Release Number: PNNL-SA-207336 Acknowledgment IM3 is a multi-institutional effort led by Pacific Northwest National Laboratory and supported by the U.S. Department of Energy's Office of Science as part of research in MultiSector Dynamics, Earth and Environmental Systems Modeling Program.

Mongird, Kendall [Pacific Northwest National Labor↗

DOE OSTI2023

BISON Fuel Fragmentation Relocation and Dispersal (FFRD) Assessment Database for Eventual Use in Bayesian Calibration

Existing light-water reactor (LWR) fuel vendors have been interested in seeking increased discharge burnups of nuclear fuel rods for improved economics for quite a few years. With increased burnups come additional challenges that must be addressed. It has been experimentally observed that average burnups higher than the current regulatory limit of 62 MWd/kgU may undergo fuel fragmentation, relocation, and dispersal (FFRD) during a loss-of-coolant accident (LOCA). Industry must demonstrate approaches to mitigate FFRD. In an effort to support industry, the Nuclear Energy Advanced Modeling and Simulation (NEAMS) program within the U.S. Department of Energy (DOE) has for several years invested in developing multiscale models and creating a validation/assessment database for these models to study the mechanisms driving FFRD. This report provides an update on changes made to the assessment database and new models added to BISON to support the study of fuel rod behavior during FFRD. An effort has been initiated this year to begin adding dedicated inputs to the publicly available Virtual Test Bed (VTB) repository for industry use. A section of this report details the efforts made in this area. NEAMS has recently developed new capabilities in the Multiphysics Object-Oriented Simulation Environment (MOOSE) framework’s stochastic tools module for calibration using Bayesian inference. The goal in the future is to use these capabilities to calibrate and identify weaknesses in the existing BISON models for FFRD. The report concludes with a discussion on the models most likely to benefit the most from such calibration.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

NASA NTRSDate not supplied

Advances in Design Capabilities for Planetary Missions from the NASA Entry Systems Modeling and Instrumentation Portfolio

The Entry Systems Modeling project (ESM) is supported by both the NASA Space Technology and the Science Mission Directorates and focuses on developing simulation tools and validated models for characterizing the performance of entry systems tailored to planetary destinations across the Solar System. ESM is organized into six technical capability areas that together address all relevant factors related to spacecraft entry, as well as some aspects of descent: Thermal Protection System (TPS) Materials; Aerothermodynamics; Entry & Descent Vehicle Dynamics; Guidance, Navigation, and Control; Vehicle Systems Analysis; and Advanced Tools and Numerical Methods. Development within the capability areas is undertaken explicitly with a focus on transition and infusion to science missions, human exploration missions, and commercial space activities. The present talk details developments that specifically impact science missions, including simulation tool capabilities that aid in mission design and model development to understand entry system performance at a given destination. Examples of the successful infusion and transition of such project outcomes to science missions also are provided. Several simulation tool development efforts within ESM have resulted in new design capabilities for missions. One such outcome is improved toolsets for mission trajectory and concept of operations design. Specifically, an initiative to couple a leading tool for entry, ascent/descent, and orbital trajectory optimization (Program to Optimize Simulated Trajectories II or POST2) to those used within the Agency for interplanetary trajectory optimization (Copernicus and Monte) has made substantial progress, with the outcomes to date promising to allow efficient trajectory optimization across mission phases. Additionally, toolchains for the evaluation of vehicle performance during entry and descent have been developed that allow assessment of multi-dimensional aeroheating on detailed vehicle geometries, characterization of deployment and inflation of parachutes, and assessment of vehicle dynamic stability during descent. These capabilities are achieved by coupling diverse sets of physics together – material response, computational fluid dynamics, radiation, and vehicle dynamics – to suitably describe complex entry and descent phenomena. Several model development and validation efforts for specific destinations and entry regimes also are underway within the ESM project. For instance, new experimental capabilities to validate radiation models at low densities/high altitudes recently have been established with project support, specifically the Low-Density Shock Tube (LDST) at the NASA Ames Research Center Electric Arc Shock Tube (EAST) facility. The LDST is being leveraged to develop improved models of shock layer kinetics and radiation in Titan atmospheres, while future studies will be conducted in the LDST and the existing high velocity shock tube to provide validation data for radiation models of Venus, Ice Giants, and Mars atmospheres. Models describing the aerothermal and thermo-structural performance of Thermal Protection System (TPS) materials has been another focus, with multiscale modeling activities on-going for the two leading TPS materials applicable to a range of entry conditions and science missions: the Phenolic-Impregnated Carbon Ablator (PICA) and woven materials like 3D Mid-Density Carbon Phenolic (3MDCP). A continual effort is made to infuse and transition outcomes from ESM simulation tool and model development activities into relevant science missions. Significant progress has been made on this front, with missions such as Dragonfly, DAVINCI, and Mars Missions benefitting from project outcomes. The groundwork also is being laid to provide insights into forward looking missions to Gas/Ice Giants as well as for potential sample returns.

