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At least 649 records · Page 36

Data Science Meets Physical Organic Chemistry

At the heart of synthetic chemistry is the holy grail of predictable catalyst design. In particular, researchers involved in reaction development in asymmetric catalysis have pursued a variety of strategies toward this goal. This is driven by both the pragmatic need to achieve high selectivities and the inability to readily identify why a certain catalyst is effective for a given reaction. While empiricism and intuition have dominated the field of asymmetric catalysis since its inception, enantioselectivity offers a mechanistically rich platform to interrogate catalyst-structure response patterns that explain the performance of a particular catalyst or substrate. In the early stages of an asymmetric reaction development campaign, the overarching mechanism of the reaction, catalyst speciation, the turnover limiting step, and many other details are unknown or posited based on related reactions. Considering the unclear details leading to a successful reaction, initial enantioselectivity data are often used to intuitively guide the ultimate direction of optimization. However, if the conditions of the Curtin-Hammett principle are satisfied, then measured enantioselectivity can be directly connected to the ensemble of diastereomeric transition states (TSs) that lead to the enantiomeric products, and the associated free energy difference between competing TSs (ΔΔ G ‡ = - RT ln[( S )/( R )], where ( S ) and ( R ) represent the concentrations of the enantiomeric products). We, and others, speculated that this important piece of information can be leveraged to guide reaction optimization in a quantitative way. Although traditional linear free energy relationships (LFERs), such as Hammett plots, have been used to illuminate important mechanistic features, we sought to develop data science derived tools to expand the power of LFERs in order to describe complex reactions frequently encountered in modern asymmetric catalysis. Specifically, we investigated whether enantioselectivity data from a reaction can be quantitatively connected to the attributes of reaction components, such as catalyst and substrate structural features, to harness data for asymmetric catalyst design. In this context, we developed a workflow to relate computationally derived features of reaction components to enantioselectivity using data science tools. The mathematical representation of molecules can incorporate many aspects of a transformation, such as molecular features from substrate, product, catalyst, and proposed transition states. Statistical models relating these features to reaction outputs can be used for various tasks, such as performance prediction of untested molecules. Perhaps most importantly, statistical models can guide the generation of mechanistic hypotheses that are embedded within complex patterns of reaction responses. Overall, merging traditional physical organic experiments with statistical modeling techniques creates a feedback loop that enables both evaluation of multiple mechanistic hypotheses and future catalyst design. In this Account, we highlight the evolution and application of this approach in the context of a collaborative program based on chiral phosphoric acid catalysts (CPAs) in asymmetric catalysis.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

Scaling of impact damage in fiber composites

Impact damage in fiber composite structures remains of much concern, and is often the limiting factor in establishing allowable strain levels. The complexity of impact damage formation usually dictates that experiments are required, but scaling of results from small laboratory scale specimens to large structures introduces additional uncertainty into the analysis. This presentation gives the results of an analytical and experimental investigation intended to develop procedures for prediction of damage formation and subsequent strength loss, with particular emphasis on scaling of results with respect to structure size. The experimental investigation involved both drop-weight and airgun impact on carbon/epoxy plates and cylinders. Five sizes of plates ranging from 50 by 50 by 1.072 mm to 250 by 250 by 5.36 mm, and two sizes of cylinders with diameters of 96.5 and 319 mm, were employed in the experimental program. Impact tests were carried out over a range of impact conditions, and specimens were inspected for damage by C-scan and deplying. Analysis procedures were developed for both quasistatic and dynamic impacts for both the plates and cylinders. As has been reported previously, comparison of predicted structural response and measured surface strains was quite good over the entire range of sizes employed in the program. The damage formation and strength loss after impact showed a number of interesting features that are significant with respect to scaling of size. The extent of delamination was observed to increase with specimen size more than would be expected if stresses controlled the delamination extent. This was explained on the basis that delamination is controlled by energy release rates, and thus incorporates the usual dependence on the absolute size characteristic of fracture mechanics. Additionally, the experiments indicated that delamination initiated at matrix cracks and is dependent on the absolute size of the ply group thicknesses. Both the initiation and propagation of delamination are seen to be controlled by fracture mechanics parameters, and thus show specific dependence on size that must be accounted for in extrapolating results from laboratory scale tests to full size structures.

