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At least 703 records · Page 39
All sourcesNASA NTRSDOE OSTI
DOE OSTI2014

Design of voice coil motor dynamic focusing unit for a laser scanner

Laser scanning systems have been used for material processing tasks such as welding, cutting, marking, and drilling. However, applications have been limited by the small range of motion and slow speed of the focusing unit, which carries the focusing optics. To overcome these limitations, a dynamic focusing system with a long travel range and high speed is needed. In this study, a dynamic focusing unit for a laser scanning system with a voice coil motor (VCM) mechanism is proposed to enable fast speed and a wide focusing range. The VCM has finer precision and higher speed than conventional step motors and a longer travel range than earlier lead zirconium titanate actuators. The system has a hollow configuration to provide a laser beam path. This also makes it compact and transmission-free and gives it low inertia. The VCM's magnetics are modeled using a permeance model. Its design parameters are determined by optimization using the Broyden–Fletcher–Goldfarb–Shanno method and a sequential quadratic programming algorithm. After the VCM is designed, the dynamic focusing unit is fabricated and assembled. The permeance model is verified by a magnetic finite element method simulation tool, Maxwell 2D and 3D, and by measurement data from a gauss meter. The performance is verified experimentally. The results show a resolution of 0.2 μm and travel range of 16 mm. These are better than those of conventional focusing systems; therefore, this focusing unit can be applied to laser scanning systems for good machining capability.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2021

Thermal Analysis of a 50 kW Three-Phase Wireless Charging System

In this paper, the thermal analysis of a 50 kW three-phase wireless charging system (WCS) is presented. Addressing the thermal challenge is essential for designing a compact charging pad for 50 kW and higher-power WCS pads. Low thermal conductivity of the Litz wire and ferrite, and uneven distribution of the coil, and core loss cause the high temperature in the charging pads. In this paper, the loss distribution of a 50 kW three-phase WCS is investigated, and the temperature distribution is simulated using finite element analysis (FEA) considering the magnetic and non-magnetic materials of a charging pad. The thermal characteristics of an extremely high-power density 50 kW WCS prototype are tested experimentally for 10 minutes of operation. The simulation and experimental results show that the coil temperature increases to 65°C, the core temperature varies between 50°C to 150°C, and the packaging temperature increases to 65°C after 10 minutes of operation at rated 50 kW output power.

Mohammad, Mostak↗
DOE OSTI2014

Strain relaxation of GaAs/Ge crystals on patterned Si substrates

We report on the mask-less integration of GaAs crystals several microns in size on patterned Si substrates by metal organic vapor phase epitaxy. The lattice parameter mismatch is bridged by first growing 2-μm-tall intermediate Ge mesas on 8-μm-tall Si pillars by low-energy plasma enhanced chemical vapor deposition. We investigate the morphological evolution of the GaAs crystals towards full pyramids exhibiting energetically stable (111) facets with decreasing Si pillar size. The release of the strain induced by the mismatch of thermal expansion coefficients in the GaAs crystals has been studied by X-ray diffraction and photoluminescence measurements. The strain release mechanism is discussed within the framework of linear elasticity theory by Finite Element Method simulations, based on realistic geometries extracted from scanning electron microscopy images.

36 MATERIALS SCIENCE↗
DOE OSTI2016

GaAs/Ge crystals grown on Si substrates patterned down to the micron scale

Monolithic integration of III-V compounds into high density Si integrated circuits is a key technological challenge for the next generation of optoelectronic devices. In this work, we report on the metal organic vapor phase epitaxy growth of strain-free GaAs crystals on Si substrates patterned down to the micron scale. The differences in thermal expansion coefficient and lattice parameter are adapted by a 2-μm-thick intermediate Ge layer grown by low-energy plasma enhanced chemical vapor deposition. The GaAs crystals evolve during growth towards a pyramidal shape, with lateral facets composed of (111) planes and an apex formed by (137) and (001) surfaces. The influence of the anisotropic GaAs growth kinetics on the final morphology is highlighted by means of scanning and transmission electron microscopy measurements. The effect of the Si pattern geometry, substrate orientation, and crystal aspect ratio on the GaAs structural properties was investigated by means of high resolution X-ray diffraction. The thermal strain relaxation process of GaAs crystals with different aspect ratio is discussed within the framework of linear elasticity theory by Finite Element Method simulations based on realistic geometries extracted from cross-sectional scanning electron microscopy images.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Integrating Experiments, Simulations, and Artificial Intelligence to Accelerate the Discovery of High-Performance Green Composites

