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Results for “Casting Modeling Simulation”

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NASA NTRS1989

Aeroservoelastic modeling and applications using minimum-state approximations of the unsteady aerodynamics

Various control analysis, design, and simulation techniques for aeroelastic applications require the equations of motion to be cast in a linear time-invariant state-space form. Unsteady aerodynamics forces have to be approximated as rational functions of the Laplace variable in order to put them in this framework. For the minimum-state method, the number of denominator roots in the rational approximation. Results are shown of applying various approximation enhancements (including optimization, frequency dependent weighting of the tabular data, and constraint selection) with the minimum-state formulation to the active flexible wing wind-tunnel model. The results demonstrate that good models can be developed which have an order of magnitude fewer augmenting aerodynamic equations more than traditional approaches. This reduction facilitates the design of lower order control systems, analysis of control system performance, and near real-time simulation of aeroservoelastic phenomena.

Tiffany, Sherwood H.↗

DOE OSTI2017

Formation Mechanism of Surface Crack in Low Pressure Casting of A360 Alloy

A surface crack defect is normally found in low pressure castings of Al alloy with a sudden contraction structure. To further understand the formation mechanism of the defect, the mold filling process is simulated by a two-phase flow model. The experimental results indicate that the main reason for the defect deformation is the mismatching between the height of liquid surface in the mold and pressure in the crucible. In the case of filling, a sudden contraction structure with an area ratio smaller than 0.5 is obtained, and the velocity of the liquid front increases dramatically with the influence of inertia. Meanwhile, the pressurizing speed in the crucible remains unchanged, resulting in the pressure not being able to support the height of the liquid level. Then the liquid metal flows back to the crucible and forms a relatively thin layer solidification shell on the mold wall. With the increasing pressure in the crucible, the liquid level rises again, engulfing the shell and leading to a surface crack. As the filling velocity is characterized by the damping oscillations, surface cracks will form at different heights. The results shed light on designing a suitable pressurizing speed for the low pressure casting process.

36 MATERIALS SCIENCE↗

DOE OSTI2026

An Ab Initio Molecular Dynamics Study of Key Thermodynamic Input Parameters for Computer Simulation of U-6Nb Solidification

The key to metallic fuel development is the fabrication of uranium metal and alloys into fuel forms. U-Nb alloys are one of the best candidates for a metallic fuel alloy with high-temperature strength sufficient to support the core, acceptable nuclear properties, good fabricability, and compatibility with usable coolant media. Melt processing has been a key component of the metallic fuel cycle, and process models require thermophysical parameters at elevated temperatures, particularly above the melting temperatures, regarding which experimental data are scarce, for accurate simulations and process development. By means of ab initio density-functional theory (DFT) quantum molecular dynamics (QMD), we have calculated the main thermophysical parameters—the density, thermal expansion coefficient, specific heat, thermal conductivity, melting temperature, latent heat of fusion, and viscosity—used in the modeling of the U-6 wt.% Nb alloy casting. The melting temperature of the U-6 wt.% Nb alloy at ambient pressure is obtained by means of QMD simulations using the Z-method. The ambient volume change and latent heat of melting of U-6 wt.% Nb are also derived from QMD simulations in conjunction with analytical fitting for the energy and pressure. The thermal conductivity for the solid U-Nb alloy is calculated from the semi-classical Boltzmann transport equation combined with an estimate of the electron relaxation time obtained from DFT simulations.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2017

High-Throughput Study of Diffusion and Phase Transformation Kinetics of Magnesium-Based Systems for Automotive Cast Magnesium Alloys