Swanson, Stephen R.↗

Hypersonic Fluid-Thermal-Structural Interactions on a Compression Ramp with an Embedded Compliant Panel

The fluid-thermal-structural interactions of a compliant panel embedded in a compression ramp are explored experimentally at Mach 6. The panel structural response is investigated for turbulent and transitional shock-wave/boundary-layer interactions at five distinct interaction strengths and up to four different pressure differentials. Upstream of the compression corner, fast-response piezoresistive pressure transducers show the feedback of the panel vibrations and static deflection on the upstream pressure fluctuations. The magnitude of the pressure fluctuation rms shows a reduction in the upstream disturbances when a pressure differential is applied across the compliant panel. Photogrammetry and IR thermography are used simultaneously to measure the panel deformations and surface temperature. Panel deformation, frequency shifting, and frequency bifurcation are consistent with post-thermal-buckling behavior.

hypersonic↗

Quantification and evaluation of strain reduction from small-bubble gas injection in Spallation Neutron Source target vessels

Small-bubble gas injection has been routinely utilized in the operation of Spallation Neutron Source (SNS) mercury targets since 2017 to mitigate cavitation-induced erosion damage to target vessels. Strain measurements of target vessels collected in-situ during initial operation with gas injection were used to study the gas injection effect on the structural response of targets to proton pulses. A significant strain reduction owing to gas injection was found by comparing the strain measurement data during operation with and without gas injection. The research presented here focuses on quantifying strain reductions in SNS targets and evaluating the effect of small-bubble gas injection by comparing different bubbler types and target designs. The strain measurement results show the gas injection significantly reduced strain in SNS target vessels; strain values decreased by 30% to 80% for targets operating with gas injection. Stress and strain responses of SNS targets were simulated to numerically evaluate the gas injection effect. Based on the predicted stresses with and without gas injection, the fatigue lifetimes of SNS jet-flow design target were estimated using fe-safe fatigue analysis software. The simulations show these reductions should improve the fatigue life of target vessels and allow SNS targets to meet their fatigue design goal.

Fatigue life estimation↗

Effects of internal swelling on residual elasticity of a quasi-brittle material through a composite sphere model

This work describes the development of a micromechanical-based constitutive model accounting for the effect of internal expansion on the residual elasticity of a Hashin composite material. This material is made of spherical inclusions that are subjected to gradual swelling within a quasi-brittle matrix. The main focus of this work is to describe and analyze the material mechanical response, with an additional focus on the internal swelling’s effect on the stress–strain response and residual elasticity. Microstructural features and parameters of major importance for the mechanical responses were identified. The innovative characteristics of the proposed approach are summarized as follows: (1) a full determination of the physics of a complete-damage problem throughout the whole process of inclusion swelling with upscaling techniques, which transfers the microcrack-related properties from the lower scale to upper scale; and (2) an evolution of the mechanical fields and the corresponding residual elasticity for various inclusion swelling levels. Concerning the matrix–inclusion composite, it was hypothesized that only the matrix was susceptible to cracking, with varied degrees of damage, whereas the inclusions behave elastically and the elastic modulus of the expanding inclusions remains constant. It is to emphasize that the gradual swelling of inclusions is modeled by an increasing strain in the current micromechanical-based constitutive model, and the microcracks are represented by a set of randomly oriented penny-shaped microcracks with identical radii (namely, closed cracks). The main contribution of the current research is to establish the exact mathematical solutions for the mechanical fields (stress, strain) caused by the swelling of the inclusions (mechanical loading) and derive the effective residual elasticity of a composite (structural response) subject to internal expansion and quasi-brittle damage. Based on the assumption of closed cracks that could be extended to open cracks in the upcoming work, the results proposed by the present paper help to understand the non-linear mechanical behavior of quasi-brittle materials subject to microcracking and provide a theoretical framework to be used as academical benchmark for numerical simulations.