The imperative for incorporating greener materials into the aerospace industry necessitates addressing significant challenges associated with the microstructural variability exhibited by recycled and sustainable feedstocks. In this study, we propose an integrated methodology that combines experimental investigations, finite element analysis, and artificial intelligence to develop sustainable composites with consistent properties. Our approach utilizes a pipeline comprising an automated mechanical tester, a finite element method simulator, and a convolutional neural network predictor to identify and optimize fabrication parameters for achieving desired mechanical characteristics in composites. By employing a nested-loop pipeline, our methodology improves sample efficiency, accuracy, and effectively bridges the gap between simulations and real-world performance. This unique methodology offers a promising avenue for facilitating the adoption of aerospace-appropriate green composites.

Athanasiou, Christos↗
DOE OSTI2022

Simulation for the fault current limiting operation of REBCO CORC superconducting cables with different core materials

With high power density and low loss, CORC superconducting cables composed of RE- Ba 2 Cu 3 O 7–δ (REBCO) coated conductors are of great interest for power transmission applications. They can also effectively be designed to serve as fault current limiters, thanks to their sharp superconducting-to-normal transition. Coupled electromagnetic-thermal finite element (FE) simulations implemented in COMSOL Multiphysics were developed and validated against the published results for the fault current limiting performance of two CORC cables of REBCO coasted conductors wound on either copper or stainless steel cores. For improved accuracy, temperature dependencies of electrical and thermal properties of all component materials were considered in the simulations. The simulations were performed in the cross-sections of the cables for every individual layer of each REBCO tape to deliver comprehensive understanding of evolution of the current distribution and temperature rise in those layers. Furthermore, the studies can suggest approaches to optimize cable design for fault current limiting (FCL) applications by assessing the role of individual components. In the paper, possible computational errors, challenges and improvements are also discussed.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2015

A new class of finite element variational multiscale turbulence models for incompressible magnetohydrodynamics

New large eddy simulation (LES) turbulence models for incompressible magnetohydrodynamics (MHD) derived from the variational multiscale (VMS) formulation for finite element simulations are introduced. The new models include the variational multiscale formulation, a residual-based eddy viscosity model, and a mixed model that combines both of these component models. Each model contains terms that are proportional to the residual of the incompressible MHD equations and is therefore numerically consistent. Moreover, each model is also dynamic, in that its effect vanishes when this residual is small. The new models are tested on the decaying MHD Taylor Green vortex at low and high Reynolds numbers. The evaluation of the models is based on comparisons with available data from direct numerical simulations (DNS) of the time evolution of energies as well as energy spectra at various discrete times. Thus a numerical study, on a sequence of meshes, is presented that demonstrates that the large eddy simulation approaches the DNS solution for these quantities with spatial mesh refinement.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
DOE OSTI2015

A hybrid approach for fusing 4D-MRI temporal information with 3D-CT for the study of lung and lung tumor motion

Purpose: Accurate visualization of lung motion is important in many clinical applications, such as radiotherapy of lung cancer. Advancement in imaging modalities [e.g., computed tomography (CT) and MRI] has allowed dynamic imaging of lung and lung tumor motion. However, each imaging modality has its advantages and disadvantages. The study presented in this paper aims at generating synthetic 4D-CT dataset for lung cancer patients by combining both continuous three-dimensional (3D) motion captured by 4D-MRI and the high spatial resolution captured by CT using the authors’ proposed approach. Methods: A novel hybrid approach based on deformable image registration (DIR) and finite element method simulation was developed to fuse a static 3D-CT volume (acquired under breath-hold) and the 3D motion information extracted from 4D-MRI dataset, creating a synthetic 4D-CT dataset. Results: The study focuses on imaging of lung and lung tumor. Comparing the synthetic 4D-CT dataset with the acquired 4D-CT dataset of six lung cancer patients based on 420 landmarks, accurate results (average error <2 mm) were achieved using the authors’ proposed approach. Their hybrid approach achieved a 40% error reduction (based on landmarks assessment) over using only DIR techniques. Conclusions: The synthetic 4D-CT dataset generated has high spatial resolution, has excellent lung details, and is able to show movement of lung and lung tumor over multiple breathing cycles.

