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Mathematical and physical modelling of materials processing

Mathematical and physical modeling of turbulence phenomena in metals processing, electromagnetically driven flows in materials processing, gas-solid reactions, rapid solidification processes, the electroslag casting process, the role of cathodic depolarizers in the corrosion of aluminum in sea water, and predicting viscoelastic flows are described.

Source record↗

Evaluation of Engineered Barrier Systems (FY19 Report)

This report describes research and development (R&D) activities conducted during fiscal year 2019 (FY19) specifically related to the Engineered Barrier System (EBS) R&D Work Package in the Spent Fuel and Waste Science and Technology (SFWST) Campaign supported by the United States (U.S.) Department of Eneregy (DOE). The R&D activities focus on understanding EBS component evolution and interactions within the EBS, as well as interactions between the host media and the EBS. A primary goal is to advance the development of process models that can be implemented directly within the Genreric Disposal System Analysis (GDSA) platform or that can contribute to the safety case in some manner such as building confidence, providing further insight into the processes being modeled, establishing better constraints on barrier performance, etc.The FY19 EBS activities involved not only modeling and analysis work, but experimental work as well. The report documents the FY19 progress made in seven different research areas as follows: (1) thermal analysis for the disposal of dual purpose canisters (DPCs) in sedimentary host rock using the semianalytical method, (2) tetravalent uranium solubility and speciation, (3) modeling of high temperature, thermal-hydrologic-mechanical-chemical (THMC) coupled processes, (4) integration of coupled thermalhydrologic- chemical (THC) model with GDSA using a Reduced-Order Model, (5) studying chemical controls on montmorillonite structure and swelling pressure, (6) transmission x-ray microscope for in-situ nanotomography of bentonite and shale, and (7) in-situ electrochemical testing of uranium dioxide under anoxic conditions. The R&D team consisted of subject matter experts from Sandia National Laboratories, Lawrence Berkeley National Laboratory (LBNL), Los Alamos National Laboratory (LANL), Pacific Northwest National Laboratory (PNNL), the Bureau de Recherches Géologiques et Minières (BRGM), the University of California Berkeley, and Mississippi State University. In addition, the EBS R&D work leverages international collaborations to ensure that the DOE program is active and abreast of the latest advances in nuclear waste disposal. For example, the FY19 work on modeling coupled THMC processes at high temperatures relied on the bentonite properties from the Full-scale Engineered Barrier EXperiment (FEBEX) Field Test conducted at the Grimsel Test Site in Switzerland. Overall, significant progress has been made in FY19 towards developing the modeling tools and experimental capabilities needed to investigate the performance of EBS materials and the associated interactions in the drift and the surrounding near-field environment under a variety of conditions including high temperature regimes.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

A situation-response model for intelligent pilot aiding

An intelligent pilot aiding system needs models of the pilot information processing to provide the computational basis for successful cooperation between the pilot and the aiding system. By combining artificial intelligence concepts with the human information processing model of Rasmussen, an abstraction hierarchy of states of knowledge, processing functions, and shortcuts are developed, which is useful for characterizing the information processing both of the pilot and of the aiding system. This approach is used in the conceptual design of a real time intelligent aiding system for flight crews of transport aircraft. One promising result was the tentative identification of a particular class of information processing shortcuts, from situation characterizations to appropriate responses, as the most important reliable pathway for dealing with complex time critical situations.

Schudy, Robert↗

Regional-Scale Modeling at NASA Goddard Space Flight Center

Over the past decade, the Goddard Mesoscale Modeling and Dynamics Group has used a popular regional scale model, MM5, to study precipitation processes. Our group is making contributions to the MM5 by incorporating the following physical and numerical packages: improved Goddard cloud processes, a land processes model (Parameterization for Land-Atmosphere-Cloud Exchange - PLACE), efficient but sophisticated radiative processes, conservation of hydrometeor mass (water budget), four-dimensional data assimilation for rainfall, and better computational methods for trace gas transport. At NASA Goddard, the MM5 has been used to study: (1) the impact of initial conditions, assimilation of satellite-derived rainfall, and cumulus parameterizations on rapidly intensifying oceanic cyclones, hurricanes and typhoons, (2) the dynamic and thermodynamic processes associated with the development of narrow cold frontal rainbands, (3) regional climate and water cycles, (4) the impact of vertical transport by clouds and lightning on trace gas distributiodproduction associated with South and North American mesoscale convective systems, (5) the development of a westerly wind burst (WWB) that occurred during the TOGA COARE and the diurnal variation of precipitation in the tropics, (6) a Florida sea breeze convective event and a Mid-US flood event using a sophisticated land surface model, (7) the influence of soil heterogeneity on land surface energy balance in the southwest GCIP region, (8) explicit simulations (with 1.33 to 4 km horizontal resolution) of hurricanes Bob (1991) and Bonnie (1998), (9) a heavy precipitation event over Taiwan, and (10) to make real time forecasts for a major NASA field program. In this paper, the modifications and simulated cases will be described and discussed.