36 MATERIALS SCIENCE↗

Objectives and Progress on Ground Vibration Testing for the Ares Launch Vehicles

NASA has conducted dynamic tests on each of its major launch vehicles during the past 45 years. Each test has provided invaluable data to correlate and correct analytical models used to predict structural responses to differing dynamics for these vehicles. With both Saturn V and Space Shuttle, hardware changes were also required to the flight vehicles to ensure crew and vehicle safety. The Ares I IVGVT will undoubtedly provide similar valuable test data to support successful flights of the Constellation Program. The IVGVT will provide test determined natural frequencies, mode shapes and damping for the Ares I. This data will be used to support controls analysis by providing this test data to reduce uncertainty in the models. The value of this testing has been proven by past launch vehicle successes and failures. Performing dynamic testing on the Ares vehicles will provide confidence that the launch vehicles will be safe and successful in their missions. In addition, IVGVT will provide the following benefits for the Ares rockets: a) IVGVT data along with Ares development flights like Ares I-X, Ares I-Y, Ares I-X Prime, and Orion-1 or others will reduce the risk to the Orion-2 crew. IVGVT will permit anchoring the various analytical and operational models used in so many different aspects of Ares operations. b) IVGVT data will permit better understanding of the structural and GN&C margins of the spacecraft and may permit mass savings or expanded day-of-launch opportunities or fewer constraints to launch. c) Undoubtedly IVGVT will uncover some of the "unknown unknowns" so often seen in developing, launching, and flying new spacecraft vehicles and data from IVGVT may help prevent a loss of vehicle or crew. d) IVGVT also will be the first time Ares I flight-like hardware is transported, handled, rotated, mated, stacked, and integrated. e) Furthermore, handling and stacking the IVGVT launch vehicle stacks will be an opportunity to understand certain aspects of vehicle operability much better (for example, handling procedures, touch-labor time to accomplish tasks, access at interfaces, access to stage mating bolts, access to avionics boxes, access to the Interstage, GSE functionality, and many other important aspects of Ares I operability). All of these results will provide for better vehicle safety and better stewardship of national resources as NASA begins its next phase of human space exploration.

Tuma, Margaret L.↗

Quantifying the cooperative evolution of microphase segregation and nanostructural order in annealed polyurethanes of MDI-BDO-PTHF

Here, we quantify the relationship between microphase segregation and local structure development in thermoplastic polyurethanes. Samples were prepared with varying ratios of 4,40 -methylene diphenyl diisocyanate (MDI) and 1,4-butanediol (BDO) to polytetrahydrofuran (PTHF) and annealed at temperatures T a between RT–140 °C for 20 h each. Distinct populations of smaller and larger ordered domains are distinguished by pair distribution func tion analysis. The intermediate-range order of nanoscale hard domains in the paracrystalline state (form I) is directly extracted and characterized. The results suggest that form I of the MDI-BDO:PTHF system presents a conformational and packing order similar to the form III structure, typically obtained from stretching/annealing, but with limited spatial coherence of 3–7 nm. Heating above T g of the hard segments is necessary to achieve a substantial structural response from the annealing treatment. Increasing T a promotes purification of the soft phase via microphase segregation, coalescence of the hard blocks, and growth of paracrystalline phase, while a minority fraction of longer-range ordered domains left over from production remains relatively constant. We observe a composition-dependent decrease in the average nearest-neighbor dis tance that can be correlated with the greater number of C C, C N, and C O bonds with increased hard segment content. A non-linear deviation in the trend is observed to correlate with sample densification. The mechanical and thermal behavior of the samples is intimately tied to the segregation state.