The objective of the proposed study is to establish a scientific foundation on kinetic modeling of diffusion, phase precipitation, and casting/solidification, in order to accelerate the design and optimization of cast magnesium (Mg) alloys for weight reduction of U.S. automotive fleet. The team has performed the following tasks: 1) study diffusion kinetics of various Mg-containing binary systems using high-throughput diffusion multiples to establish reliable diffusivity and mobility databases for the Mg-aluminum (Al)-zinc (Zn)-tin (Sn)-calcium (Ca)-strontium (Sr)-manganese (Mn) systems; 2) study the precipitation kinetics (nucleation, growth and coarsening) using both innovative dual-anneal diffusion multiples and cast model alloys to provide large amounts of kinetic data (including interfacial energy) and microstructure atlases to enable implementation of the Kampmann-Wagner numerical model to simulate phase transformation kinetics of non-spherical/non-cuboidal precipitates in Mg alloys; 3) implement a micromodel to take into account back diffusion in the solid phase in order to predict microstructure and microsegregation in multicomponent Mg alloys during dendritic solidification especially under high pressure die-casting (HPDC) conditions; and, 4) widely disseminate the data, knowledge and information using the Materials Genome Initiative infrastructure (http://www.mgidata.org) as well as publications and digital data sharing to enable researchers to identify new pathways/routes to better cast Mg alloys.

36 MATERIALS SCIENCE↗

DOE OSTI2023

Microstructure-process relationships in monolithic U-10Mo fuel foil single-pass rolling: A parametric simulation study

In this work, a previously validated coupling of Kinetic Monte Carlo (KMC) Potts Model and finite element method (FEM) simulations was implemented to investigate the effects of microstructural features in as-cast and homogenized monolithic U-10Mo foils on the emergent microstructure after rolling and reheating. Parameters that could potentially affect recrystallization behavior of the rolled U-10Mo foils were considered: grain size distribution, uranium carbide (UC) size distribution, UC volume fraction, spatial distribution of UC, and rolling reduction magnitude. Grain structure and the magnitude of rolling reduction have the strongest influence on recrystallization kinetics and the fabricated grain size distribution. The UC distribution had only a weak effect on the recrystallization kinetics and final microstructures. While particle-stimulated nucleation (PSN) occurred in simulation more frequently as grain size increased, its incidence did not appear to considerably affect the recrystallization kinetics or grain size distribution.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2018

Metal plasticity and ductile fracture modeling for cast aluminum alloy parts

Here in this study, plasticity and ductile fracture properties were characterized by performing various tension, shear, and compression tests. A series of 10 experiments were performed using notched round bars, flat-grooved plates, in-plane shear plates, and cylindrical bars. Two cast aluminum alloys used in automotive suspension systems were selected. Plasticity modelling was performed and the results were compared with experimental and corresponding simulation results; further, the relationships among the stress triaxiality, Lode angle parameter, and equivalent plastic strain at the onset of failure were determined to calibrate a ductile fracture model. Finally, the proposed ductile fracture model shows good agreement with experimental results.

36 MATERIALS SCIENCE↗

DOE OSTI2016

ON THE MISALIGNMENT BETWEEN CHROMOSPHERIC FEATURES AND THE MAGNETIC FIELD ON THE SUN

Observations of the upper chromosphere show an enormous amount of intricate fine structure. Much of this comes in the form of linear features, which are most often assumed to be well aligned with the direction of the magnetic field in the low plasma β regime that is thought to dominate the upper chromosphere. We use advanced radiative magnetohydrodynamic simulations, including the effects of ion-neutral interactions (using the generalized Ohm’s law) in the partially ionized chromosphere, to show that the magnetic field is often not well aligned with chromospheric features. This occurs where the ambipolar diffusion is large, i.e., ions and neutral populations decouple as the ion-neutral collision frequency drops, allowing the field to slip through the neutral population; where currents perpendicular to the field are strong; and where thermodynamic timescales are longer than or similar to those of ambipolar diffusion. We find this often happens in dynamic spicule or fibril-like features at the top of the chromosphere. This has important consequences for field extrapolation methods, which increasingly use such upper chromospheric features to help constrain the chromospheric magnetic field: our results invalidate the underlying assumption that these features are aligned with the field. In addition, our results cast doubt on results from 1D hydrodynamic models, which assume that plasma remains on the same field lines. Finally, our simulations show that ambipolar diffusion significantly alters the amount of free energy available in the coronal part of our simulated volume, which is likely to have consequences for studies of flare initiation.

