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DOE OSTI2025

A novel peridynamics-based approach to predict pharmaceutical tablet robustness

The pharmaceutical drug product development process can be greatly accelerated through the use of modeling and simulation techniques to predict the manufacturability and performance of a given formulation. The anticipation and possible mitigation of tablet damage due to manufacturing stresses represents a specific area of interest in the pharmaceutical industry for predicting formulation and tableting performance. While the finite element method (FEM) has been extensively used for predicting the mechanical behavior of powder material in the compaction processes, a shortcoming of the approach is the inherent difficulty to predict discontinuities (e.g., damage or cracking) within a tablet as FEM is a continuum-based approach. In this work, we propose a novel method utilizing peridynamics (PD), a numerical method that can capture discontinuities such as tablet fracture, to predict the evolution of damage and breakage in pharmaceutical tablets. The approach links (1) the finite element method – to elucidate the behavior of powders during die compaction – with (2) the peridynamics modeling technique – to model the discontinuous nature of damage and predict tablet breakage during the critical stages of unloading and ejection from the compression die. This short communication presents a proof of concept including a workflow to calibrate the linked FEM-PD simulation models. Further, it demonstrates promising results from a preliminary experimental validation of the approach. Following further development, this approach could be used to guide the optimization of compression processes through targeted changes to formulation material properties, compression process conditions, and/or tooling geometries to deliver improved process efficiency and tablet robustness.

36 MATERIALS SCIENCE↗

DOE OSTI2023

Transformer Leakage Inductance Design Methodology

The leakage inductance exhibited by a transformer depends on its winding geometry, which generally involves the selection of several key design parameters in addition to the winding structure and the interleaving configuration. With few resources explaining the effects of these design choices on the observed leakage inductance, numerous trial-and-error iterations become necessary to realize the desired leakage inductance. This paper explores more than a hundred winding geometries feasible in a 2-winding transformer comprising the same magnetic core, number of turns, and wire gauge, and finds the leakage inductance for each unique design using 2-D finite element method (FEM) simulations in association with the semi-analytical double- 2-D model. These leakage inductances are plotted and further analyzed to understand the effects of different design parameters on the effective leakage inductance. The results presented herein and the conclusions drawn from this research can serve as a valuable resource for future design practitioners from both industry and academia.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2019

The Oxidation Mechanism of Pure Magnesium Powder Particles: A Mathematical Approach

In this study, the mechanism of nonisothermal oxidation of magnesium powder was determined using a tension analysis, which was performed by mathematical modeling and the finite element method. The results revealed that phase transformation of magnesium hydroxide to magnesium oxide in the oxide layer plays an important role in this process so that formation of magnesium hydroxide in the early stages of oxidation (< 450 °C) leads to the formation of compressive stresses through the oxide layer, and as a result, the beginning of measurable oxidation is delayed. The results obtained by the mathematical model and finite element method were validated by the experimental results.

36 MATERIALS SCIENCE↗

DOE OSTI2021

NEAMS TH CRAB

The MOOSE framework is a library designed to make it straightforward for physicists and engineers to model partial differential equations using finite element and finite volume methods. Finite elements have been a part of the framework library since MOOSE's inception over a decade ago. Initial finite volume capability, however, was added only as recently as May of 2020. Since that time, significant work has been conducted to develop fluid modeling capability based on the finite volume method. Much of this work has taken place in MOOSE's navier_stokes module and in the NEAMS program's coarse mesh CFD code Pronghorn. We report here on development in MOOSE and Pronghorn of incompressible, porous incompressible, and weakly compressible finite volume simulation capabilities and their application to modeling of MSR and FHR advanced reactor concepts.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2025

Enriched immersed finite element and isogeometric analysis: algorithms and data structures