processing-structure-properties↗

Vibration Testing of Stirling Power Convertors

The NASA John H. Glenn Research Center (GRC) and the U.S. Department of Energy (DOE) are currently developing a high efficient, long life, free piston Stirling convertor for use as an advanced spacecraft power system for future NASA missions. As part of this development, a Stirling Technology Demonstrator Convertor (TDC), developed by Stirling Technology Company (STC) for DOE, was vibration tested at GRC s Structural Dynamics Laboratory (SDU7735) in November- December 1999. This testing demonstrated that the Stirling TDC is able to withstand the harsh random vibration (20 to 2000 Hertz) seen during a typical spacecraft launch and survive with no structural damage or functional power performance degradation, thereby enabling its usage in future spacecraft power systems. The Stirling Vibration Test Team at NASA GRC and STC personnel conducted tests on a single 55 electric watt TDC. The purpose was to characterize the TDC s structural response to vibration and determine if the TDC could survive the vibration criteria established by the Jet Propulsion Laboratory (JPL) for launch environments. The TDC was operated at full-stroke and full power conditions during the vibration testing. The TDC was tested in two orientations, with the direction of vibration parallel and perpendicular to the TDC s moving components (displacer and piston). The TDC successfully passed a series of sine and random vibration tests. The most severe test was a 12.3 Grms random vibration test (peak vibration level of 0.2 g2/Hz from 50 to 250 Hertz) with test durations of 3 minutes per axis. The random vibration test levels were chosen to simulate, with margin, the maximum anticipated launch vibration conditions. As a result of this very successful vibration testing and successful evaluations in other key technical readiness areas, the Stirling power system is now considered a viable technology for future application for NASA spacecraft missions. Possible usage of the Stirling power system would be to supply on- board electric spacecraft power for future NASA Deep-Space Missions, performing as an attractive alternative to Radioisotope Thermoelectric Generators (RTG). Usage of the Stirling technology is also being considered as the electric power source for future Mars rovers, whose mission profiles may exclude the use of photovoltaic power systems (such as exploring at high Martian latitudes or for missions of lengthy durations). GRC s Thermo-Mechanical Systems Branch (5490) provides Stirling technology expertise under a Space Act Agreement with the DOE. Additional vibration testing, by GRC s Structural Systems Dynamics Branch (7733, is planned to continue to demonstrate the Stirling power system s vibration capability as its technology and flight system designs progress.

Hughes, Bill↗

Jahn–Teller distortion controls electron transfer in photoexcited Cu( I ) donor–acceptor systems

The Jahn–Teller distortion (JTD) is a defining structural response to electronic excitation in Cu( I )-based transition metal complexes, yet its role in photoinduced electron transfer (PET) remains largely unexplored. Here, we demonstrate that the JTD governs charge separation (CS) through a vibronically controlled conical intersection in heteroleptic Cu( I ) bisphenanthroline–naphthalene diimide (CuHETPHEN-NDI) donor–acceptor dyads. Using 20-fs broadband transient absorption spectroscopy combined with coherent vibrational wavepacket (CVWP) analysis and quantum chemical calculations, we directly track nuclear motions that steer the system from the metal-to-ligand charge-transfer ( 1 MLCT) state to the CS state. Steric bulkiness of the pendant groups at the 2,9-positions of the phenanthroline ligand systematically slows both JTD and CS. Short-time Fourier transformation and Fourier filtering analyses identify two key vibrational signatures: a low-frequency breathing mode (∼100 cm −1 ) via a bond distance change between Cu and ligated Ns (Cu–N) that modulates the NDI anion absorption and acts as a vibronic coupling coordinate, and a higher-frequency mode (∼313 cm −1 ) that evolves along the PET trajectory. Normal mode analysis and potential energy surface calculations show that the JTD brings the 1 MLCT and CS states into degeneracy, while the Cu–N breathing motion dynamically modulates donor–acceptor electronic coupling to enable ultrafast nonadiabatic electron transfer. Steric hindrance exerted by the groups at the 2,9 positions of the phenanthroline ligands suppresses this vibronic coupling, leading to faster CVWP decoherence for the 313 cm −1 mode and slower CS. These findings unravel JTD-controlled vibronic coupling at conical intersection as a governing factor for CS and provide insight into designing Cu-based photosensitizers by harnessing structural dynamics to control PET.