Justin Haskins↗

DOE OSTI2021

A mechanistic damage model for solid oxide fuel cell ceramic materials - Part I: Constitutive modeling

A multiscale mechanistic damage model for solid oxide fuel cell (SOFC) ceramics that combines micromechanics of stiffness reduction due to material porosity change and microcracking with a continuum damage mechanics (CDM) description for the evolution of microcracks up to fracture is developed in this work. The model also accounts for volumetric swelling of the anode due to redox cycling. Porosity change and swelling during redox combined with normal operating thermomechanical loads could increase the stress, strain and damage distributions in SOFC stacks leading them to failure. The proposed model involves three governing parameters: (i) the porosity in terms of the pore or void volume fraction, (ii) material swelling magnitude prescribed at a given loading step, and (iii) the damage variable that describes microcracking caused by thermomechanical loads and swelling. Pores and microcracks in the ceramics are modeled as randomly distributed ellipsoidal inclusions with negligible stiffness by an Eshelby-Mori-Tanaka formulation combined with an inclusion orientation distribution method. Microcracking damage evolution is described by a CDM formulation. Volumetric swelling is treated in a similar way to thermal expansion in the constitutive relations. After validation and numerical checks, the damage model is used to analyze a simplified SOFC positive-electrode/electrolyte/negative-electrode (PEN) structure subjected a redox cycle in addition to thermomechanical loads experienced during normal operation of a SOFC stack.

30 DIRECT ENERGY CONVERSION↗

DOE OSTI2022

Load‐Balancing Intense Physics Calculations to Embed Regionalized High‐Resolution Cloud Resolving Models in the E3SM and CESM Climate Models

Abstract We design a new strategy to load‐balance high‐intensity sub‐grid atmospheric physics calculations restricted to a small fraction of a global climate simulation's domain. We show why the current parallel load balancing infrastructure of Community Earth System Model (CESM) and Energy Exascale Earth Model (E3SM) cannot efficiently handle this scenario at large core counts. As an example, we study an unusual configuration of the E3SM Multiscale Modeling Framework (MMF) that embeds a binary mixture of two separate cloud‐resolving model grid structures that is attractive for low cloud feedback studies. Less than a third of the planet uses high‐resolution (MMF‐HR; sub‐km horizontal grid spacing) relative to standard low‐resolution (MMF‐LR) cloud superparameterization elsewhere. To enable MMF runs with Multi‐Domain cloud resolving models (CRMs), our load balancing theory predicts the most efficient computational scale as a function of the high‐intensity work's relative overhead and its fractional coverage. The scheme successfully maximizes model throughput and minimizes model cost relative to precursor infrastructure, effectively by devoting the vast majority of the processor pool to operate on the few high‐intensity (and rate‐limiting) high‐resolution (HR) grid columns. Two examples prove the concept, showing that minor artifacts can be introduced near the HR/low‐resolution CRM grid transition boundary on idealized aquaplanets, but are minimal in operationally relevant real‐geography settings. As intended, within the high (low) resolution area, our Multi‐Domain CRM simulations exhibit cloud fraction and shortwave reflection convergent to standard baseline tests that use globally homogenous MMF‐LR and MMF‐HR. We suggest this approach can open up a range of creative multi‐resolution climate experiments without requiring unduly large allocations of computational resources.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2025

A rheological model for loose sands with insights from DEM

A rheological model for loose granular media is developed to capture both solid-like and fluid-like responses during shearing. The proposed model is built by following the mathematical structure of an extended Kelvin–Voigt model, where an elastic spring and plastic slider act in parallel to a viscous damper. This arrangement requires the partition of the total stress into rate-independent and rate-dependent stress components. To model the solid-like behavior, a simple frictional plasticity model is adopted without modifications, thus contributing to the rate-independent stress. Instead, the fluid-like or rate-dependent stress is further decomposed into deviatoric and volumetric parts, by proposing a new formulation based on a combination of the μ(I) relation, originally developed under pressure-controlled shear, with a pressure-shear rate relation derived under volume-controlled shear. The proposed formulation allows the model to capture both the increase in the friction coefficient and the enhanced dilation at high shear rates. High-fidelity simulation data, obtained from discrete element method and multiscale modelling, are used to evaluate the performance of the proposed constitutive model. The model provides accurate results under both drained and undrained simple shear paths across a wide range of shear rates. Furthermore, it successfully reproduces at much lower computational cost the flowslide mobility computed through multiscale simulations, which is primarily regulated by the shear rate dependence of the material properties during the dynamic runout stage.

