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At least 757 records · Page 42
All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

Learning two-phase microstructure evolution using neural operators and autoencoder architectures

Abstract Phase-field modeling is an effective but computationally expensive method for capturing the mesoscale morphological and microstructure evolution in materials. Hence, fast and generalizable surrogate models are needed to alleviate the cost of computationally taxing processes such as in optimization and design of materials. The intrinsic discontinuous nature of the physical phenomena incurred by the presence of sharp phase boundaries makes the training of the surrogate model cumbersome. We develop a framework that integrates a convolutional autoencoder architecture with a deep neural operator (DeepONet) to learn the dynamic evolution of a two-phase mixture and accelerate time-to-solution in predicting the microstructure evolution. We utilize the convolutional autoencoder to provide a compact representation of the microstructure data in a low-dimensional latent space. After DeepONet is trained in the latent space, it can be used to replace the high-fidelity phase-field numerical solver in interpolation tasks or to accelerate the numerical solver in extrapolation tasks.

36 MATERIALS SCIENCE↗
DOE OSTI2015

Atomistic to continuum modeling of solidification microstructures

We summarize recent advances in modeling of solidification microstructures using computational methods that bridge atomistic to continuum scales. We first discuss progress in atomistic modeling of equilibrium and non-equilibrium solid–liquid interface properties influencing microstructure formation, as well as interface coalescence phenomena influencing the late stages of solidification. The latter is relevant in the context of hot tearing reviewed in the article by M. Rappaz in this issue. We then discuss progress to model microstructures on a continuum scale using phase-field methods. We focus on selected examples in which modeling of 3D cellular and dendritic microstructures has been directly linked to experimental observations. Finally, we discuss a recently introduced coarse-grained dendritic needle network approach to simulate the formation of well-developed dendritic microstructures. The approach reliably bridges the well-separated scales traditionally simulated by phase-field and grain structure models, hence opening new avenues for quantitative modeling of complex intra- and inter-grain dynamical interactions on a grain scale.

36 MATERIALS SCIENCE↗
NASA NTRS2007

Solidification Behavior of gamma'-Ni3Al Containing Alloys in the Ni-Al-O System

The chemical activities of Al and Ni in gamma(prime)-Ni3Al-containing systems were measured using the multi-cell Knudsen effusion-cell mass spectrometry technique (multi-cell KEMS), over the composition range 8 - 32 at.%Al and temperature range T = 1400 - 1750 K. From these measurements a better understanding of the equilibrium solidification behaviour of gamma(prime)-Ni3Al-containing alloys in the Ni-Al-O system was established. Specifically, these measurements revealed that (1) gamma(prime)-Ni3Al forms via the peritectiod reaction, gamma + Beta (+ A12O3) = gamma (prime) (+ Al2O3), at 1633 +/- 1 K, (2) the {gamma + Beta + Al2O3} phase field is stable over the temperature range 1633 through 1640 K, and (3) equilibrium solidification occurs by the eutectic reaction, L (+ Al2O3) = gamma + Beta (+ Al2O3), at 1640 +/- 1 K and a liquid composition of 24.8 +/- 0.2 at.%Al (at an unknown oxygen content). When projected onto the Ni-Al binary, this behaviour is inconsistent with the current Ni-Al phase diagram and a new diagram is proposed. This new Ni-Al phase diagram explains a number of unusual steady-state solidification structures reported previously and provides a much simpler reaction scheme in the vicinity of the gamma(prime)-Ni3Al phase field.