60 APPLIED LIFE SCIENCES↗
DOE OSTI2017

Newmark local time stepping on high-performance computing architectures

In multi-scale complex media, finite element meshes often require areas of local refinement, creating small elements that can dramatically reduce the global time-step for wave-propagation problems due to the CFL condition. Local time stepping (LTS) algorithms allow an explicit time-stepping scheme to adapt the time-step to the element size, allowing near-optimal time-steps everywhere in the mesh. We develop an efficient multilevel LTS-Newmark scheme and implement it in a widely used continuous finite element seismic wave-propagation package. In particular, we extend the standard LTS formulation with adaptations to continuous finite element methods that can be implemented very efficiently with very strong element-size contrasts (more than 100x). Capable of running on large CPU and GPU clusters, we present both synthetic validation examples and large scale, realistic application examples to demonstrate the performance and applicability of the method and implementation on thousands of CPU cores and hundreds of GPUs.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2022

Smoothed boundary method for simulating incompressible flow in complex geometries

Simulating flow through porous media with explicit considerations of complex microstructures is very challenging using conventional sharp-interface methods because of the difficulties in generating meshes conformal to complex geometries. In this work, a diffuse interface embedded boundary method known as the Smoothed Boundary Method (SBM) is utilized to facilitate simulations of fluid dynamics involving complex geometries. In diffuse-interface methods, the geometry is described by a domain parameter. The SBM allows the straightforward reformulation of the time-dependent Navier-Stokes equations in terms of this domain parameter, using only algebraic identities. Thus, enforcing the appropriate boundary conditions at the irregular embedded boundary is greatly simplified. Adaptive mesh refinement is used to increase the accuracy of the diffuse interface method by allowing thinner interfacial thickness to be used in the domain parameter. Here, the SBM-formulated Navier-Stokes equations are solved with the Finite Difference Method on refined mesh systems. Sharp-interface Finite Element Method simulations using the commercial software COMSOL on body-conforming meshes are also provided for comparison. Favorable agreement between the two methods is observed. Since it is no longer necessary for the mesh to conform to the complex geometry, the grid system for the SBM simulations can be generated rapidly and without additional manual interventions, making the entire simulation process more expedient.

36 MATERIALS SCIENCE↗
DOE OSTI2013

Prediction and Monitoring Systems of Creep-Fracture Behavior of 9Cr-1Mo Steels for Teactor Pressure Vessels

A recent workshop on next-generation nuclear plant (NGNP) topics underscored the need for research studies on the creep fracture behavior of two materials under consideration for reactor pressure vessel (RPV) applications: 9Cr-1Mo and SA-5XX steels. This research project will provide a fundamental understanding of creep fracture behavior of modified 9Cr-1Mo steel welds for through modeling and experimentation and will recommend a design for an RPV structural health monitoring system. Following are the specific objectives of this research project: Characterize metallurgical degradation in welded modified 9Cr-1Mo steel resulting from aging processes and creep service conditions; Perform creep tests and characterize the mechanisms of creep fracture process; Quantify how the microstructure degradation controls the creep strength of welded steel specimens; Perform finite element (FE) simulations using polycrystal plasticity to understand how grain texture affects the creep fracture properties of welds; Develop a microstructure-based creep fracture model to estimate RPVs service life; Manufacture small, prototypic, cylindrical pressure vessels, subject them to degradation by aging, and measure their leak rates; Simulate damage evolution in creep specimens by FE analyses; Develop a model that correlates gas leak rates from welded pressure vessels with the amount of microstructural damage; Perform large-scale FE simulations with a realistic microstructure to evaluate RPV performance at elevated temperatures and creep strength; Develop a fracture model for the structural integrity of RPVs subjected to creep loads; and Develop a plan for a non-destructive structural health monitoring technique and damage detection device for RPVs.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2018