79 ASTRONOMY AND ASTROPHYSICS↗

NASA NTRS1978

Evaluation of ceramics for stator application: Gas turbine engine report

Current ceramic materials, component fabrication processes, and reliability prediction capability for ceramic stators in an automotive gas turbine engine environment are assessed. Simulated engine duty cycle testing of stators conducted at temperatures up to 1093 C is discussed. Materials evaluated are SiC and Si3N4 fabricated from two near-net-shape processes: slip casting and injection molding. Stators for durability cycle evaluation and test specimens for material property characterization, and reliability prediction model prepared to predict stator performance in the simulated engine environment are considered. The status and description of the work performed for the reliability prediction modeling, stator fabrication, material property characterization, and ceramic stator evaluation efforts are reported.

Trela, W.↗

DOE OSTI2018

Numerical Simulation of the Effects of Horizontal and Vertical EMBr on Jet Flow and Mold Level Fluctuation in Continuous Casting

In this article, a new type of electromagnetic braking (EMBr), named vertical EMBr (V-EMBr) was introduced in the continuous casting process. In order to investigate its capability and applicability, the impacts of horizontal and vertical EMBrs on the flow pattern in a continuous casting mold were simulated by means of an implemented Reynolds-averaged Navier–Stokes (RANS) SST k–ω turbulence model. The characteristics of electromagnetic field and flow field inside a 1450 mm × 230 mm mold with Ruler-EMBr and V-EMBr have been compared. The numerical simulation results indicate that the static magnetic field generated by Ruler-EMBr can cover the main part of the discharging jet flow, which has a better control of the flow pattern in lower part of the mold. The static magnetic field generated by V-EMBr can cover both the vicinity of the mold narrow faces and the impingement region of the jet flow, which can effectively control the liquid steel flow in the upper recirculation zone. The parametric study also shows that the large vortices beneath the jet flow can be almost completely eliminated at an optimized magnetic flux density with Ruler-EMBr. In addition, the surface velocity and steel/slag interface fluctuation can be suppressed with the application of V-EMBr to acceptable values even with a wide variation of SEN port angles. It is estimated that to reach the same level of braking effect on the upper recirculation flow, a magnetic flux density of 0.1 T is sufficient for V-EMBr, while 0.2 T is needed for Ruler-EMBr. Based on the results, a second-generation V-EMBr has been developed, which combines both of the merits of Ruler-EMBr and V-EMBr.

36 MATERIALS SCIENCE↗

NASA NTRS1993

Direct simulation of isothermal-wall supersonic channel flow

The motivation for this work is the fact that in turbulent flows where compressibility effects are important, they are often poorly understood. A few examples of such flows are those associated with astrophysical phenomena and those found in combustion chambers, supersonic diffusers and nozzles, and over high-speed airfoils. For this project, we are primarily interested in compressibility effects near solid surfaces. Our main objective is an improved understanding of the fundamentals of compressible wall-bounded turbulence, which can in turn be used to cast light upon modeling concepts such as the Morkovin hypothesis and the Van Driest transformation. To this end, we have performed a direct numerical simulation (DNS) study of supersonic turbulent flow in a plane channel with constant-temperature walls. All of the relevant spatial and temporal scales are resolved so that no sub grid scale or turbulence model is necessary. The channel geometry was chosen so that finite Mach number effects can be isolated by comparing the present results to well established incompressible channel data. Here the fluid is assumed to be an ideal gas with constant specific heats, constant Prandtl number, and power-law temperature-dependent viscosity. Isothermal-wall boundary conditions are imposed so that a statistically stationary state may be obtained. The flow is driven by a uniform (in space) body force (rather than a mean pressure gradient) to preserve stream wise homogeneity, with the body force defined so that the total mass flux is constant.