Copland, Evan↗
DOE OSTI2018

Evolution Mechanism of Oxide Inclusions in Titanium-Stabilized AISI 443 Stainless Steel

The evolution mechanism of oxide inclusions in Ti-bearing AISI 443 stainless steel was investigated by industrial experiment and thermodynamic calculation. The chemical compositions of steel and the characteristics of inclusions in steel were analyzed. After the addition of Al, the main type of inclusions in molten steel was irregular MgO·Al{sub 2}O{sub 3} spinel. The MgO·Al{sub 2}O{sub 3} inclusions were modified to be spherical CaO-Al{sub 2}O{sub 3}-MgO inclusions after calcium treatment. Thermodynamic calculation results indicated that several ppm Ca could significantly expand the liquid oxide phase field and decrease the stability of spinel. After titanium addition, two types of inclusions were formed: spherical Al{sub 2}O{sub 3}-TiO{sub x} inclusions and complex CaO-TiO{sub x}-Al{sub 2}O{sub 3}-MgO inclusions. The compositions of steel after Ti addition were mostly located in Al{sub 2}O{sub 3}-TiO{sub x} stability phase field. Based on the characteristics of inclusions in steel and thermodynamic calculation, inclusions consisting of liquid and CaTiO{sub 3} were formed in molten steel with more than 10 ppm Ca during the Ti addition process. The evolution mechanism of oxide inclusions was discussed with the consideration of the initial calcium content before Ti addition.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Multiscale Modeling of Microstructural Evolution in Fused-Coating Additive Manufacturing

A quantitative phase field model with adaptive-computational-domain-expansion (ACDE) method was developed to simulate the microstructural evolution in fused-coating additive manufacturing process. A heat transfer and fluid flow model was established to investigate the solidification behavior of the molten pool in a single deposited layer. The solidification parameters such as temperature gradient and solidification rate were calculated from the macroscopic model and then fed into the phase field model to get the microstructure at different positions within a single deposited layer. Columnar dendrites were formed at the bottom of the deposited layer, and equiaxed dendrites appeared in the upper part of the layer. The ACDE method is used to improve the simulation efficiency. The metallographic experiments and energy-dispersive spectrometer analysis for composition were conducted on the fused-coating specimen, and the results were in good accordance with the simulations.

36 MATERIALS SCIENCE↗
DOE OSTI2017

Model Development in MARMOT for High Burn-up Structure Formation

A phase field model for the formation of High Burn-up Structure (HBS) was developed and implemented in MARMOT. The model takes into consideration the chemical energy of gas atoms, interfacial energies of grain boundaries and bubble surfaces, and strain energy associated with dislocations, which renders the model capable of simulating the concurrent formation and growth of both bubbles and sub-grains. Moreover, in contrast to existing phase-field models of recrystallization, the current model makes no ad hoc or a priori assumptions for the nucleation rate or recrystallized grain size and shape. All the model parameters were quantified in terms of thermodynamic and kinetic properties. The model predicts a strong effect of magnitude and distribution of dislocation density, grain boundary energy, and bubble surface energy on the formation of sub-grains. The model results were shown to agree well with theoretical predictions. For polycrystalline UO 2 at 1200K, the recrystallized average grain size was found to be on the order of of 0.6-1.3 microns at a burn-up in the range of 98-105 GWD/tU. These values lie well within the range of reported data in literature.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2018

High-Temperature Deformation Behavior of Ti-6Al-2Sn-4Zr-2Mo Alloy with Lamellar Microstructure Under Plane-Strain Compression

High-temperature plane-strain compression of a Ti-6Al-2Sn-4Zr-2Mo (Ti-6242) alloy with a lamellar structure was applied by a thermal simulation machine Gleeble 3800 at a temperature of 1223-1370 K and a strain rate of 0.01-10 s{sup −1}. Constitutive relations between the flow stress and strain at different temperatures and strain rates were constructed based on the Arrhenius equation. Processing maps based on the dynamic material model at strains of 0.5, 1.0, and 1.25 were also constructed to analyze the mechanism and instability of high-temperature deformation. Dynamic recrystallization was found to occur at 1223-1313 K and 0.01-0.1 s{sup −1}, with a peak efficiency of power dissipation of 70%. Observations of the microstructure demonstrated that α platelets and dynamic globularization were responsible for dynamic softening in the α + β phase field. Flow instability behaviors occurred at 1263-1343 K/1.78-10 s{sup −1}, 1233-1283 K/0.1-3.16 s{sup −1}, and 1353-1373 K/0.56-1.78 s{sup −1}, and adiabatic shear bands and microcracks were observed in these domains. Thus, for the lamellar Ti-6242 alloy, the recommended hot rolling parameters were 1243-1333 K and 0.01-0.1 s{sup −1}. Electron backscattered diffraction results revealed that the dynamic restoration mechanism in the β phase field was dynamic recovery when the strain rate was as high as 10 s{sup −1}.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Resolution requirements for high-speed droplet impact along a rigid wall

