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DOE OSTI2021

Liquid Chromatography Coupled to Refractive Index or Mass Spectrometric Detection for Metabolite Profiling in Lysate-based Cell-free Systems

Engineering cellular metabolism for targeted biosynthesis can require extensive design-build-test-learn (DBTL) cycles as the engineer works around the cell's survival requirements. Alternatively, carrying out DBTL cycles in cell-free environments can accelerate this process and alleviate concerns with host compatibility. A promising approach to cell-free metabolic engineering (CFME) leverages metabolically active crude cell extracts as platforms for biomanufacturing and for rapidly discovering and prototyping modified proteins and pathways. Realizing these capabilities and optimizing CFME performance requires methods to characterize the metabolome of lysate-based cell-free platforms. That is, analytical tools are necessary for monitoring improvements in targeted metabolite conversions and in elucidating alterations to metabolite flux when manipulating lysate metabolism. In this work, metabolite analyses using high-performance liquid chromatography (HPLC) coupled with either optical or mass spectrometric detection were applied to characterize metabolite production and flux in E. coli S30 lysates. Specifically, this report describes the preparation of samples from CFME lysates for HPLC analyses using refractive index detection (RID) to quantify the generation of central metabolic intermediates and by-products in the conversion of low-cost substrates (i.e., glucose) to various high-value products. The analysis of metabolite conversion in CFME reactions fed with 13 C-labeled glucose through reversed-phase liquid chromatography coupled to tandem mass spectrometry (MS/MS), a powerful tool for characterizing specific metabolite yields and lysate metabolic flux from starting materials, is also presented. Altogether, applying these analytical methods to CFME lysate metabolism enables the advancement of these systems as alternative platforms for executing faster or novel metabolic engineering tasks.

59 BASIC BIOLOGICAL SCIENCES↗

NASA NTRS1999

Acoustic Treatment Design Scaling Methods: Test Plans, Hardware, Results, and Evaluation - Volume 3

The ability to design, build, and test miniaturized acoustic treatment panels on scale-model fan rigs representative of the full-scale engine provides not only a cost-savings, but an opportunity to optimize the treatment by allowing tests of different designs. To be able to use scale model treatment as a full-scale design tool, it is necessary that the designer be able to reliably translate the scale model design and performance to an equivalent full-scale design. The primary objective of the study presented in this volume of the final report was to conduct laboratory tests to evaluate liner acoustic properties and validate advanced treatment impedance models. These laboratory tests include DC flow resistance measurements, normal incidence impedance measurements, DC flow and impedance measurements in the presence of grazing flow, and in-duct liner attenuation as well as modal measurements. Test panels were fabricated at three different scale factors (i.e., full-scale, half-scale, and one-fifth scale) to support laboratory acoustic testing. The panel configurations include single-degree-of-freedom (SDOF) perforated sandwich panels, SDOF linear (wire mesh) liners, and double-degree-of-freedom (DDOF) linear acoustic panels.

Yu, J.↗

NASA NTRS2006

Modern Design of Resonant Edge-Slot Array Antennas

Resonant edge-slot (slotted-waveguide) array antennas can now be designed very accurately following a modern computational approach like that followed for some other microwave components. This modern approach makes it possible to design superior antennas at lower cost than was previously possible. Heretofore, the physical and engineering knowledge of resonant edge-slot array antennas had remained immature since they were introduced during World War II. This is because despite their mechanical simplicity, high reliability, and potential for operation with high efficiency, the electromagnetic behavior of resonant edge-slot antennas is very complex. Because engineering design formulas and curves for such antennas are not available in the open literature, designers have been forced to implement iterative processes of fabricating and testing multiple prototypes to derive design databases, each unique for a specific combination of operating frequency and set of waveguide tube dimensions. The expensive, time-consuming nature of these processes has inhibited the use of resonant edge-slot antennas. The present modern approach reduces costs by making it unnecessary to build and test multiple prototypes. As an additional benefit, this approach affords a capability to design an array of slots having different dimensions to taper the antenna illumination to reduce the amplitudes of unwanted side lobes. The heart of the modern approach is the use of the latest commercially available microwave-design software, which implements finite-element models of electromagnetic fields in and around waveguides, antenna elements, and similar components. Instead of building and testing prototypes, one builds a database and constructs design curves from the results of computational simulations for sets of design parameters. The figure shows a resonant edge-slot antenna designed following this approach. Intended for use as part of a radiometer operating at a frequency of 10.7 GHz, this antenna was fabricated from dimensions defined exclusively by results of computational simulations. The final design was found to be well optimized and to yield performance exceeding that initially required.

