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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.

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At least 469 records · Page 26
All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

Adaptively remeshed multiphysical modeling of resistance forge welding with experimental validation of residual stress fields and measurement processes

Welding processes used in the production of pressure vessels impart residual stresses in the manufactured component. Computational modeling is critical to predicting these residual stress fields and understanding how they interact with notches and flaws to impact pressure vessel durability. Here, in this work, we present a finite element model for a resistance forge weld and validate it using laboratory measurements. Extensive microstructural changes, near-melt temperatures, and large localized deformations along the weld interface pose significant challenges to Lagrangian finite element modeling. The proposed modeling approach overcomes these roadblocks in order to provide a high-fidelity simulation that can predict the residual stress state in the manufactured pressure vessel; a rich microstructural constitutive model accounts for material recrystallization dynamics, a frictional-to-tied contact model is coordinated with the constitutive model to represent interfacial bonding, and adaptive remeshing is employed to alleviate severe mesh distortion. An interrupted-weld approach is applied to the simulation to facilitate comparison to displacement measures. Several techniques are employed for residual stress measurement in order to validate the finite element model: neutron diffraction, the contour method, and the slitting method. Model-measurement comparisons are supplemented with detailed simulations that reflect the configurations of the residual-stress measurement processes themselves. The model results show general agreement with experimental measurements, and we observe some similarities in the features around the weld region. Factors that contribute to model-measurement differences are identified. Finally, we conclude with some discussion of the model development and residual stress measurement strategies, including how to best leverage the efforts put forth here for other weld problems.

36 MATERIALS SCIENCE↗
DOE OSTI2021

An integrated numerical model for coupled poro-hydro-mechanics and fracture propagation using embedded meshes

Integrated models for fluid-driven fracture propagation and general multiphase flow in porous media are valuable to the study and engineering of several systems, including hydraulic fracturing, underground disposal of waste, and geohazard mitigation across such applications. This work extends the coupled model multiphase flow and poromechanical model of Ren et al. (2018) to admit fracture propagation (FP). The coupled XFEM-EDFM scheme utilizes a separate fracture mesh that is embedded on a static background mesh. The onset and dynamics of fracture propagation are governed by the equivalent stress intensity factor (SIF) criterion. A domain-integral method (J integral) is applied to compute this information. Additionally, an adaptive time-marching scheme is proposed to rapidly restrict and grow temporal resolution to match the underlying time-scales. The proposed model is verified with analytical solutions, and shows the capability to accurately and adaptively co-simulate fluid transport and deformation as well as the propagation of multiple fractures.

42 ENGINEERING↗
DOE OSTI2025

Material Fracturing and Failure Simulation Datasets

Fracturing is a fundamental physics phenomena with broad relevance across multiple domains, ranging from infrastructure integrity, aerospace durability, reservoir production, and seismic events. We present a diverse dataset of simulated fracture evolution and material failure generated from two numerical solvers: the phase-field method and the combined finite-discrete element method (FDEM). These solvers differ in formulation, physical fidelity, and computational efficiency. The dataset includes five materials: PBX, anisotropic shale, tungsten, aluminum, and steel. For each, phase-field simulations span 400,000 cases: 200,000 under uniaxial tension and 200,000 under biaxial tension. The computationally expensive FDEM simulations include 90,000 split evenly among PBX, shale, and tungsten under uniaxial loading. All simulations begin with randomized initial fracture patterns. Each entry includes temporal data capturing fracture propagation dynamics. This comprehensive dataset is designed to support the development of foundational or surrogate machine learning approaches for predicting material failure. While no such models are introduced here, the dataset lays a robust foundation for advancing future research and innovation in these areas.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Galerkin formulation of path integrals in lattice field theory

We present a mathematical framework for Galerkin formulations of path integrals in lattice field theory. The framework is based on using the degrees of freedom (DOFs) associated to a Galerkin discretization as the fundamental lattice variables. We formulate standard concepts in lattice field theory, such as the partition function and correlation functions, in terms of the DOFs. For example, using continuous finite element spaces, we show that the two-point spatial correlation function can be defined between any two points on the domain (as opposed to at just lattice sites) and furthermore, this two-point function satisfies a weak propagator (or Green’s function) identity, in analogy to the continuum case, as well as a convergence estimate obtained from the standard finite element techniques. Furthermore, this framework leads naturally to higher-order formulations of lattice field theories by considering higher-order finite element spaces for the Galerkin discretization. We consider analytical and numerical examples of scalar field theory to investigate how increasing the order of piecewise polynomial finite element spaces affect the approximation of lattice observables. Finally, we sketch an outline of this Galerkin framework in the context of gauge field theories.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2020

Auxiliary Space Preconditioning of Finite Element Equations Using a Nonconforming Interior Penalty Reformulation and Static Condensation