The mechanical and thermal loads that are produced on high-speed projectiles from a droplet are key in the projectile development.To accurately predict the pressure produced along the wall surface during impact, it is important to correctly model the air/water interface of the droplet. Novel modeling approaches such as the Phase-Field enable control of the (numerical) interface thickness. However, the interplay between the grid resolution (including potential adaptive mesh refinement) and the interface thickness is unclear. In this work, the resolution requirements for numerical simulations of a two-dimensional cylindrical water droplet impacting a rigid wall at Mach four are computationally investigated. Numerical simulations are performed using a second-order accurate scheme with adaptive mesh refinement and a Phase-Field interface model. The choice of numerical interface thickness and resolution parameters affects the maximum pressure and location of the maximum pressure along the wall. The overall maximum pressure does not converge even at high resolutions. The number of levels and thickness (number of cells across the interface) play a role in obtaining a well behaved solution.

Burrell, E.↗
DOE OSTI2017

Spatiotemporal multiplexing based on hexagonal multicore optical fibres

Based on a genetic algorithm, we have solved in this paper the problem of finding the parameters of optical Gaussian pulses which make their efficient nonlinear combining possible in one of the peripheral cores of a 7-core hexagonal fibre. Two approaches based on individual selection of peak powers and field phases of the pulses launched into the fibre are considered. Finally, the found regimes of Gaussian pulse combining open up new possibilities for the development of devices for controlling optical radiation.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Controlled Nucleation and Stabilization of Ferroelectric Domain Wall Patterns in Epitaxial (110) Bismuth Ferrite Heterostructures

Ferroelectric domain walls, topological entities separating domains of uniform polarization, are promising candidates as active elements for nanoscale memories. In such applications, controlled nucleation and stabilization of domain walls are critical. In this work, using in situ transmission electron microscopy and phase-field simulations, a controlled nucleation of vertically oriented 109° domain walls in (110)-oriented BiFeO 3 (BFO) thin films is reported. In the switching experiment, reversed domains that are nucleated preferentially at the nanoscale edges of the “crest and sag” pattern-like electrode under external bias subsequently grow into a stable stripe configuration. In addition, when triangular pockets (with an in-plane polarization component) are present, these domain walls are pinned to form stable flux-closure domains. Phase field simulations show that i) field enhancement at the edges of the electrode causes site-specific domain nucleation, and ii) the local electrostatics at the domain walls drives the formation of flux closure domains, thus stabilizing the striped pattern, irrespective of the initial configuration. The results demonstrate how flux closure pinning can be exploited in conjunction with electrode patterning and substrate orientation to achieve a desired topological defect configuration. These insights constitute critical advancements in exploiting domain walls in next generation ferroelectronic devices.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
NASA NTRS2026

Controlled Parametric Forcing During Directional Solidification of a Bulk Organic Alloy Under Microgravity

The response of dendritic microstructures to step-like pulling velocity conditions is investigated using microgravity directional solidification experiments conducted on DECLIC-DSI combined with phase-field simulations. Under a constant pulling velocity of 1.5 µm/s, the evolution toward steady-state growth is characterized in terms of primary spacing, dendrite drift, and tip dynamics. For the first time, side-view observations enabled direct measurement of tip radius and sidebranching frequency. When step-like oscillations of the pulling velocity are imposed, the dendritic array exhibits a strongly period-dependent response: short periods lead to rapid tip adaptation, whereas longer periods induce a phase lag between tip position and morphology, resulting in progressive tip flattening and, above a critical period, interface destabilization and dendrite splitting. Quantitative phase-field simulations, including a realistic thermal field and stochastic noise, reproduce the experimental observations and provide insight into the governing mechanisms, highlighting the role of characteristic relaxation times, sequence-dependent effects, and the irreversible reorganization of the microstructure following splitting.