Immersed finite element methods provide a convenient analysis framework for problems involving geometrically complex domains, such as those found in topology optimization and microstructures for engineered materials. However, their implementation remains a major challenge due to, among other things, the need to apply nontrivial stabilization schemes and generate custom quadrature rules. This article introduces the robust and computationally efficient algorithms and data structures comprising an immersed finite element preprocessing framework. The input to the preprocessor consists of a background mesh and one or more geometries defined on its domain. The output is structured into groups of elements with custom quadrature rules formatted such that common finite element assembly routines may be used without or with only minimal modifications. The key to the preprocessing framework is the construction of material topology information, concurrently with the generation of a quadrature rule, which is then used to perform enrichment and generate stabilization rules. While the algorithmic framework applies to a wide range of immersed finite element methods using different types of meshes, integration, and stabilization schemes, the preprocessor is presented within the context of the extended isogeometric analysis. This method utilizes a structured B-spline mesh, a generalized Heaviside enrichment strategy considering the material layout within individual basis functions’ supports, and face-oriented ghost stabilization. Using a set of examples, the effectiveness of the enrichment and stabilization strategies is demonstrated alongside the preprocessor’s robustness in geometric edge cases. Additionally, the performance and parallel scalability of the implementation are evaluated.

Computer implementation↗

DOE OSTI2013

Nonlinear diffusion acceleration for the multigroup transport equation discretized with S{sub N} and continuous FEM with rattlesnake

Nonlinear diffusion acceleration (NDA) can improve the performance of a neutron transport solver significantly especially for the multigroup eigenvalue problems. The high-order transport equation and the transport-corrected low-order diffusion equation form a nonlinear system in NDA, which can be solved via a Picard iteration. The consistency of the correction of the low-order equation is important to ensure the stabilization and effectiveness of the iteration. It also makes the low-order equation preserve the scalar flux of the high-order equation. In this paper, the consistent correction for a particular discretization scheme, self-adjoint angular flux (SAAF) formulation with discrete ordinates method (S{sub N}) and continuous finite element method (CFEM) is proposed for the multigroup neutron transport equation. Equations with the anisotropic scatterings and a void treatment are included. The Picard iteration with this scheme has been implemented and tested with RattleS{sub N}ake, a MOOSE-based application at INL. Convergence results are presented. (authors)

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2018

Hybrid Finite Element--Spectral Method for the Fractional Laplacian: Approximation Theory and Efficient Solver

Here, a numerical scheme is presented for approximating fractional order Poisson problems in two and three dimensions. The scheme is based on reformulating the original problem posed over $\Omega$ on the extruded domain $\mathcal{C}=\Omega\times[0,\infty)$ following. The resulting degenerate elliptic integer order PDE is then approximated using a hybrid FEM-spectral scheme. Finite elements are used in the direction parallel to the problem domain $\Omega$, and an appropriate spectral method is used in the extruded direction. The spectral part of the scheme requires that we approximate the true eigenvalues of the integer order Laplacian over $\Omega$. We derive an a priori error estimate which takes account of the error arising from using an approximation in place of the true eigenvalues. We further present a strategy for choosing approximations of the eigenvalues based on Weyl's law and finite element discretizations of the eigenvalue problem. The system of linear algebraic equations arising from the hybrid FEM-spectral scheme is decomposed into blocks which can be solved effectively using standard iterative solvers such as multigrid and conjugate gradient. Numerical examples in two and three dimensions suggest that the approach is quasi-optimal in terms of complexity.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2025

Advanced System Thermal Fluids Solver Development for SAM

This work summarizes a feasibility study on testing numerical algorithms that are suitable and efficient for advanced system analysis code development under the mutli-physics framework, MOOSE. The key is the implementation of a high-order one-dimensional staggered-grid finite volume method (SG-FVM), and its direct interaction with the linear/nonlinear solver, PETSc. Leveraging the existing capabilities of the SAM code, significant code coverages were established in the finite volume method code. This in turn allows for a suite of test problems with different problem sizes and levels of complexity to be used to quantify the performance improvement of the finite volume method code. As evidently shown in this study, the implemented SG-FVM demonstrated superior performance improvement against a direct finite element method implementation through MOOSE for the wide range of selected problems. On two computer systems, the speedup was observed to be significant, with at least one order of magnitude of solving time reduction. In addition, for a complex reactor model, transient simulation was performed using the finite volume method code, the results of which agree very well with the reference results from the finite element method code. Overall, this study demonstrates a successful feasibility study on the proposed numerical algorithms and software structure to support advanced system analysis tool development. In this work, short-term priority development and testing items were identified, and long-term code adoption and integration plans were made for the eventual deployment of the finite volume method in the SAM code.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗

DOE OSTI2016

A novel Lagrangian approach for the stable numerical simulation of fault and fracture mechanics

The simulation of the mechanics of geological faults and fractures is of paramount importance in several applications, such as ensuring the safety of the underground storage of wastes and hydrocarbons or predicting the possible seismicity triggered by the production and injection of subsurface fluids. However, the stable numerical modeling of ground ruptures is still an open issue. The present work introduces a novel formulation based on the use of the Lagrange multipliers to prescribe the constraints on the contact surfaces. The variational formulation is modified in order to take into account the frictional work along the activated fault portion according to the principle of maximum plastic dissipation. The numerical model, developed in the framework of the Finite Element method, provides stable solutions with a fast convergence of the non-linear problem. The stabilizing properties of the proposed model are emphasized with the aid of a realistic numerical example dealing with the generation of ground fractures due to groundwater withdrawal in arid regions. - Highlights: • A numerical model is developed for the simulation of fault and fracture mechanics. • The model is implemented in the framework of the Finite Element method and with the aid of Lagrange multipliers. • The proposed formulation introduces a new contribution due to the frictional work on the portion of activated fault. • The resulting algorithm is highly non-linear as the portion of activated fault is itself unknown. • The numerical solution is validated against analytical results and proves to be stable also in realistic applications.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2017

The shifted boundary method for embedded domain computations. Part I: Poisson and Stokes problems

We propose a new finite element method for embedded domain computations, which falls in the category of surrogate/approximate boundary algorithms. The key feature of the proposed approach is the idea of shifting the location where boundary conditions are applied from the true to the surrogate boundary, and to appropriately modify the shifted boundary conditions, enforced weakly, in order to preserve optimal convergence rates of the numerical solution. This process yields a method which, in our view, is simple, efficient, and also robust, since it is not affected by the small-cut-cell problem. Although general in nature, here we apply this new concept to the Poisson and Stokes problems. We present in particular the full analysis of stability and convergence for the case of the Poisson operator, and numerical tests for both the Poisson and Stokes equations, for geometries of progressively higher complexity.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2017

Simulation of the RPI Reactor Critical Facility Core Using High-Fidelity Neutronics Code PROTEUS

The PROTEUS code is a high-fidelity three-dimensional (3D) deterministic neutron transport code developed by ANL under the DOE Nuclear Energy Advanced Modeling and Simulation (NEAMS) program. The code contains the SN2ND (second order discrete ordinates method) and two MOC transport solvers, MOCFE and MOCEX (first order methods of characteristics), based on unstructured finite element meshes which allow users to model complex or unconventional geometry reactor problems. Among the two MOC solvers which normally perform better than SN for heterogeneous geometry problems, MOCEX is based on a rigorous formulation using the two-dimensional (2D) MOC radially and the discontinuous Galerkin finite element method axially to overcome the drawbacks of MOCFE with the full 3D MOC representation which requires enormous memory and computational efforts. The Reactor Critical Facility (RCF), an open tank research reactor at the Rensselaer Polytechnic Institute (RPI), became operational in 1956 under the American Locomotive company and has been operating using low-enriched uranium fuel pins, which makes it the only university research facility to use fuel rods similar to operating commercial light water reactors (LWRs). This paper presents modeling and simulation results of the RCF using PROTEUS for code verification and validation which also supports an ongoing NEUP project in which a set of benchmark validation experiments for multiphysics coupling is being developed.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2013