Elasticity↗

NASA NTRS1997

Advanced Modeling Techniques to Study Anthropogenic Influences on Atmospheric Chemical Budgets

This research work is a collaborative effort between research groups at MCNC and the University of North Carolina at Chapel Hill. The overall objective of this research is to improve the level of understanding of the processes that determine the budgets of chemically and radiatively active compounds in the atmosphere through development and application of advanced methods for calculating the chemical change in atmospheric models. The research performed during the second year of this project focused on four major aspects: (1) The continued development and refinement of multiscale modeling techniques to address the issue of the disparate scales of the physico-chemical processes that govern the fate of atmospheric pollutants; (2) Development and application of analysis methods utilizing process and mass balance techniques to increase the interpretive powers of atmospheric models and to aid in complementary analysis of model predictions and observations; (3) Development of meteorological and emission inputs for initial application of the chemistry/transport model over the north Atlantic region; and, (4) The continued development and implementation of a totally new adaptive chemistry representation that changes the details of what is represented as the underlying conditions change.

Mathur, Rohit↗

DOE OSTI2024

20A44-121: Modeling and characterization of α-U to accelerate metallic fuels development [Slides]

This presentation contains a high-level description of the Idaho National Laboratory Laboratory Directed Research and Development (LDRD) project, 20A44-121: Modeling and characterization of α-U to accelerate metallic fuels development. It frames the problem, describes a motivation, outlines the research plan involving multiscale modeling and experiments, discusses impact and details research developments.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

NASA NTRSDate not supplied

Multiscale and Multifidelity Modeling of a 3D Woven Composite Thermal Protection System

Complex three-dimensional (3D) woven composites have been considered by multiple NASA projects in recent years as a means of offering improved mechanical and thermal performance over traditional laminated composite systems. Parallel efforts have focused on developing simulation capabilities for these systems, which have traditionally and heavily relied on experimental testing to evaluate composite performance. One system is the Heatshield for Extreme Entry Environment Technology (HEEET), which is being considered for the thermal protection system on reentry spacecraft. Optical microscopy was used to characterize the blended carbon and phenolic fiber tows. A section of HEEET insulation layer was imaged with high-resolution micro-computed tomography (microCT) and segmented to separate individual tows, porous matrix, and voids. These data were used to develop multiscale thermomechanical computational models within the NASA Multiscale Analysis Tool (NASMAT). Two NASMAT modeling approaches were considered to capture the details of the 3D woven architecture: a coarse model appropriate for inclusion in multiscale structural analyses and a high-fidelity model created by downsampling the microCT data. Both elastic and thermal properties were computed and compared. The feasibility and challenges associated with modeling complex, hybrid 3D woven composites were also addressed.

NASMAT↗

DOE OSTI2025

Cross-Scale Catalyst Modeling Applied to H 2 Storage and Release via Formic Acid

Here, we propose the Systems-to-Atoms (S2A) modeling framework that integrates the kinetics of reaction chemistry and structural configurations across various length scales with the aim of establishing a versatile template for multiscale modeling of reactive flow problems and to predict the operando activity of catalyst materials. The approach encompasses a microkinetic model to analyze surface reactions on individual facets of catalyst nanoparticles coupled with the computation of average surface reaction rates for catalyst nanoparticles of specific size distributions. Macro-homogeneous surface reaction kinetics are derived as a function of catalyst loading and used as input parameters for the continuum-scale reactor model. The cross-scale framework enables the optimization of catalyst utilization through reactor design and operating strategy. To demonstrate the framework, we studied the storage and release of hydrogen from formic acid, a promising liquid organic hydrogen carrier (LOHC), over Pd, Pt, and Cu catalysts. The framework predicts observed trends in formic acid dehydrogenation activity for catalysts with comparable weight loadings and metal particle diameters, demonstrating satisfactory quantitative alignment. Finally, the seamless transmission of parameter uncertainties between scales is also discussed.