Tao, W.-K.↗

Perspectives on AI Architectures and Codesign for Earth System Predictability

Abstract Recently, the U.S. Department of Energy (DOE), Office of Science, Biological and Environmental Research (BER), and Advanced Scientific Computing Research (ASCR) programs organized and held the Artificial Intelligence for Earth System Predictability (AI4ESP) workshop series. From this workshop, a critical conclusion that the DOE BER and ASCR community came to is the requirement to develop a new paradigm for Earth system predictability focused on enabling artificial intelligence (AI) across the field, laboratory, modeling, and analysis activities, called model experimentation (ModEx). BER’s ModEx is an iterative approach that enables process models to generate hypotheses. The developed hypotheses inform field and laboratory efforts to collect measurement and observation data, which are subsequently used to parameterize, drive, and test model (e.g., process based) predictions. A total of 17 technical sessions were held in this AI4ESP workshop series. This paper discusses the topic of the AI Architectures and Codesign session and associated outcomes. The AI Architectures and Codesign session included two invited talks, two plenary discussion panels, and three breakout rooms that covered specific topics, including 1) DOE high-performance computing (HPC) systems, 2) cloud HPC systems, and 3) edge computing and Internet of Things (IoT). We also provide forward-looking ideas and perspectives on potential research in this codesign area that can be achieved by synergies with the other 16 session topics. These ideas include topics such as 1) reimagining codesign, 2) data acquisition to distribution, 3) heterogeneous HPC solutions for integration of AI/ML and other data analytics like uncertainty quantification with Earth system modeling and simulation, and 4) AI-enabled sensor integration into Earth system measurements and observations. Such perspectives are a distinguishing aspect of this paper. Significance Statement This study aims to provide perspectives on AI architectures and codesign approaches for Earth system predictability. Such visionary perspectives are essential because AI-enabled model-data integration has shown promise in improving predictions associated with climate change, perturbations, and extreme events. Our forward-looking ideas guide what is next in codesign to enhance Earth system models, observations, and theory using state-of-the-art and futuristic computational infrastructure.

54 ENVIRONMENTAL SCIENCES↗

Perspectives on AI Architectures and Co-design for Earth System Predictability

Recently, the U.S. Department of Energy (DOE), Office of Science, Biological and Environmental Research (BER), and Advanced Scientific Computing Research (ASCR) programs organized and held the Artificial Intelligence for Earth System Predictability (AI4ESP) workshop series. From this workshop, a critical conclusion that the DOE BER and ASCR community came to is the requirement to develop a new paradigm for Earth system predictability focused on enabling artificial intelligence (AI) across the field, laboratory, modeling, and analysis activities, called model experimentation (ModEx). BER’s ModEx is an iterative approach that enables process models to generate hypotheses. The developed hypotheses inform field and laboratory efforts to collect measurement and observation data, which are subsequently used to parameterize, drive, and test model (e.g., process based) predictions. A total of 17 technical sessions were held in this AI4ESP workshop series. This paper discusses the topic of the AI Architectures and Codesign session and associated outcomes. The AI Architectures and Codesign session included two invited talks, two plenary discussion panels, and three breakout rooms that covered specific topics, including 1) DOE high-performance computing (HPC) systems, 2) cloud HPC systems, and 3) edge computing and Internet of Things (IoT). We also provide forward-looking ideas and perspectives on potential research in this codesign area that can be achieved by synergies with the other 16 session topics. These ideas include topics such as 1) reimagining codesign, 2) data acquisition to distribution, 3) heterogeneous HPC solutions for integration of AI/ML and other data analytics like uncertainty quantification with Earth system modeling and simulation, and 4) AI-enabled sensor integration into Earth system measurements and observations. Such perspectives are a distinguishing aspect of this paper.