Gosselin, R. B.↗

DOE OSTI2026

Performance-Aligned LLMs for Generating Fast HPC Code

Optimizing scientific software is a difficult task because codebases are often large and complex, and performance can depend upon several factors including the algorithm, its implementation, and hardware among others. Causes of poor performance can originate from disparate sources and be difficult to diagnose. Recent years have seen a multitude of work that use large language models (LLMs) to assist in software development tasks. However, these tools are trained to model the distribution of code as text, and are not specifically designed to understand performance aspects of code. In this work, we introduce a reinforcement learning based methodology to align the outputs of code LLMs with performance. This allows us to build upon the current code modeling capabilities of LLMs and extend them to generate better performing code. Here, we demonstrate that our fine-tuned model improves the expected speedup of generated code over base models for a set of benchmark tasks from 0.9 to 1.6 for serial code and 1.9 to 4.5 for OpenMP parallel code.

Computer science↗

DOE OSTI2021

Isopod (inverse Optimization And Design): Moose-based Application For Performing Inverse Optimization On Multiphysics Modeling And Simulation

ISOPOD (InverSe OPtimizatiOn and Design) will be a MOOSE (Multiphysics Object Oriented Simulation Environment)-based framework which will iteratively estimate the parameters by minimizing the difference between simulated and experimental observables. While inverse optimization has long been used for parameter estimation, the unique feature of ISOPOD is rapid solution of new inverse problems, leading to accelerated Research, Development and Demonstration (RD&D) for complex parameter estimation problems. This will be achieved by extending the software structure of MOOSE to inverse optimization, as well as building on the unique automatic differentiation feature of MOOSE.

Munday, LynnB↗

DOE OSTI2020

Using a Genetic Algorithm to Optimize Configurations in a Data-Driven Application

Users of highly-configurable software systems often want to optimize a particular objective such as improving a functional outcome or increasing system performance. One approach is to use an evolutionary algorithm. However, many applications today are data-driven, meaning they depend on inputs or data which can be complex and varied. Hence, a search needs to be run (and re-run) for all inputs, making optimization a heavy-weight and potentially impractical process. In this paper, we explore this issue on a data-driven highly-configurable scientific application. We build an exhaustive database containing 3,000 configurations and 10,000 inputs, leading to almost 100 million records as our oracle, and then run a genetic algorithm individually on each of the 10,000 inputs. We ask if (1) a genetic algorithm can find configurations to improve functional objectives; (2) whether patterns of best configurations over all input data emerge; and (3) if we can we use sampling to approximate the results. We find that the original (default) configuration is best only 34% of the time, while clear patterns emerge of other best configurations. Out of 3,000 possible configurations, only 112 distinct configurations achieve the optimal result at least once across all 10,000 inputs, suggesting the potential for lighter weight optimization approaches. We show that sampling of the input data finds similar patterns at a lower cost.

Sinha, Urjoshi↗

DOE OSTI2025

Effect of Solvents on Lignin–Surface Interactions via Molecular Dynamics Simulations

Lignin, an essential building block of lignocellulosic biomass, is a potential abundant source of aromatic monomers for the polymer and chemical industry. Reductive catalytic fractionation (RCF) is one promising process that can produce high yields of phenolic monomers and oligomers from lignin under different catalytic conditions. An important choice in optimizing RCF is the selection of solvent; however, detailed insights into solvent effects on lignin behaviors and interactions remain limited. Here, in this work, we perform all-atom molecular dynamics simulations to study the solvation of lignin, solvent-mediated conformational changes, and the interaction of solvated lignin oligomers with model surfaces. We focus on the behavior of an oligomeric lignin model compound in methanol, ethanol, a binary mixture of ethanol and water, and water at both the RCF reaction temperature (473 K) and room temperature. Analysis of structural features of lignin suggests that these three organic solvent systems favorably solvate lignin, resulting in a more extended conformation suitable for catalytic conversion to valuable chemicals. We further introduce model palladium (Pd) and carbon (C) surfaces to understand how solvent choice impacts adsorption onto a representative catalytic surface and support, and to quantify the competition among the reactant and solvent molecules for the surface. Unbiased simulations suggest strong adsorption of lignin on both Pd and C surfaces at 473 K, with notable solvent-mediated differences in adsorption energies. Additionally, our findings indicate that lignin adsorption is promoted by the entropy change resulting from the displacement of solvent molecules from the surface. This study provides a molecular perspective of adsorption of lignin onto varying surfaces, which is a step towards understanding and optimizing the catalytic conversion of lignin into valuable chemicals.