08 HYDROGEN↗

DOE OSTI2023

Intermittent Defect Fluctuations in Oxide Heterostructures

Abstract The heterogeneous nature, local presence, and dynamic evolution of defects typically govern the ionic and electronic properties of a wide variety of functional materials. While the last 50 years have seen considerable efforts into development of new methods to identify the nature of defects in complex materials, such as the perovskite oxides, very little is known about defect dynamics and their influence on the functionality of a material. Here, the discovery of the intermittent behavior of point defects (oxygen vacancies) in oxide heterostructures employing X‐ray photon correlation spectroscopy is reported. Local fluctuations between two ordered phases in strained SrCoO x with different degrees of stability of the oxygen vacancies are observed. Ab‐initio‐informed phase‐field modeling reveals that fluctuations between the competing ordered phases are modulated by the oxygen ion/vacancy interaction energy and epitaxial strain. The results demonstrate how defect dynamics, evidenced by measurement and modeling of their temporal fluctuations, give rise to stochastic properties that now can be fully characterized using coherent X‐rays, coupled for the first time to multiscale modeling in functional complex oxide heterostructures. The study and its findings open new avenues for engineering the dynamical response of functional materials used in neuromorphic and electrochemical applications.

36 MATERIALS SCIENCE↗

DOE OSTI2023

Empirical and mechanistic transient fission gas release model for high-burnup LOCA conditions

In response to the nuclear industry desire to extend burnup beyond current licensing practices, the US Nuclear Regulatory Commission (NRC) released a research information letter (RIL) that provides a basis for analyzing fuel fragmentation, relocation, and dispersal (FFRD) in light-water reactors. Of the five elements discussed, the most ambiguous is the significance of transient fission gas (FG) release (FGR) (tFGR) and its effects on fuel performance under loss-of-coolant accident conditions. In fresh fuel, FG migration and eventual release is primarily governed by diffusion-based mechanisms at higher temperatures (>1,000 °C). However, the mechanisms governing FGR changes as burnup increases. More recent research indicates that FGR increases as burnup increases, specifically under temperature transient conditions, and this release occurs at lower temperatures with a new release mechanism. This behavior has been attributed to microcracking in the fuel and is likely related to microstructure embrittlement with the presence of over pressurized FG bubbles. The NRC RIL outlines the complexity of the phenomenon and a need for a deeper understanding to adequately address FFRD for regulatory application. Here, therefore, this manuscript intends to summarize the publicly available tFGR data and discuss the observed dependencies (e.g., burnup, heating rate, sample geometry, terminal temperature). An empirical model has been developed and benchmarked against recently published experimental data. However, this empirical model is limited to conditions for which fitting data exist and, therefore, a high-level discussion is included to provide a roadmap for atomistically-informed multiscale modeling in conjunction with experimental data collection to develop a mechanistic tFGR model widely applicable to a broad range of nuclear fuel conditions at high burnup.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2025

Development and Validation of MALAMUTE model for Electric Field Assisted Sintering of Structural Materials

Fusion power plant designs feature extreme material performance requirements for structural material candidates. In addition to conventional alloys, more advanced composites and oxide dispersion strengthened (ODS) alloys are being explored, however, achieving the desired microstructures to maximize performance using traditional manufacturing methods can be challenging. The advanced manufacturing (AM) electric field-assisted sintering (EFAS) technique offers improved control over the final microstructure through higher heating and cooling rates and moderate pressures. Modeling and simulation tools show promise in elucidating the process-structure-property-performance (PSPP) correlation for AM-produced parts, including the EFAS process. An inherently multiscale process, the EFAS technique aligns well with the multiscale modeling capability of the open-source Multiphysics Object-Oriented Simulation Environment (MOOSE)[cite]. We present here an electro-thermo-mechanical approach to modeling the EFAS process using the MOOSE Application Library for Advanced Manufacturing UTilitiEs (MALAMUTE) code. Prediction of the field and gradient distributions across the EFAS tooling is required to accurately describe the conditions for the lower-scale microstructural evolution models. In this work we present the MALAMUTE model developed to predict the electrical potential, temperature, and mechanical stress distribution across the EFAS graphite tooling and part at the larger engineering-scale. Validation of the MALAMUTE engineering-scale model is completed using data from experimental densification and pre-densified runs of iron powder via EFAS at 1000oC. These runs were conducted using a Thermal Technology DCS-5 EFAS system. Data collected during the experiment runs include the direct current (DC) supplied to the graphite tooling, the temperature of the graphite tooling as measured with a pyrometer, and the force applied to the top of the graphite tooling stack, and the data were recorded every 10 seconds. Our validation approach used the current and force data from the EFAS run as boundary condition inputs to the MAMALUTE simulation; the temperature data were used to evaluate the MALAMUTE EFAS model prediction. Results of the MALAMUTE simulations are employed to connect the external pyrometer temperature measurement to the temperature profile across the part undergoing consolidation. We investigate the impact of material property variation and mesh deformation on the temperature profile as predicted by MALAMUTE. We conclude by highlighting projects where the MALAMUTE EFAS modeling and simulation capabilities will be used to assist experimental design.

36 - MATERIALS SCIENCE↗