Coleman, Gary N.↗

DOE OSTI2022

Impact of carbonation on leaching of constituents from a cementitious waste form for treatment of low activity waste at the DOE Hanford site

Carbonation can be a major aging process during disposal of alkaline cementitious waste forms and can impact constituent leaching by changes in material alkalinity, pore structure, and controlling mineral phases. The effect of carbonation on the leaching of major and trace constituents from Cast Stone, a cementitious waste form developed to treat high salt content low activity waste, was studied through a combination of leaching experiments and reactive transport simulations. Diffusive transport of constituents in the waste form was evaluated using reactive transport modeling of diffusion-controlled leaching test results and a geochemical speciation model derived from pH-dependent leaching. Comparisons between Cast Stone materials aged under nitrogen, air, and 2% carbon dioxide in nitrogen showed that carbonation impacts solubility, physical retention and observed diffusivity of major and trace constituents. Carbonation under 2% CO 2 decreased the diffusion-controlled leaching of chromium by two orders of magnitude. Finally, modeling results suggest that carbonation may also decrease solubility of technetium while changes to microstructure by carbonation increases effective diffusivity of constituents in Cast Stone.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

NASA NTRS1991

Space - A unique environment for process modeling R&D

Process modeling, the application of advanced computational techniques to simulate real processes as they occur in regular use, e.g., welding, casting and semiconductor crystal growth, is discussed. Using the low-gravity environment of space will accelerate the technical validation of the procedures and enable extremely accurate determinations of the many necessary thermophysical properties. Attention is given to NASA's centers for the commercial development of space; joint ventures of universities, industries, and goverment agencies to study the unique attributes of space that offer potential for applied R&D and eventual commercial exploitation.

Overfelt, Tony↗

NASA NTRS2023

Experimental Investigation of Distributed Sand-Grain Roughness Effects on Transition Onset and Turbulent Heating at Mach 6

An experimental investigation of distributed sand-grain surface roughness effects on hypersonic boundary-layer transition and turbulent heating has been performed. Two representative entry vehicle geometries, a sphere-cone aeroshell and a spherical-cap aeroshell, were considered. Cast ceramic models of each geometry were fabricated with distributed sand-grain roughness patterns of different heights that simulated an ablated thermal protection system. Wind tunnel testing was performed at Mach 6 over a range of Reynolds numbers sufficient to produce laminar, transitional, and turbulent flow. Aeroheating and boundary-layer transition onset data were obtained using global phosphor thermography. The experimental heating data are presented herein, as are comparisons to laminar and turbulent smooth-wall heat transfer distributions from computational flow field simulations. The boundary-layer transition data were found to correlate with a functional representation developed in prior roughness studies, although the data scatter was greater owing to the height variability of distributed sand-grain roughness.

Brian R Hollis↗

DOE OSTI2015

Characterisation and modelling of defect formation in direct-chill cast AZ80 alloy

Wrought magnesium alloys for demanding structural applications require high quality defect free cast feedstock. The aim of this study was to first identify and characterise typical defects in direct chill cast magnesium–aluminium–zinc (AZ) alloy billet and then use modelling to understand the origins of these defects so they can be prevented. Defects were first located using ultrasonic inspection and were then characterised using X-ray computed tomography (XCT) and serial sectioning, establishing the presence of oxide films and intermetallic particles Al{sub 8}Mn{sub 5} in all defects. A model was developed to predict the flow patterns and growth kinetics of the intermetallic phases during casting, which influence the formation of defects. Simulation of the growth of the intermetallic particles demonstrated that precipitation from the liquid occurs in the mould. The combination of the entrained oxide films and intermetallic particles recirculates in the liquid metal and continues to grow, until large enough to settle, which is predicted to occur at the centre of the mould where the flow is the slowest. Based on these predictions, strategies to reduce the susceptibility to defect formation are suggested. - Highlights: • Casting defects in magnesium direct chill casting have been imaged and characterised in 3-dimensions. • The occurrences of co-located clusters of particles and oxide films have been characterised and explained. • A coupled model has been developed to help interpret the observed trend for defects located towards the centre of billets.

36 MATERIALS SCIENCE↗

DOE OSTI2018

Direct numerical simulation of mechanical response in synthetic additively manufactured microstructures

Additive manufacturing (AM) processes for metals can yield as-built microstructures that vary significantly from their cast or wrought counterparts. These microstructural variations can in turn, have profound effects on the properties of a component. Here, a modeling methodology is presented to investigate microstructurally-influenced mechanical response in additively manufactured structures via direct numeral simulation. Three-dimensional, synthetic voxelized microstructures are generated by kinetic Monte Carlo (kMC) additive manufacturing process simulations performed at four scan speeds to create a thin-wall cylindrical geometry notionally constructed using a concentric-pathed directed energy deposition AM process. The kMC simulations utilize a steady-state molten pool geometry that is held constant throughout the study. Resultant microstructures are mapped onto a highly-refined conformal finite-element mesh of a part geometry. A grain-scale anisotropic crystal elasticity model is then used to represent the constitutive response of each grain. Here, the response of the structure subjected to relatively simple load conditions is studied in order to provide understanding of both the influence of AM processing on microstructure as well as the microstructure's influence on the macroscale mechanical response.