adsorption↗

DOE OSTI2021

QAOAKit: A Toolkit for Reproducible Study, Application, and Verification of the QAOA

Understanding the best known parameters, performance, and systematic behavior of the Quantum Approximate Optimization Algorithm (QAOA) remain open research questions, even as the algorithm gains popularity. We introduce QAOAKit, a Python toolkit for the QAOA built for exploratory research. QAOAKit is a unified repository of preoptimized QAOA parameters and circuit generators for common quantum simulation frameworks. We combine, standardize, and cross-validate previously known parameters for the MaxCut problem, and incorporate this into QAOAKit. We also build conversion tools to use these parameters as inputs in several quantum simulation frameworks that can be used to reproduce, compare, and extend known results from various sources in the literature. We describe QAOAKit and provide examples of how it can be used to reproduce research results and tackle open problems in quantum optimization.

Shaydulin, Ruslan↗

DOE OSTI2020

Assessment of the Griffin Reactor Multiphysics Application Using the Empire Micro Reactor Design Concept

In late 2019, INL and ANL agreed to jointly develop the reactor physics code named Griffin based on the integration of the two code suites, MAMMOTH/Rattlesnake (INL) and MC2 - 3/PROTEUS (ANL). Griffin is being developed based on the MOOSE framework and MOOSE quality assurance procedures. This decision was made to be able to allow DOE-NE to efficiently invest funding to this area and to provide effective and timely support for existing and potential users; the latter includes industry and government organizations who are developing various types of advanced reactors in the near and long term. Since MAMMOTH/Rattlesnake has been developed based on the MOOSE framework, the INL/ANL Griffin development team agreed to build Griffin beginning with a merger of MAMMOTH and Rattlesnake into a single code and moving forward by implementing capabilities from the PROTEUS suite into Griffin. Moving forward, both ANL and INL efforts are equally invested in the Griffin project, with management support, to provide an advanced reactor multiphysics tool to assist in reactor design, optimization, and safety analysis. Much work remains in moving Griffin forward to migrate PROTEUS capabilities and to optimize performance to meet user needs. The main objective of this work is to assess the current status of Griffin capabilities in terms of performance and accuracy, to determine priorities for PROTEUS migration, and to identify capabilities and features to improve for supporting the code integration effort. For this assessment, the Empire micro reactor problem that was developed in the ARPA-E MEITNER program was selected as an advance reactor concept of interest to the technical community. The Empire reactor problem was expanded from its original incomplete specification to be a small heat-pipe-cooled micro reactor core with ~113 cm radius and 70 cm in height, composed of 18 fuel assemblies, 12 control drums, and beryllium radial and axial reflectors. In the current model, using 5 cm axial reflectors specified in the original Empire assembly model, more than 10% of neutrons leak axially and through the empty center safety hole, as well as through heat pipe channels in fuel assembly elements that extend through the top reflector region. Several calculation models of the core were defined for systematic assessment, including 2-D and 3-D fuel assemblies and whole cores with cylindrical boundaries. Cross sections were generated using Serpent 2, and meshes were produced using the Argonne mesh tool or the INL neutronics meshing tools combined with CUBIT. Cross sections and meshes were converted to the ISOXML and Exodus formats, respectively, so that Griffin and PROTEUS could use consistent data for solving the reactor problems. With the prepared cross sections and meshes, PROTEUS was run first to ensure that all input data were correctly generated and input options in terms of angle, mesh, and energy group were accurately determined. Comparisons against Serpent 2 solutions were made in terms of eigenvalue and pin power. The same calculations and comparisons were then conducted using Griffin. For the fuel assembly and whole core problems, the PROTEUS eigenvalues agreed well with reference Serpent 2 solutions within 100 and 30 pcm, respectively, and pin power differences relative to Serpent 2 were overall less than 2.2% and RMS 0.8% for the whole core models. This indicated that all input data were properly prepared. Using the same data, Griffin was run selecting the SAAF-CFEM SN solver with Legendre-Gaussian quadrature and NDA and DSA for acceleration. It was found that the SAAF-CFEM solver of Griffin required finer meshes to achieve eigenvalue and pin power solutions in good agreement with Serpent 2, consequently requiring more memory requirement and longer computation time. On the other hand, the SPH-Diffusion 2-D core calculations performed using Griffin were able to recover the exact eigenvalue from the reference Serpent 2 solutions, resulting in a pin-power distribution with an RMS of 0.6% and maximum absolute difference of less than 1.4%. The runtimes for SPH-Diffusion for the 2-D core were less than 3 minutes on 40 cores. During this evolution of this evaluation, many updates were made in Griffin by the Griffin development team of INL (focusing on software updates) and ANL (reviewing and supporting software updates) to complete this assessment. Observations from the code assessment are presented in the conclusion section of this report, followed by a discussion of recommendations for future work.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2025