We modify the well-known interior penalty finite element discretization method so that it allows for element-by-element assembly. This is possible due to the introduction of additional unknowns associated with the interfaces between neighboring elements. The resulting bilinear form, and a Schur complement (reduced) version of it, are utilized in a number of auxiliary space preconditioners for the original conforming finite element discretization problem. Furthermore, these preconditioners are analyzed on the fine scale, and their performance is illustrated on model second order scalar elliptic problems discretized with high order elements.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2020

Deformation heterogeneity and intragrain lattice misorientation in high strength contrast, dual-phase bridgmanite/periclase

A bridgmanite/periclase aggregate is investigated due to its prevalence in the Earth’s lower mantle and its importance for understanding geodynamic processes. In dual-phase polycrystalline aggregates, both strength contrast between phases and single crystal elastic and plastic anisotropy are known to influence the development of intragrain misorientation, and the evolution of crystallographic texture. In this study, full-field crystal plasticity simulations are performed with a finite element solution method, and applied to an aggregate of a mechanically strong orthorhombic phase with perovskite structure (bridgmanite, MgSiO 3 ), and a relatively weaker cubic phase (periclase, MgO). The relative strengths of the phases are parameterized to elucidate the effect that strength contrast has on texture evolution and single-phase simulations are performed for comparison. Altogether, results indicate that the relative strength between the two phases influences the development of plasticity, and the overall texture evolution. Results are discussed in light of trends related to the evolution of plasticity and misorientation in the aggregate, and their dependence on both the strength contrast between phases as well as the spatial distribution of grains and phases.

36 MATERIALS SCIENCE↗
DOE OSTI2023

A scalable domain decomposition method for FEM discretizations of nonlocal equations of integrable and fractional type

Nonlocal models allow for the description of phenomena which cannot be captured by classical partial differential equations. The availability of efficient solvers is one of the main concerns for the use of nonlocal models in real world engineering applications. Here, we present a domain decomposition solver that is inspired by substructuring methods for classical local equations. In numerical experiments involving finite element discretizations of scalar and vectorial nonlocal equations of integrable and fractional type, we observe improvements in solution time of up to 14.6x compared to commonly used solver strategies.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2021

Crystal plasticity model of residual stress in additive manufacturing using the element elimination and reactivation method

Selective laser melting is receiving increasing interest as an additive manufacturing technique. Residual stresses induced by the large temperature gradients and inhomogeneous cooling process can favour the generation of cracks. In this work, a crystal plasticity finite element model is developed to simulate the formation of residual stresses and to understand the correlation between plastic deformation, grain orientation and residual stresses in the additive manufacturing process. The temperature profile and grain structure from thermal-fluid flow and grain growth simulations are implemented into the crystal plasticity model. An element elimination and reactivation method is proposed to model the melting and solidification and to reinitialize state variables, such as the plastic deformation, in the reactivated elements. The accuracy of this method is judged against previous method based on the stiffness degradation of liquid regions by comparing the plastic deformation as a function of time induced by thermal stresses. The method is used to investigate residual stresses parallel and perpendicular to the laser scan direction, and the correlation with the maximum Schmid factor of the grains along those directions. The magnitude of the residual stress can be predicted as a function of the depth, grain orientation and position with respect to the molten pool. The simulation results are directly comparable to X-ray diffraction experiments and stress–strain curves.

316 stainless steel↗
DOE OSTI2024

An Inverse Heat Conduction Algorithm Used to Calculate the Temperatures on the Inner and Outer Cylindrical Surfaces of an HMX-based PBX Explosive Annulus

In this work, a new Inverse Heat Conduction (IHC) algorithm is applied to estimate the surface temperatures at twelve locations on the inner and outer cylindrical boundaries of an HMX-based Plastic Bonded Explosive (PBX) annulus. This IHC algorithm was developed in references using a set of Direct Heat Conduction (DHC) solutions and a temperature correction method. The DHC solutions were calculated using a Galerkin based finite element (FE) method. This HMX based PBX annulus was used in the Large Scale Annular Cookoff (LSAC) experiment, Shot 5. The reason Shot 5 was chosen as a prototype mathematical model for this study is that the temperature was measured at eighteen locations in the midplane of the HMX-based PBX annulus. In addition, this annulus underwent an experimental thermal ignition and a deflagration that caused a thermal explosion and the disassembly of the experiment. The objective of this study is to describe how the application of the temperature correction algorithm produced the convergence of the DHC solutions to the measured temperatures at twelve internal locations in the midplane of the HMX-based PBX annulus.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Islet: interpolation semi-Lagrangian element-based transport

Abstract. Advection of trace species, or tracers, also called tracer transport, in models of the atmosphere and other physical domains is an important and potentially computationally expensive part of a model's dynamical core. Semi-Lagrangian (SL) advection methods are efficient because they permit a time step much larger than the advective stability limit for explicit Eulerian methods without requiring the solution of a globally coupled system of equations as implicit Eulerian methods do. Thus, to reduce the computational expense of tracer transport, dynamical cores often use SL methods to advect tracers. The class of interpolation semi-Lagrangian (ISL) methods contains potentially extremely efficient SL methods. We describe a finite-element ISL transport method that we call the interpolation semi-Lagrangian element-based transport (Islet) method, such as for use with atmosphere models discretized using the spectral element method. The Islet method uses three grids that share an element grid: a dynamics grid supporting, for example, the Gauss–Legendre–Lobatto basis of degree three; a physics parameterizations grid with a configurable number of finite-volume subcells per element; and a tracer grid supporting use of Islet bases with particular basis again configurable. This method provides extremely accurate tracer transport and excellent diagnostic values in a number of verification problems.