Microgravity↗
DOE OSTI2016

Nanoscale Origins of Ferroelastic Domain Wall Mobility in Ferroelectric Multilayers

Here we investigate the nanoscale origins of ferroelastic domain wall motion in ferroelectric multilayer thin films that lead to giant electromechanical responses. We present direct evidence for complex underpinning factors that result in ferroelastic domain wall mobility using a combination of atomic-level aberration corrected scanning transmission electron microscopy and phase-field simulations in model epitaxial (001) tetragonal (T) PbZr x Ti 1-x O 3 (PZT)/rhombohedral (R) PbZr x Ti 1-x O 3 (PZT) bilayer heterostructures. The local electric dipole distribution is imaged on an atomic scale for a ferroelastic domain wall that nucleates in the R-layer and cuts through the composition breaking the T/R interface. Our studies reveal a highly complex polarization rotation domain structure that is nearly on the knife-edge at the vicinity of this wall. Induced phases, namely tetragonal-like and rhombohedral-like monoclinic were observed close to the interface, and exotic domain arrangements, such as a half-four-fold closure structure, are observed. Phase field simulations show this is due to the minimization of the excessive elastic and electrostatic energies driven by the enormous strain gradient present at the location of the ferroelastic domain walls. Thus, in response to an applied stimulus, such as an electric field, any polarization reorientation must minimize the elastic and electrostatic discontinuities due to this strain gradient, which would induce a dramatic rearrangement of the domain structure. This insight into the origins of ferroelastic domain wall motion will allow researchers to better “craft” such multilayered ferroelectric systems with precisely tailored domain wall functionality and enhanced sensitivity, which can be exploited for the next generation of integrated piezoelectric technologies.

36 MATERIALS SCIENCE↗
DOE OSTI2016

Features in simulation of crystal growth using the hyperbolic PFC equation and the dependence of the numerical solution on the parameters of the computational grid

We investigate the three-dimensional mathematical model of crystal growth called PFC (Phase Field Crystal) in a hyperbolic modification. This model is also called the modified model PFC (originally PFC model is formulated in parabolic form) and allows to describe both slow and rapid crystallization processes on atomic length scales and on diffusive time scales. Modified PFC model is described by the differential equation in partial derivatives of the sixth order in space and second order in time. The solution of this equation is possible only by numerical methods. Previously, authors created the software package for the solution of the Phase Field Crystal problem, based on the method of isogeometric analysis (IGA) and PetIGA program library. During further investigation it was found that the quality of the solution can strongly depends on the discretization parameters of a numerical method. In this report, we show the features that should be taken into account during constructing the computational grid for the numerical simulation.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2016

Multiscale Model for Simulating Fission-Induced Recrystallization in U-Mo Alloy

U-Mo alloy is one of the most promising fuels for the future high performance research and test reactors due to its high uranium loading density and stable irradiation behavior. However, a major concern to its qualification is the fuel swelling at high fission density due to the formation of large fission-gas bubbles. The fission-induced recrystallization further expedites the formation and growth of gas bubbles. So far, the exact mechanism of recrystallization is still unclear. One possible driving force for recrystallization is the production of point defects and interstitial loops due to irradiation. Following this, we developed a multi-scale model by integrating the rate-theory and phase-field models to study microstructural evolutions in irradiated U-Mo alloy, i.e., fission-induced gas bubble evolution and recrystallization. Density function theory (DFT) calculations are utilized to predict the defect formation energies, diffusivities of defects, the interfacial energy of gas bubble, and the elastic constants of U-Mo alloy, etc. The dislocation density evolution is predicted by the rate-theory developed by Jeff. The grain subdivision occurs once the dislocation density is above a critical value. The grain growth coupled with gas bubbles evolution is modeled using a multi-phase phase-field model. The effects of fission rate and initial grain microstructure on the recrystallization process are systematically investigated. The simulated dislocation density, sub-grain size distribution, and volume fraction of the recrystallization grains under different fission density are comparable with experimental data. (authors)