58 GEOSCIENCES↗

Data-driven surrogates for high dimensional models using Gaussian process regression on the Grassmann manifold

This paper introduces a surrogate modeling scheme based on Grassmannian manifold learning to be used for cost-efficient predictions of high-dimensional stochastic systems. The method exploits subspace-structured features of each solution by projecting it onto a Grassmann manifold. This point-wise linear dimensionality reduction harnesses the structural information to assess the similarity between solutions at different points in the input parameter space. The method utilizes a solution clustering approach in order to identify regions of the parameter space over which solutions are sufficiently similarly such that they can be interpolated on the Grassmannian. In this clustering, the reduced-order solutions are partitioned into disjoint clusters on the Grassmann manifold using the eigen-structure of properly defined Grassmannian kernels and, the Karcher mean of each cluster is estimated. Then, the points in each cluster are projected onto the tangent space with origin at the corresponding Karcher mean using the exponential mapping. For each cluster, a Gaussian process regression model is trained that maps the input parameters of the system to the reduced solution points of the corresponding cluster projected onto the tangent space. Using this Gaussian process model, the full-field solution can be efficiently predicted at any new point in the parameter space. In certain cases, the solution clusters will span disjoint regions of the parameter space. In such cases, for each of the solution clusters we utilize a second, density-based spatial clustering to group their corresponding input parameter points in the Euclidean space. The proposed method is applied to two numerical examples. Here, the first is a nonlinear stochastic ordinary differential equation with uncertain initial conditions where the surrogate is used to predict the time history solution. The second involves modeling of plastic deformation in a model amorphous solid using the Shear Transformation Zone theory of plasticity, where the proposed surrogate is used to predict the full strain field of a material specimen under large shear strains.

42 ENGINEERING↗

Dynamic domain kinematic modelling for predicting interflow over leaky impeding layers

Traditional Boussinesq or kinematic simulations of interflow (i.e., lateral subsurface flow) assume no leakage through the impeding layer and require a no-flow boundary condition at the ridge top. However, recent analyses of many interflow-producing landscapes indicate that leaky impeding layers are common, that most interflow percolates well before reaching the toe slope, and therefore, the downslope contributing length is shorter than the hillslope length. In watersheds characterised by perched interflow over a low conductivity layer through permeable topsoil, interflow with percolation may be modelled with a kinematic wave model using a mobile upslope boundary condition defining the hillslope portion contributing interflow to valleys. Here, we developed and applied a dynamic interflow model to simulate interflow using a downslope travel distance concept such that only the active contributing length is modelled at any time. The model defines a variable active area based on the depth of the perched layer, the topographic slope and the ratio of the hydraulic conductivity of topsoil to that of the impeding layer. It incorporates a two-layer soil moisture accounting water balance analysis, a pedo-transfer function, and percolation and evaporation routines to predict interflow rates in continuous and event-based scenarios. We tested the modelling concept on two sets of data (2-year dataset of rainfall observations for the continuous simulation and a multi-day irrigation experiment for the event simulation) from a 121-m-long open interflow collection trench on an experimental hillslope at the Savannah River Site, South Carolina. The continuous model simulation partially represented the observed interflow hydrograph and perched water depth in the experimental hillslope with correlation coefficients of 0.85 and 0.35, respectively. Model performance improved significantly at event-scale analysis. The modelling approach realistically represents interflow dynamics in hillslopes with leaky impeding layers and can be integrated into catchment-scale hydrology models for more detailed hillslope process modelling.

54 ENVIRONMENTAL SCIENCES↗

Mineral Recovery Enhanced Desalination (MRED) process: An innovative technology for desalinating hard brackish water

Desalination of water containing high concentrations of calcium, dissolved carbon dioxide, sulfate, silica and other sparingly soluble salts is difficult because of the scaling potential. An innovative pre-treatment scheme was investigated at bench scale that selectively removes these constituents and produces a soft water to enable desalination with high feed water recovery. The process first removes dissolved carbon dioxide by air stripping at low pH. Magnesium is removed by precipitation at high pH. Calcium is removed by ion exchange (IX), and sulfate is removed by nanofiltration (NF). Cation regenerant from IX, containing calcium, and concentrate from NF, containing sulfate, is combined to precipitate gypsum. Concentrate from the desalination process consisting of a concentrated NaCl solution is used to regenerate the IX resins. The selective precipitation, IX, and NF processes were tested in laboratory experiments and produced magnesium hydroxide and gypsum at greater than 90% and 95% purity respectively. A process model was developed to calculate process performance, mass and liquid flow rates. Finally, the MRED process offers the following benefits: 1) greater recovery of brackish feedwater by a desalination process, 2) recovery of marketable commodities and 3) reduction in the volume and mass of waste products from the treatment process.