Preserving spherical symmetry in axisymmetric coordinates for diffusion problems

Persevering symmetric solutions, even in the under-converged limit, is important to the robustness of production simulation codes. We explore the symmetry preservation in both a continuous nodal and a mixed finite element method. In their standard formulation, neither method preserves spherical solution symmetry in axisymmetric (RZ) coordinates. We propose two methods, one for each family of finite elements, that recover spherical symmetry for low-order finite elements on linear or curvilinear meshes. This is a first step toward understanding achieving symmetry for higher-order elements. (authors)

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗

DOE OSTI2020

NRC Multiphysics Analysis Capability Deployment FY2020: Part 3

This report details progress and activities of Idaho National Laboratory (INL) on the Nuclear Regulatory Commission (NRC) project “Development and Modeling Sup- port for Advanced Non-Light Water Reactors.” The tasks completed for this report are: Task2c: Explicit modeling of pebble transient temperature response. In this simulation, the 400 MWth Pebble-Bed Modular Reactor (PBMR) design, PBMR- 400, experiences a 20-second power ramp from 100% to 150% power. This is followed by a similar reduction in the power back to 100%. Several multiscale pebble coupling approaches are tested with one pebble per mesh element in the active core region. The results show good conservation behavior and the stability of the coupling.; Extended scope part 1: An assessment of the computational efficiency of the Discontinuous Finite Element Method (DFEM) heat transfer solver shows good scalability. The DFEM solver is a factor of 4 more expensive in solution time than the Finite Element Method (FEM) solver for heat transfer problems due to the increased number of degrees of freedom. Nonetheless, the DFEM approach provides the user with the flexibility to model gap heat transfer problems.; Extended scope part 2: The GapHeatTransferInterfaceMaterial was improved to give the user increased flexibility with the modeling of heat transfer through gaps with the DFEM solver. A number of gap parameters can now be coupled both through functions and variables.; Extended scope part 3: Demonstration of how the gap width between hexagonal fuel cells can be calculated during a heat-up transient and used in the GapHeatTransferInterface model. A full-domain DFEM model with gap expansion is coupled to a SubApp that models the thermal expansion of the base plate. The results show the expected physical behavior, although have not been fully bench-marked at this point in time.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2019

Experimental and 3D Micromechanical Analysis of Stress–Strain Behavior and Damage Initiation in Dual-Phase Steels

In the recent decade, dual-phase steel has been used extensively in the industry due to its high strength and formability. In this paper, deformation pattern and mechanical behavior of DP steel are predicted using the 2D and 3D representative volume element (RVE) and finite elements method. Also, the obtained results were compared with the experimental SEM images. The experiments are performed in three stages to obtain the stress–strain curve and failure pattern in the specimens with the different state of stress distribution at the test sections. In the 3D state of stress, the state of applied stress to the RVE is obtained from macro-modeling of the test specimens and this model was analyzed using the finite element method. Furthermore, the effects of volume fraction and mesh size in 3D simulation on the stress–strain behavior are investigated. Metallography and SEM images are also used to access the failure mechanism at the microscale. It is shown that the martensite particles remain almost in their original form and their deformations are very small for the specimens with the thickness-to-width ratio of 0.8 (3D state of stress). This phenomenon is completely different from those obtained for smaller thickness-to-width ratio that the martensite particles were pulled and its length was increased. On the other hand, SEM images show that voids are located in the phase boundaries. According to the experimental and numerical results, although the main factor in the formation and growth of 2D voids is shear stress, in the 3D state of stress, the voids grow in spherical form due to the existence of large hydrostatic stresses.

36 MATERIALS SCIENCE↗

DOE OSTI2022

Deep Learning-Assisted Real-Time Forward Modeling of Electromagnetic Logging in Complex Formations

Higher dimensional (i.e., 2-D and 3-D) modeling is indispensable to correctly evaluate the responses of electromagnetic logging tools in complex formation environments. However, limited by the high computational cost of rigorous modeling such as finite difference method and the finite element method, the real-time applications in the well logging industry primarily rely on the 1-D forward solver, which would result in erroneous formation evaluation for complex scenarios. As a result, aiming at realizing fast modeling for electromagnetic logging tools in complex formations, this paper proposes a general framework assisted by deep neural networks (DNNs). The framework consists of three modules: earth model classification, parameter extraction, and surrogate construction. Separate DNNs are trained and tested for different modules. The accuracy and efficiency of the DNN assisted fast modeling are validated by several experiments. Here, this study finds that the fast modeling assisted by DNNs is able to calculate the tool responses and reconstruct the subsurface formations in real-time.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2018