Characterization of the arc in crossflow using a two-temperature nonequilibrium plasma flow model

Diverse industrial applications such as circuit breakers and wire arc spraying involve the interaction between an electric arc and a stream of gas impinging perpendicular to it, a configuration commonly referred to as the arc in crossflow. The arc in crossflow is simulated using a three-dimensional time-dependent two-temperature (heavy-species and electrons) plasma flow model to better capture plasma-gas interactions and deviations from Local Thermodynamic Equilibrium (LTE). The coupled fluid-electromagnetic flow model is solved in a monolithic manner using Variational Multiscale Finite Element Method. Simulation findings are validated with experimental findings and contrasted against results obtained with a LTE model. Results from the two-temperature model corroborate experimental observations while providing quantification of the deviation between heavy-species and electron temperatures. The model is used to characterize the arc in crossflow as a function of the Reynolds and Enthalpy dimensionless numbers, which encapsulate the inter-dependence among the main parameters total current, inflow velocity, and inter-electrode spacing. Furthermore, the characterization revealed the behavior of arc shape, voltage drop, arc power, the degree of nonequilibrium, as well as the characteristic plasma front thickness, with varying controlling parameters.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2016

Towards performance-portability of the Albany Finite Element analysis code using the Kokkos library of Trilinos

Performance portability on heterogeneous high-performance computing (HPC) systems is a major challenge faced today by code developers: parallel code needs to execute correctly as well as with high performance on machines with different architectures, operating systems, and software libraries. The Finite Element Method (FEM) is a popular and flexible method for discretizing partial differential equations arising in a wide variety of scientific, engineering, and industry applications that require HPC. This paper presents some preliminary results pertaining to our development of a performance portable implementation of the FEM-based Albany code. Performance portability is achieved using the Kokkos library of Trilinos. We present performance results for two different physics simulations modules in Albany: the Aeras global atmosphere dynamical code and the FELIX land-ice solver. As a result, numerical experiments show that our single code implementation gives reasonable performance across two multi-core/many-core architectures: NVIDIA GPUs and multi-core CPUs.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2015

Effect of realistic 3D microstructure in crystal plasticity finite element analysis of polycrystalline Ti-5Al-2.5Sn

The effect of constitutive parameters and microstructure on the kinematic and constitutive responses within grains in a crystal plasticity finite element (CPFE) simulation of a polycrystalline titanium alloy are compared with experimental results. Finally, the simulation of a Ti- 5Al-2.5 Sn sample deformed in uniaxial tension at room temperature used a phenomenological power-law based CPFE model, which includes four families of slip systems commonly observed in structural metals with a hexagonal lattice structure.

36 MATERIALS SCIENCE↗
DOE OSTI2014

Sequential lateral solidification of silicon thin films on low-k dielectrics for low temperature integration

We present the excimer laser crystallization of amorphous silicon on a low dielectric constant (low-k) insulator for very large scale integration monolithic 3D integration and demonstrate that low dielectric constant materials are suitable substrates for 3D integration through laser crystallization of silicon thin films. We crystallized 100 nm amorphous silicon on top of SiO{sub 2} and SiCOH (low-k) dielectrics, at different material thicknesses (1 μm, 0.75 μm, and 0.5 μm). The amorphous silicon crystallization on low-k dielectric requires 35% less laser energy than on an SiO{sub 2} dielectric. This difference is related to the thermal conductivity of the two materials, in agreement with one dimensional simulations of the crystallization process. We analyzed the morphology of the material through defect-enhanced microscopy, Raman spectroscopy, and X-ray diffraction analysis. SEM micrographs show that polycrystalline silicon is characterized by micron-long grains with an average width of 543 nm for the SiO{sub 2} sample and 570 nm for the low-k samples. Comparison of the Raman spectra does not show any major difference in film quality for the two different dielectrics, and polycrystalline silicon peaks are closely placed around 517 cm{sup −1}. From X-ray diffraction analysis, the material crystallized on SiO{sub 2} shows a preferential (111) crystal orientation. In the SiCOH case, the 111 peak strength decreases dramatically and samples do not show preferential crystal orientation. A 1D finite element method simulation of the crystallization process on a back end of line structure shows that copper (Cu) damascene interconnects reach a temperature of 70 °C or lower with a 0.5 μm dielectric layer between the Cu and the molten Si layer, a favorable condition for monolithic 3D integration.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2019