58 GEOSCIENCES↗
DOE OSTI2020

Scale bridging damage model for quasi-brittle metals informed with crack evolution statistics

Computationally efficient methods for bridging length scales, from highly resolved micro/meso-scale models that can explicitly model crack growth, to macro-scale continuum models that are more suitable for modeling large parts, have been of interest to researchers for decades. In this work, an improved brittle damage model is presented for the simulation of dynamic fracture in continuum scale quasi-brittle metal components. Crack evolution statistics, including the number, length, and orientation of individual cracks, are extracted from high-fidelity, finite discrete element method (FDEM) simulations and used to generate effective material moduli that reflect the material’s damaged state over time. This strategy allows for the retention of small-scale physical behaviors such as crack growth and coalescence in continuum scale hydrodynamic simulations. However, the high-fidelity simulations required to generate the crack statistics are computationally expensive. Thus, steps were taken to produce a flexible constitutive model to reduce the number of costly high-fidelity simulations needed to produce accurate results. A new stress based degradation criterion is introduced for the degradation of individual material zones. This allows for the development of a heterogeneous damage distribution within the bulk material. Then a flow stress model is added to the hydrodynamic simulation to account for plasticity in quasi-brittle materials. As a result, the effective moduli model can be applied to a larger range of materials. The effective moduli constitutive model is used to simulate beryllium flyer plate experiments. The results from the continuum scale simulations using statistics from a single high-fidelity simulation are found to be in excellent agreement with numerical and experimental velocity interferometer data. The same set of crack statistics are used to extrapolate the results of a higher rate flyer plate case using the effective moduli model. In conclusion, the extension of this model to higher rate cases shows promise for further reducing the number of costly high-fidelity simulations needed to generate crack statistics.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Fourier Analyses of High-Order Continuous and Discontinuous Galerkin Methods

In this paper, we present a Fourier analysis of wave propagation problems subject to a class of continuous and discontinuous discretizations using high-degree Lagrange polynomials. This allows us to obtain explicit analytical formulas for the dispersion relation and group velocity and, for the first time to our knowledge, characterize analytically the emergence of gaps in the dispersion relation at specific wavenumbers, when they exist, and compute their specific locations. Wave packets with energy at these wavenumbers will fail to propagate correctly, leading to significant numerical dispersion. We also show that the Fourier analysis generates mathematical artifacts, and we explain how to remove them through a branch selection procedure conducted by analysis of eigenvectors and associated reconstructed solutions. The higher frequency eigenmodes, named erratic in this study, are also investigated analytically and numerically.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2022

The estimation of Poisson’s ratio by time-averaging and Cornu’s method for isotropic beams

Prior research suggests that direct static (e.g., uniaxial testing) and dynamic (e.g., ultrasonic wave propagation analysis) measurements differ in the estimation of Poisson’s ratio because anisotropies and heterogeneities in the sample material affect the two types of tests differently. Even assuming isotropic and homogeneous material properties, prior research further suggests that discrepancies between static/dynamic test results will exist because the error of the diagnostic techniques for the measurand are inherently different. Finally, thermodynamic effects are not present in static tests but can significantly affect dynamic test results. Given the potential for all these variables to produce discrepancies, it would be helpful to have the measurement of Poisson’s ratio obtainable from the same theory and experimental measurements by either static or dynamic testing methods. Our finite element calculations show that by combining time-averaged scanning digital holography with Cornu’s method, it is theoretically possible to estimate the effective Poisson’s ratio from the anticlastic contours at the antinode of the first out-of-plane bending mode shape. This is true regardless of frequency and therefore applicable for both static and dynamic measurements. Our results show that the estimate of Poisson’s ratio by Cornu’s method using data from simulations of mode shapes approaches the true value of Poisson’s ratio. Additionally, our research suggests that beam geometry and boundary conditions are fundamental factors limiting the convergence of the estimate of Poisson’s ratio to the true value of Poisson’s ratio regardless of performing a static or dynamic test.

42 ENGINEERING↗
DOE OSTI2023

Machine learning simulation of finite element analysis in augmented reality

Media, method and system for approximating a finite element analysis texture map for an object. To accomplish this, the object is converted to a computer generated model and finite element analysis is performed for a plurality of different simulated inputs to generate a plurality of simulated mappings. Each simulated mapping is converted into a simulated texture map. A machine learning model is trained on the simulated inputs and simulated texture maps to generate a texture map which approximates a finite element analysis. The machine learning model receives a user input and generates the texture map therefrom. The texture map is then wrapped to the object and displayed.

Scherer, Derek Carl↗