42 ENGINEERING↗

A stochastic model for particle impingements on orbiting spacecraft

A general methodology for simulating particle impingements on orbiting spacecraft is developed. Major steps in the modeling process are presented as (1) modeling objective, (2) construction of the spacecraft geometrical model, (3) simulation of the particles in the space environment, (4) particle impact and subsequent events of interest, and (5) results of the simulation. A simulation of the expected meteoroid impingements on the Hubble Space Telescope and the resulting angular momentum transfers which can cause telescope pointing disturbances is given to illustrate these methods.

Howell, L. W., Jr.↗

A stochastic model for particle impingements on orbiting spacecraft

A general methodology for simulating particle impingements on orbiting spacecraft is developed. Major steps in the modeling process are presented as (1) modeling objective, (2) construction of the spacecraft geometrical model, (3) simulation of the particles in the space environment, (4) particle impact and subsequent events of interest, and (5) results of the simulation. A simulation of the expected meteoroid impingements on the Hubble Space Telescope and the resulting angular momentum transfers which can cause telescope pointing disturbances is given to illustrate these methods.

Howell, Leonard W., Jr.↗

C3 System Performance Simulation and User Manual. Getting Started: Guidelines for Users

This document is a User's Manual describing the C3 Simulation capabilities. The subject work was designed to simulate the communications involved in the flight of a Remotely Operated Aircraft (ROA) using the Opnet software. Opnet provides a comprehensive development environment supporting the modeling of communication networks and distributed systems. It has tools for model design, simulation, data collection, and data analysis. Opnet models are hierarchical -- consisting of a project which contains node models which in turn contain process models. Nodes can be fixed, mobile, or satellite. Links between nodes can be physical or wireless. Communications are packet based. The model is very generic in its current form. Attributes such as frequency and bandwidth can easily be modified to better reflect a specific platform. The model is not fully developed at this stage -- there are still more enhancements to be added. Current issues are documented throughout this guide.

Source record↗

Applying Modeling Tools to Ground System Procedures

As part of a long-term effort to revitalize the Ground Systems (GS) Engineering Section practices, Systems Modeling Language (SysML) and Business Process Model and Notation (BPMN) have been used to model existing GS products and the procedures GS engineers use to produce them.

modeling↗

Nonlinear Unsteady Aerodynamic Modeling Using Empirical Orthogonal Functions

Empirical orthogonal function modeling is explained and applied to identify compact discrete-time nonlinear unsteady aerodynamic models from data generated by an unsteady three-dimensional compressible Navier-Stokes flow solver for an airfoil undergoing various pitching motions. Model structures, model parameter estimates, and model parameter uncertainty estimates for nondimensional lift, drag, and pitching moment coefficient models were determined autonomously and directly from the data. Prediction tests using data that were not used in the modeling process showed that the identified models exhibited excellent prediction capability, which is a strong indicator of an accurate model.

empirical↗

Incorporating corrosion design constraints in desalination process optimization: A case study in mechanical vapor compression

Corrosion is an expensive and complex challenge for desalination, yet current design approaches do not explicitly account for corrosion mechanisms in process modeling and technoeconomic analysis. Here, to address this gap, we present a workflow for incorporating corrosion design constraints directly into desalination process optimization models. We develop surrogate models for general and localized corrosion metrics as functions of temperature, pH, salinity, dissolved oxygen, and material using data from OLI Systems’ Corrosion Analyzer. We then integrate these surrogates as corrosion design constraints in a cost-optimization MVC model that minimizes the levelized cost of water (LCOW). For a case study of mechanical vapor compression (MVC) treating seawater across a range of recoveries, we find dissolved oxygen (DO) is the dominant driver of localized corrosion, and thus of cost-optimal material choice and operating conditions. Reducing the DO from 8 mg/L to 0.5 mg/L reduces the LCOW by 15-35%, informing the breakeven costs for implementing DO removal or selecting highly corrosion-resistant alloys. This framework is broadly applicable across corrosion types, materials, and components and enables desalination process design that minimizes capital costs.