Modeling of the Heat-Affected and Thermomechanically Affected Zones in a Ti-6Al-4V Inertia Friction Weld

Inertia friction welding has been used across the aerospace, automotive, and power-generation industries for the fabrication of complex axisymmetric components for over forty years. The process involves one axisymmetric piece being held stationary and another piece being brought into contact set to rotate about its axis of symmetry by a flywheel with the system under an applied load across the joint. Plasticization at the joint interface through the frictional heating sees the two pieces bond together. The titanium alloy Ti-6Al-4V has been widely studied for inertia welding applications. A successful selection of processing parameters (flywheel energy and mass, applied load) allows an inertia welding process which produces a very high-integrity weld, with a minimal heat-affected zone (HAZ) and thermomechanically affected zone (TMAZ), formed as a narrow band at the interface and extending further into the material. The width of this narrow band of heated material is dependent upon the process parameters used. A series of experimental inertia friction welds were performed using Ti-6Al-4V, and a finite element (FE) modeling framework was developed using the FE code Deform in order to predict the widths of the HAZ and TMAZ at the weld interface. The experimentally observed HAZ boundaries were correlated with the thermal fields from the FE model, while TMAZ boundaries were correlated with the Von Mises plastic strain fields.

42 ENGINEERING↗
DOE OSTI2016

Seismic and LOCA safety testing and analysis program for Westinghouse PWR fuel under end of life conditions

The NRC issued Information Notice - IN 2012-09 in June 2012 which challenges approved assumptions based on the beginning of life (BOL) conditions in seismic and LOCA analysis. Westinghouse manufactures a variety of PWR fuel designs, including 14*14, 15*15, 16*16 and 17*17 array, also different fuel lengths from 12 feet to 14 feet. The fuels are supplied to the cores designed by Westinghouse and Combustion Engineering, and other cores around world. To address IN 2012-09 efficiently and economically, Westinghouse and PWR Owner Groups launched a testing and analysis program funded by PWROG. The program planed testing and analysis matrices based on types of fuel designs. The testing plan includes grid crush tests, fuel assembly mechanical tests and flowing water damping tests. Applying modelling technique, the program will reduce the number of test and cost. The ultimate goal of the program is to generate fuel assembly EOL models for all fuel designs manufactured by Westinghouse and to be ready for any plant specific seismic and LOCA analysis to address NRC IN for EOL effect. The phase I of PWROG for EOL conditions has been completed and several conclusions are obtained. First, the gapped grids reduce grid dynamic stiffness, local impact stiffness and crush strength. Also, due to gapped grids, both the fuel assembly natural frequency and stiffness are reduced. Secondly, applying higher fuel assembly damping due to the flowing water effect can significantly reduce fuel assembly impact forces. However, during a seismic event the reactor coolant pumps may trip resulting in a coast-down. As such, reduced flow rates that occur during the pump coast-down must be considered. Thirdly, the analytical model representation of a reactor core adequately characterizes the core response under seismic and LOCA excitations. Static and dynamic structural test results of a fuel assembly compared with analytical predictions indicate that the fuel assembly lateral and axial structural behavior can be fully determined with finite element models. Fourthly, analyses for EOL fuel assemblies under seismic and LOCA loads demonstrate EOL effect and flowing water damping effect. With flowing water damping benefit, significant margin can be recovered for fuel assemblies with EOL conditions and under seismic loads.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2016

A Well-Posed Two Phase Flow Model and its Numerical Solutions for Reactor Thermal-Fluids Analysis

A 7-equation two-phase flow model and its numerical implementation is presented for reactor thermal-fluids applications. The equation system is well-posed and treats both phases as compressible flows. The numerical discretization of the equation system is based on the finite element formalism. The numerical algorithm is implemented in the next generation RELAP-7 code (Idaho National Laboratory (INL)’s thermal-fluids code) built on top of an other INL’s product, the massively parallel multi-implicit multi-physics object oriented code environment (MOOSE). Some preliminary thermal-fluids computations are presented.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