Comparative Analysis of HEATNETS for Geothermal Network Performance: Preprint

Thermal energy networks (TENs), also known as 5th generation district energy systems, or more specifically geothermal networks when exchanging heat with geothermal boreholes, are an important technology for decarbonization. In these networks an ambient loop connects buildings and thermal sources, such as a borehole field, to exchange energy and maintain a desired loop temperature. Water-source heat pumps are used at the buildings to connect to the ambient or thermal loop to meet to the building heating and cooling loads and maintain comfort. A semi-transient, reduced-order technical model and techno-economic model, called HEATNETS, has been developed at NREL that captures the flow of energy around a TEN. In this work, a comparison of the HEATNETS technical model and a well-known coding platform used for modeling geothermal networks, TRNSYS, has been completed for a proposed geothermal network as a verification process. Hourly data provided from the TRNSYS simulation included building loads, pumping power, heat pump power, temperature entering and leaving the borehole field, and mass flow rates. The hourly borehole temperatures were used to create a linear regression model utilized in HEATNETS to estimate the borehole field heat exchange. The building loads and mass flow rates were direct inputs to HEATNETS while the pumping power, heat pump power, borehole temperatures, and coefficients of performance were all simulated and calculated by HEATNETS, allowing for direct comparison of the thermal energy transfer, rather than also comparing control systems responses. HEATNETS considers the full process from design inputs to economic outputs and can provide modeling options for high-level initial system design and operational optimization. This study shows that HEATNETS, while not intended to replace other modeling tools, can be a unique modeling tool for the performance of a full geothermal network system.

15 GEOTHERMAL ENERGY↗

DOE OSTI2024

Production of Astatine-211 for Translational Science in Radiotherapy (Research Performance Progress Report)

In this proposal we outline the methods to improve the isotope production of astatine-211 at the University of Pennsylvania Cyclotron Facility. Astatine-211 is an isotope that emits alpha- radiation and has high potential for treating otherwise untreatable cancers. The goal of this proposal is two fold, 1) Optimize current production of astatine-211 and maintain routine production and 2) develop new isotope production target systems and chemical isolation systems. By completing this proposal we will ensure that the University of Pennsylvania Cyclotron Facility continues to build it’s isotope program in an effort that unites under DOE isotope network supply initiatives with the overall goal of increasing the national supply of isotopes. The University of Pennsylvania is uniquely located in the northeast corridor of the United States of America and has access to dozens of institutions that could use astatine-211 in their research. With the support of the DOE we have the opportunity to provide additional momentum to this growing field of research and will be able to provide the foundation for economical development of astatine-211 research and application in medicine.

62 RADIOLOGY AND NUCLEAR MEDICINE↗

NASA NTRS2011

Launch Vehicle Demonstrator Using Shuttle Assets

The Advanced Concepts Office at NASA's George C. Marshall Space Flight Center undertook a study to define candidate early heavy lift demonstration launch vehicle concepts derived from existing space shuttle assets. The objective was to determine the performance capabilities of these vehicles and characterize potential early demonstration test flights. Given the anticipated budgetary constraints that may affect America's civil space program, and a lapse in U.S. heavy launch capability with the retirement of the space shuttle, an early heavy lift launch vehicle demonstration flight would not only demonstrate capabilities that could be utilized for future space exploration missions, but also serve as a building block for the development of our nation s next heavy lift launch system. An early heavy lift demonstration could be utilized as a test platform, demonstrating capabilities of future space exploration systems such as the Multi Purpose Crew Vehicle. By using existing shuttle assets, including the RS-25D engine inventory, the shuttle equipment manufacturing and tooling base, and the segmented solid rocket booster industry, a demonstrator concept could expedite the design-to-flight schedule while retaining critical human skills and capital. In this study two types of vehicle designs are examined. The first utilizes a high margin/safety factor battleship structural design in order to minimize development time as well as monetary investment. Structural design optimization is performed on the second, as if an operational vehicle. Results indicate low earth orbit payload capability is more than sufficient to support various vehicle and vehicle systems test programs including Multi-Purpose Crew Vehicle articles. Furthermore, a shuttle-derived, hydrogen core vehicle configuration offers performance benefits when trading evolutionary paths to maximum capability.