Sierra/RKPM: Current State and Applications

The Reproducing Kernel Particle Method (RKPM), a meshfree method, has been implemented in Sandia's Sierra/Solid Mechanics in a collaboration between Sandia and the University of California San Diego's Center for Extreme Events Research (UCSD/CEER). Meshfree methods, like RKPM, have an advantage over mesh-based methods, like the Finite Element Method (FEM), in applications where achieving or maintaining a quality mesh becomes burdensome or impractical. For example, using FEM for problems with very large deformations will result in poor element Jacobians which causes problems with the parametric mapping. RKPM constructs the approximation functions in the physical domain, circumventing the parametric mapping issue. Also, reconstructing the approximation functions at very large deformations is straight-forward. RKPM has an advantage over traditional meshfree methods such as Smoothed-Particle Hydrodynamics (SPH) due to its ability to reproduce linear or higher-order functions exactly. This removes the tensile instabilities that are present in SPH and allows preservation of angular momentum. The point of this memo is to explore the capabilities and limitations of the current implementation by testing it on three different applications: 1) a quasi-static ductile shearing problem 2) a dynamic concrete panel perforation problem and 3) a set of dynamic metal panel perforation problems. In summary, areas where RKPM appears to be a promising alternative to current methods have been identified. Also, outstanding inefficiencies and issues (bugs) with code are noted, ways to improve the capabilities using material from literature are mentioned and areas deserving of new research are highlighted.

42 ENGINEERING↗

DOE OSTI2019

Initial Simulations of Empty Room Collapse and Reconsolidation at the Waste Isolation Pilot Plant

The Waste Isolation Pilot Plant (WIPP) is a geologic repository for defense-related nuclear waste. If left undisturbed, the virtually impermeable rock salt surrounding the repository will isolate the nuclear waste from the biosphere. If humans accidentally intrude into the repository in the future, then the likelihood of a radionuclide release to the biosphere will depend significantly on the porosity and permeability of the repository itself. Room ceilings and walls at the WIPP tend to collapse over time, causing rubble piles to form on floors of empty rooms. The surrounding rock formation will gradually compact these rubble piles until they eventually become solid salt, but the length of time for a rubble pile to reach a certain porosity and permeability is unknown. This report details the first efforts to build models to predict the porosity and permeability evolution of an empty room as it closes. Conventional geomechanical numerical methods would struggle to model empty room collapse and rubble pile consolidation, so three different meshless methods, the Immersed Isogeometric Analysis Meshfree, Reproducing Kernel Particle Method (RKPM), and the Conformal Reproducing Kernel method, were assessed. First, the meshless methods and the finite element method each simulated gradual room closure, without ceiling or wall collapse. All three methods produced equivalent room closure predictions with comparable computational speed. Second, the Immersed Isogeometric Analysis Meshfree method and RKPM simulated two-dimensional empty room collapse and rubble pile consolidation. Both methods successfully simulated large viscoplastic deformations, fracture, and rubble pile rearrangement to produce qualitatively realistic results. In addition to geomechanical simulations, the flow channels in damaged salt and crushed salt were measured using micro-computed tomography, and input into a computational fluid dynamics simulation to predict the salt's permeability. Although room for improvement exists, the current simulation approaches appear promising.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2015

Convergence study of Rattlesnake solutions for the two-dimensional C5G7 MOX benchmark

This paper presents the convergence study of a specific transport scheme, self-adjoint angular flux (SAAF) formulation with the discrete ordinates (SN) method and continuous finite element method (CFEM), implemented with Rattlesnake, on solving the well known two-dimensional C5G7 MOX benchmark. Both the convergence in space and angle are studied. Numerical results show the convergence of the spatial and angular refinements.

Benchmark↗