Kim, Pyosang [Argonne National Laboratory (ANL), A↗

Verification of numerical models for seismic fluid-structure interaction analysis of internal components in liquid-filled advanced reactors

Earthquake shaking of a liquid-filled advanced reactor induces fluid-structure interaction (FSI) between the reactor vessel (tank), its internal components, and the contained liquid. Seismic design, qualification, and risk assessment of such reactors must consider fluid-structure responses, their geometries and support conditions, and three-directional seismic inputs, all of which require numerical simulations. Numerical models used for analysis of safety-related nuclear equipment must be verified and validated. Here, this paper verifies numerical models of submerged components using analytical solutions. Seismic FSI analysis of the numerical models is performed using the Arbitrary Lagrangian-Eulerian (ALE) and Incompressible Computational Fluid Dynamics (ICFD) solvers in LS-DYNA. Prior analytical solutions are reworked in this paper, and calculation errors are identified and corrected. The solutions address frequencies of two concentric cylindrical pipes filled with liquid: the inner pipe is a submerged component, and the outer pipe contains the liquid. A unitless frequency coefficient is defined and presented for pipes of different materials, filled with different liquids, and with a range of dimensions for application to advanced reactors. The numerical models are verified here by comparing the lateral frequencies of submerged components with those calculated using the corrected analytical solutions. Recommendations for verification of numerical models of internal components in advanced reactors for seismic FSI analysis are provided. Although the unitless frequency coefficients and verification procedures are developed for application to advanced nuclear reactors, they are broadly applicable to FSI analysis of submerged components in liquid-filled vessels such as storage tanks, boilers, and steam generators.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

Highly Nonstoichiometric YAG Ceramics with Modified Luminescence Properties

Abstract Y 3 Al 5 O 12 (YAG) is a widely used phosphor host. Its optical properties are controlled by chemical substitution at its YO 8 or AlO 6 /AlO 4 sublattices, with emission wavelengths defined by rare‐earth and transition‐metal dopants that have been explored extensively. Nonstoichiometric compositions Y 3+x Al 5‐x O 12 ( x ≠ 0) may offer a route to new emission wavelengths by distributing dopants over two or more sublattices simultaneously, producing new local coordination environments for the activator ions. However, YAG typically behaves as a line phase, and such compositions are therefore challenging to synthesize. Here, a series of highly nonstoichiometric Y 3+x Al 5‐x O 12 with 0 ≤ x ≤ 0.40 is reported, corresponding to ≤20% of the AlO 6 sublattice substituted by Y 3+ , synthesized by advanced melt‐quenching techniques. This impacts the up‐conversion luminescence of Yb 3+ /Er 3+ ‐doped systems, whose yellow‐green emission differs from the red‐orange emission of their stoichiometric counterparts. In contrast, the YAG:Ce 3+ system has a different structural response to nonstoichiometry and its down‐conversion emission is only weakly affected. Analogous highly nonstoichiometric systems should be obtainable for a range of garnet materials, demonstrated here by the synthesis of Gd 3.2 Al 4.8 O 12 and Gd 3.2 Ga 4.8 O 12 . This opens pathways to property tuning by control of host stoichiometry, and the prospect of improved performance or new applications for garnet‐type materials.