36 MATERIALS SCIENCE↗

Physics-informed machine-learning model of temperature evolution under solid phase processes

We model temperature dynamics during Shear Assisted Proccess Extrusion (ShAPE), a solid phase process that plasticizes feedstock with a rotating tool and subsequently extrudes it into a consolidated tube, rod, or wire. Control of temperature is critical during ShAPE processing to avoid liquefaction, ensure smooth extrusion, and develop desired material properties in the extruded products. Accurate modeling of the complicated thermo-mechanical feedbacks between process inputs, material temperature, and heat generation presents a significant barrier to predictive modeling and process design. In particular, connecting micro-structural scale mechanisms of heat generation to macro-scale predictions of temperature can become computationally intractable. In this work we use a neural network (NN) model of heat generation to bridge this gap, by combining it with a simplified model of the temperature dynamics due to conduction and convection to capture the macro scale evolution of temperature. We inform the construction of the NN heat generation model using crystal plasticity simulations at the micro-structural scale to model the effects of process inputs on generation of heat. We achieved close fits of the temperature dynamics model to a diverse experimental data-set. Further, the relationships learned by the NN model between process inputs and heat generation showed qualitative agreement with those predicted by crystal plasticity simulations.

36 MATERIALS SCIENCE↗

A Catchment-Based Approach to Modeling Land Surface Processes in a GCM: Parameter Estimation and Model Demonstration - Part 2

The viability of a new catchment-based land surface model (LSM) developed for use with general circulation models is demonstrated. First, simple empirical functions -- tractable enough for operational use in the LSM -- are established that faithfully capture the control of topography on the subgrid variability of soil moisture and the surface water budget, as predicted by theory. Next, the full LSM is evaluated offline. Using forcing and validation datasets developed for PILPS Phase 2c, the minimally calibrated model is shown to reproduce observed evaporation and runoff fluxes successfully in the Red-Arkansas River Basin. A complementary idealized study that employs the range of topographic variability seen over North America demonstrates that the simulated surface water budget does vary strongly with topography, which can, by itself, induce variations in annual evaporation as high as 20%.

Ducharne, Agnes↗

Design of Multi-Stage Solvent Extraction Process for Separation of Rare Earth Elements

Flowsheet design and stage determination for the separation of rare earth elements (REEs) using solvent extraction (SX) is a challenging task because of the chemical similarity of the REEs. Low separation factors between the elements and complex equilibrium chemistry provide unique challenges to designing an efficient flowsheet for the separation of elements. The multi-stage nature of the SX process adds further complexity, making the assessment of products for a proposed design and stage combination difficult. Therefore, to develop a SX flowsheet, it is essential to quantify the performance for various design and separation conditions. This paper attempts to address the challenge by utilizing an equilibrium and process modeling approach. Results from a bench-scale study performed on a 10 g/L rare earth salt mixture were used in studying the extraction/stripping behavior and developing equilibrium models. DEHPA with TBP as a phase modifier was used as an extractant, while hydrochloric acid was utilized as a stripping agent. The results obtained were used in developing extraction/stripping models, which were integrated into a process framework of a SX train in a Matlab/Simulink environment. The models were programmed as a function block routine and used for developing a flowsheet, which was simulated for differing separation and design conditions. To identify optimum stage combinations, a particle swarm optimization (PSO) routine was developed and implemented for each SX train. Recovery and purity of elements of interest were used as objective function criteria. The stage combination leading to the minimization of the objective function was used to identify the optimum stage combination for a series of SX trains to attempt a balance of purity and recovery. The models and optimization method were implemented to separate a feed mixture containing REEs, which indicated that 99.52 and 85.41 percent purity is achievable for Yttrium and Lanthanum separation using 8-12-3 and 10-3-5 stage combination for loading, scrubbing, and striping. The model also indicated difficult separability between neodymium, praseodymium, and cerium.

Srivastava, Vaibhav (ORCID:0000000212645987)↗