42 ENGINEERING↗

DOE OSTI2018

Similarity Criteria for the Study of Removal of Spherical Non-metallic Inclusions in Physical Models of Continuous Casting Tundishes: A More Fundamental Approach

Physical modeling is widely used for studying steelmaking processes. The accuracy of this technique depends on the use of appropriate similarity criteria during experimental design. The present work deduced rigorously the similarity criteria for the study of spherical non-metallic inclusions in isothermal physical models of tundishes. Initially, macroscopic quantities were used to simplify the multiphase problem. Then, the similarity criteria were obtained from the dimensionless form of the exact equation of motion for an inclusion in Stokes regime. The validity range of these criteria was discussed and they were compared with common literature practice. Some practical considerations were also presented. This work clarifies various implicit assumptions usually adopted in literature. Additionally, a restrictive criterion to choose the density of the inclusion simulating particles was obtained, which can be satisfied, for example, by hollow glass particles in water models. This criterion is necessary to adequately describe the inclusion motion in regions where fluid elements suffer strong acceleration (e.g., inside nozzles, near flow controllers or in the entering fluid jet). Moreover, it was established an upper limit for the concentration of particles injected in the inlet nozzle of physical models, which do not simulate the phenomenon of inclusion aggregation.

36 MATERIALS SCIENCE↗

DOE OSTI2019

Study of Non-Newtonian Behavior of CaO-SiO{sub 2}-Based Mold Slag and Its Effect on Lubrication in Continuous Casting of Steel

To understand the effect of the non-Newtonian behavior of mold slag on lubrication during continuous casting of steel, the current study investigated the rheology of CaO-SiO{sub 2}-based mold slag using a rotational viscometer with variable rotating speed. The constitutive equations at different temperatures were determined. Subsequently, the obtained viscosity as a function of temperature and shear rate was incorporated into a validated mathematical model. The main results demonstrated that slag viscosity decreased dramatically with increased shear rate as the experimental temperature approached the break temperature of mold slag, meaning that the mold slag had a property of shear thinning. The predicted evolution of slag viscosity during mold oscillation was consistent with the shear thinning as the shear rate exerted on the slag channel varied. The calculated slag consumption was higher than that for slag treated as a Newtonian fluid, which agreed well with measurements using a miniature continuous caster. This study finds that the consideration of the non-Newtonian behavior of mold slag is significant to understand the lubrication mechanism and optimize related parameters via simulation.

36 MATERIALS SCIENCE↗

DOE OSTI2019

Engineering Nucleation Kinetics of Graphite Nodules in Inoculated Cast Iron for Reducing Porosity

Inoculation of cast iron with spherical graphite (SGI) controls nucleation kinetics of graphite nodules and is used for improving casting performance and eliminating solidification micro-porosity. In this study, thermodynamic simulations were used to design inoculants. Thermal and chemical stability of different potential heterogeneous nuclei formed in the melt above the liquidus temperature and in the mushy zone during solidification was predicted. Several inoculation treatments of SGI were performed in laboratory heats. An automated SEM/EDX analysis was applied to examine the graphite nodule size distribution and the family of the non-metallic inclusions in the experimental castings. The data were used to reconstruct a relative graphite nodule nucleation rate in the castings. It was shown that the graphite nodule nucleation kinetics in the castings were significantly different from those predicted by classical nucleation models. In inoculated SGI, the observed bi-modal distribution of graphite nodules was related to a continuous nucleation that occurred towards the end of solidification. The origin of the continuous nucleation and the possibility of engineering graphite nodules nucleation kinetics to control SGI casting soundness by inoculation are discussed.

36 MATERIALS SCIENCE↗