Chemistry↗

Soft Polymer Janus Nanoparticles at Liquid–Liquid Interfaces

Abstract Soft polymeric Janus nanoparticles (JNPs), made from polystyrene‐ b ‐poly(butadiene)‐ b ‐poly(methylmethacrylate), PS‐PB‐PMMA, triblock terpolymers, assemble into a monolayer at the water–oil interface to reduce interfacial tension. The extent to which the polymer chains can deform influences the packing density of the JNPs at the interface. The longer the polymer chains are relative to the core, the softer are the JNPs, resulting in a JNPs assembly with a lower initial lateral packing density. The interfacial activity of JNPs can be further tuned by complexation of the PMMA chains with lithium ions that are introduced into the water phase. This work provides a fundamental understanding of soft JNPs packing at the water–oil interface and provides a strategy to tailor the areal density of soft JNPs at liquid–liquid interface, enabling the design of smart responsive structured‐liquid systems.

Jiang, Yufeng↗

Soft Polymer Janus Nanoparticles at Liquid–Liquid Interfaces

Abstract Soft polymeric Janus nanoparticles (JNPs), made from polystyrene‐ b ‐poly(butadiene)‐ b ‐poly(methylmethacrylate), PS‐PB‐PMMA, triblock terpolymers, assemble into a monolayer at the water–oil interface to reduce interfacial tension. The extent to which the polymer chains can deform influences the packing density of the JNPs at the interface. The longer the polymer chains are relative to the core, the softer are the JNPs, resulting in a JNPs assembly with a lower initial lateral packing density. The interfacial activity of JNPs can be further tuned by complexation of the PMMA chains with lithium ions that are introduced into the water phase. This work provides a fundamental understanding of soft JNPs packing at the water–oil interface and provides a strategy to tailor the areal density of soft JNPs at liquid–liquid interface, enabling the design of smart responsive structured‐liquid systems.

Jiang, Yufeng↗

Structural stability and artificial buckling modes in topology optimization

Abstract This paper demonstrates how a strain energy transition approach can be used to remove artificial buckling modes that often occur in stability constrained topology optimization problems. To simulate the structural response, a nonlinear large deformation hyperelastic simulation is performed, wherein the fundamental load path is traversed using Newton’s method and the critical buckling load levels are estimated by an eigenvalue analysis. The goal of the optimization is to minimize displacement, subject to constraints on the lowest critical buckling loads and maximum volume. The topology optimization problem is regularized via the Helmholtz PDE-filter and the method of moving asymptotes is used to update the design. The stability and sensitivity analyses are outlined in detail. The effectiveness of the energy transition scheme is demonstrated in numerical examples.

Dalklint, Anna (ORCID:0000000346195205)↗

Minimum feature size control in level set topology optimization via density fields

A level set topology optimization approach that uses an auxiliary density field to nucleate holes during the optimization process and achieves minimum feature size control in optimized designs is explored. The level set field determines the solid-void interface and the density field describes the distribution of a fictitious porous material using the solid isotropic material with penalization. These fields are governed by two sets of independent optimization variables which are initially coupled using a penalty for hole nucleation. The strength of the density field penalization and projection is gradually increased during the optimization process to promote a 0-1 density distribution. In addition, a second penalty regulates the evolution of the density field in the void phase. The treatment of the density field combined with the second penalty mitigate the appearance of small design features. The minimum feature size of optimized designs is controlled by the radius of the linear filter applied to the density optimization variables. The structural response is predicted by the extended finite element method, the sensitivities by the adjoint method, and the optimization variables are updated by a gradient-based optimization algorithm. Numerical examples investigate the robustness of this approach with respect to algorithmic parameters and mesh refinement. The results show the applicability of the combined density level set topology optimization approach for both optimal hole nucleation and for minimum feature size control in 2D and 3D. This comes, however, at the cost of a more complex problem formulation and additional computational cost due to an increased number of optimization variables.