Creech, Dennis M.↗

DOE OSTI2023

Process-structure-property relationships for droplet-on-demand liquid-metal-jetted parts

Liquid metal jetting droplet-on-demand additive manufacturing is an attractive alternative to industry-standard, laser-based metal additive manufacturing techniques that use powder feedstocks and produce large heat affected zones. Liquid metal jetting provides a low feedstock footprint, minimal materials waste, less contamination and inclusions from feedstock, and is compatible with a large range of materials. However, little has been reported on the liquid metal jetting process-structure-property relationships that are crucial to understanding how to consistently print high quality metal parts. We investigate the effects of build plate temperature, infill pattern, and track raster rate on the macro- and microstructure, density, hardness, and tensile strength of metal parts created with our custom droplet-on-demand setup using pure tin feedstock as a surrogate for more relevant structural materials. We found that although the build plate temperature had the largest influence on the structure and properties, the infill pattern is an important factor for optimal structural integrity. It was observed that the track raster rate influenced track-to-track porosity and should be considered in toolpath development. Despite printing in ambient air, we could not identify oxide on the surface or in the bulk of the parts and saw no adverse effects on microstructure or tensile performance. The results and methods of this study will help guide future work in optimizing the liquid metal jetting process to reliably print parts using any liquid metal jetting system for a wide variety of metal feedstocks.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Optimizing Control for Efficient Load Shifting with Thermal Energy Storage in Existing HVAC Systems

This project developed the integration of a direct-contact heat exchanger (DCHX) based thermal energy storage (TES) system with a chiller–air handling unit (AHU) plant to evaluate its potential for reducing building energy costs. Detailed physical models of the TES unit, building envelope, and HVAC components were developed alongside simplified control-oriented models to support both high-fidelity simulation and real-time optimization. Two control strategies were implemented and compared: a rule-based control (RBC) aligned with utility time-of-use (ToU) rates, and a model predictive control (MPC) framework leveraging forecasts of building load, weather, and internal gains.Simulation results show that the RBC strategy reduced daily electricity costs by around 30% by shifting cooling production from on-peak to off-peak hours. In contrast, the MPC strategy achieved significantly greater performance, reducing daily operating costs by up to 44% and peak-hour costs by more than 60%. Both strategies maintained indoor thermal comfort within acceptable limits, with MPC further improving load distribution and reducing equipment cycling.The outcomes confirm that TES integration, particularly when coordinated with advanced predictive control, can provide substantial cost savings and on-peak demand reduction. . These findings directly support the U.S. Department of Energy’s goals for grid-interactive efficient buildings and demonstrate the potential of TES-enabled HVAC systems for scalable deployment across the commercial building.

99 GENERAL AND MISCELLANEOUS↗

NASA NTRSDate not supplied

A Cost and Benefit Analysis of Orbital Debris Remediation, Mitigation,Tracking, and Characterization

Orbital debris may collide with crewed and robotic spacecraft, placing them at risk. The wide range of debris, from 9,000-kilogram rocket bodies to millions of millimeter-size debris, has led to a similarly wide range of proposed actions for addressing the risks posed by debris. However, the costs and benefits of these actions have historically been unknown. This is a challenge for decision makers who are choosing which actions to support through technology development or policy changes. NASA’s Office of Technology, Policy, and Strategy is addressing these technical and economic uncertainties by building a capability to (1) complete rigorous calculations of the net present value of each action, (2) identify an optimal portfolio of actions to reduce risk, and (3) quantitatively analyze policies related to space sustainability. This report describes our progress toward that capability and to solicit feedback from the space and economic communities. Our previous work(Colvin, Karcz, and Wusk. 2023), referred to here as Phase 1, assessed the costs and benefits of performing debris remediation on operationally relevant timescales. The current paper summarizes the work of Locke and Colvin (2024), which contains major updates to the risk model used in Phase 1 and expands the breadth of actions considered to include mitigating the creation of debris, improving the ability to track debris, and more methods for cleaning up existing debris. We demonstrate that our approach of measuring risks in dollars allows for the effectiveness of seemingly incommensurate actions to be compared and generates insights that other approaches to measuring risk have missed.