42 ENGINEERING↗

Deep learning-enhanced design for functionally graded auxetic lattices

Auxetic materials with counterintuitive negative Poisson’s ratio have been of significant interest due to potential applications across diverse engineering fields. Functionally grading such auxetics further enables customization of the structural response and harnesses the potential for multi-functional applications. However, a critical challenge in designing functionally graded lattices is to efficiently determine the spatial variation of the functional gradient and the corresponding geometric designs to achieve the desired response. In this paper, a highly efficient deep learning-based inverse design framework for functionally graded tetra-petal auxetics with spatially tailored properties is presented. This framework significantly improves the efficiency of tailoring functionally graded auxetics where many unit cells need to be tailor-designed. The graded tetra-petal auxetics obtained from the inverse design framework are additively manufactured and subjected to impact tests. The results show superior impact performance compared with uniform designs, demonstrating the effectiveness of the proposed inverse design framework, which can be inspirable to promote advanced structures/materials with enhanced impact resistance.

42 ENGINEERING↗

A predictive modeling tool for damage analysis and design of hydrogen storage composite pressure vessels

In this study, a predictive modeling tool is developed for damage analysis and design of hydrogen (H 2 ) storage composite pressure vessels. It integrates micromechanics of matrix cracking into a continuum damage mechanics (CDM) description for damage evolution, and three-dimensional (3D) finite element (FE) modeling of the vessel structural response. At the scale of the composite layer (mesoscale), the temperature-dependent stiffness reduction law in terms of the damage variable for transverse matrix cracking is computed using an Eshelby-Mori-Tanaka approach for the initial composite thermoelastic properties and a self-consistent model for the stiffness reduction as a function of the damage variable. While transverse matrix cracking obeying a damage evolution relation can progressively evolve from an initiation to a saturation state, fiber failure is predicted by a micromechanical fiber rupture criterion that accounts for the fiber strength and matrix stress. The implementation of this integrated multiscale modeling model into a 3D FE formulation enables damage analysis and design of H 2 storage composite pressure vessels. The developed tool is illustrated through 3D damage analyses of a cryogenically compressed H 2 storage vessel model subjected to thermomechanical loadings to investigate effects of the helical layer fiber orientation and loading scenario on damage development, vessel integrity and burst pressure.

08 HYDROGEN↗

Temporally continuous thermofluidic–thermomechanical modeling framework for metal additive manufacturing

Additive manufacturing (AM) is known to generate large magnitudes of residual stresses (RS) within builds due to steep and localized thermal gradients. In the current state of commercial AM technology, manufacturers generally perform heat treatments in effort to reduce the generated RS and its detrimental effects on part distortion and in-service failure. Computational models that effectively simulate the deposition process can provide valuable insights to improve RS distributions. Accordingly, it is common to employ Computational fluid dynamics (CFD) models or finite element (FE) models. While CFD can predict geometric and thermal-fluid behavior, it cannot predict the structural response (e.g., stress–strain) behavior. On the other hand, an FE model can predict mechanical behavior, but it lacks the ability to predict geometric and fluid behavior. Thus, an effectively integrated thermofluidic–thermomechanical modeling framework that exploits the benefits of both techniques while avoiding their respective limitations can offer valuable predictive capability for AM processes. In contrast to previously published efforts, the work herein describes a one-way coupled CFD-FEA framework that abandons major simplifying assumptions, such as geometric steady-state conditions, the absence of material plasticity, and the lack of detailed RS evolution/accumulation during deposition, as well as insufficient validation of results. Here, the presented framework is demonstrated for a directed energy deposition (DED) process, and experiments are performed to validate the predicted geometry and RS profile. Both single- and double-layer stainless steel 316L builds are considered. Geometric data is acquired via 3D optical surface scans and X-ray micro-computed tomography, and residual stress is measured using neutron diffraction (ND). Comparisons between the simulations and measurements reveal that the described CFD-FEA framework is effective in capturing the coupled thermomechanical and thermofluidic behaviors of the DED process. The methodology presented is extensible to other metal AM processes, including power bed fusion and wire-feed-based AM.

42 ENGINEERING↗