Orbital Debris↗

DOE OSTI2020

Speeding up particle track reconstruction using a parallel Kalman filter algorithm

One of the most computationally difficult problems expected for the High-Luminosity Large Hadron Collider (HL-LHC) is determining the trajectory of charged particles during event reconstruction. Algorithms used at the LHC today rely on Kalman filtering, which builds physical trajectories incrementally while incorporating material effects and error estimation. Recognizing the need for faster computational throughput, we have adapted Kalman-filter-based methods for highly parallel, many-core SIMD architectures that are now prevalent in high-performance hardware. In this paper, we discuss the design and performance of the improved tracking algorithm, referred to as mkFit. A key piece of the algorithm is the Matriplex library, containing dedicated code to optimally vectorize operations on small matrices. The physics performance of the mkFit algorithm is comparable to the nominal CMS tracking algorithm when reconstructing tracks from simulated proton-proton collisions within the CMS detector. We study the scaling of the algorithm as a function of the parallel resources utilized and find large speedups both from vectorization and multi-threading. mkFit achieves a speedup of a factor of 6 compared to the nominal algorithm when run in a single-threaded application within the CMS software framework.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

DOE OSTI2025

Optimizing Control for Efficient Load Shifting with Thermal Energy Storage in Existing HVAC Systems

This project developed the integration of a direct-contact heat exchanger (DCHX) based thermal energy storage (TES) system with a chiller–air handling unit (AHU) plant to evaluate its potential for reducing building energy costs. Detailed physical models of the TES unit, building envelope, and HVAC components were developed alongside simplified control-oriented models to support both high-fidelity simulation and real-time optimization. Two control strategies were implemented and compared: a rule-based control (RBC) aligned with utility time-of-use (ToU) rates, and a model predictive control (MPC) framework leveraging forecasts of building load, weather, and internal gains. Simulation results show that the RBC strategy reduced daily electricity costs by around 30% by shifting cooling production from on-peak to off-peak hours. In contrast, the MPC strategy achieved significantly greater performance, reducing daily operating costs by up to 44% and peak-hour costs by more than 60%. Both strategies maintained indoor thermal comfort within acceptable limits, with MPC further improving load distribution and reducing equipment cycling. The outcomes confirm that TES integration, particularly when coordinated with advanced predictive control, can provide substantial cost savings and on-peak demand reduction. . These findings directly support the U.S. Department of Energy’s goals for grid-interactive efficient buildings and demonstrate the potential of TES-enabled HVAC systems for scalable deployment across the commercial building.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2025

Macro-micro multiscale modeling to assist the design of HPDC Al castings microstructure and alloys for EV super-large body structures (Phase 1)

Implementation of High Pressure Die Casting (HPDC) Aluminum (Al) body structures for high volume electrified vehicles (EV) to improve electric efficiency remains a key strategy within many original equipment manufacturer (OEM)s. In addition to high strength for safety requirements, superior Self-Piercing Riveting (SPR) performance is demanded for HPDC Al alloys to be compatible with high volume SPR joining. In this work, it is proposed to extend and validate an existing Contractor finite element multiscale macro-micro modeling approach to quantify the influence of the microstructure of HPDC alloys on the fracture strain/displacement under 3-point bend and clinch testing. The success of this work will allow to replace solution treatment stage with low energy consumption heat treatment (HT) processes, or to design new non heat treatable (NHT) HPDC Al alloys to eliminate HT requirements. Ultimately, this project will facilitate the application of HPDC Al alloys for super-large vehicle structures to significantly reduce vehicle weight, and thus improving energy efficiency. The purpose of this project is to extend and validate an existing finite element code, which is based on the Contractor developed macro-micro multi-scale modeling approach, to numerically simulate the three-point bending and clinch test and study the influences of material microstructural characteristics and phase properties on the rivetability. The macro-micro modeling approach begins with a sample scale model and identify the location, which is mostly prone to failure, the deformation history of the boundaries of that location calculated will be used to drive a microstructure-based sub-models where the material microstructure and microscale properties are considered. Using this approach, the wrap-bending failure for two Al alloys are correctly predicted for the first time. This will start with phase I effort of building a framework of macro-micro three point bending test and clinch test of Al10SiMgMn HPDC alloy in the as-cast and T7 heat treated conditions. Those results will then be validated with experimental test results. The phase II effort will involve the utilization of the knowledge learned in phase I to establish the quantitative correlation between the microstructure characteristics and the riveting performance, which will be further used to guide the optimization of HPDC Al alloy microstructure using heat treatment process to achieve sufficient rivetability to join large thin-wall HPDC alloys.

36 MATERIALS SCIENCE↗