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2022

Fragmentation of faceted crystalline wires

The reduction of surface energy is a well-known driving force for the fragmentation of nanowires. Fragmentation can limit the service life of those small low-dimensional building blocks or can be controlled to induce beneficial shape changes. For isotropic surface energy, fragmentation is analogous to the classic Rayleigh-Plateau instability of liquid jets. However, commonly synthesized crystalline nanowires have strongly anisotropic surface energies and exhibit facets coinciding with cusps in the Wulff plot. Depending on growth orientation, different fragmentation behaviors have been seen in nanowires. Using phase-field simulations, we show that fragmentation of faceted nanowires with cubic crystal symmetry may occur by a finite-amplitude nonlinear instability, as opposed to a Rayleigh-Plateau-like linear instability, depending on nanowire growth orientation. Here, we carry out a weakly nonlinear analysis based on sharp interface theory to characterize the faceted nanowire shape corresponding to a surface-energy saddle point. The analysis predicts that the minimum amplitude of a periodic shape perturbation to trigger fragmentation increases with cusp strength but decreases inversely proportionally to the perturbation wavelength for long wavelengths, in good quantitative agreement with phase-field predictions. The results provide the theoretical foundation to predict nanowire stability as a function of length and surface energy in diverse applications.

36 MATERIALS SCIENCE↗
DOE OSTI2015

Oscillatory cellular patterns in three-dimensional directional solidification

We present a phase-field study of oscillatory breathing modes observed during the solidification of three-dimensional cellular arrays in micro-gravity. Directional solidification experiments conducted onboard the International Space Station have allowed for the first time to observe spatially extended homogeneous arrays of cells and dendrites while minimizing the amount of gravity-induced convection in the liquid. In situ observations of transparent alloys have revealed the existence, over a narrow range of control parameters, of oscillations in cellular arrays with a period ranging from about 25 to 125 minutes. Cellular patterns are spatially disordered, and the oscillations of individual cells are spatiotemporally uncorrelated at long distance. However, in regions displaying short-range spatial ordering, groups of cells can synchronize into oscillatory breathing modes. Quantitative phase-field simulations show that the oscillatory behavior of cells in this regime is linked to a stability limit of the spacing in hexagonal cellular array structures. For relatively high cellular front undercooling (\ie low growth velocity or high thermal gradient), a gap appears in the otherwise continuous range of stable array spacings. Close to this gap, a sustained oscillatory regime appears with a period that compares quantitatively well with experiment. For control parameters where this gap exist, oscillations typically occur for spacings at the edge of the gap. However, after a change of growth conditions, oscillations can also occur for nearby values of control parameters where this gap just closes and a continuous range of spacings exists. In addition, sustained oscillations at to the opening of this stable gap exhibit a slow periodic modulation of the phase-shift among cells with a slower period of several hours. While long-range coherence of breathing modes can be achieved in simulations for a perfect spatial arrangement of cells as initial condition, global disorder is observed in both three-dimensional experiments and simulations from realistic noisy initial conditions. The, erratic tip splitting events promoted by large amplitude oscillations contribute to maintaining the long-range array disorder, unlike in thin sample experiments where long-range coherence of oscillations is experimentally observable.

36 MATERIALS SCIENCE↗
NASA NTRS2019

In Situ Observation of Growth Dynamics in DECLIC Directional Solidification Insert Onboard ISS: DSI-R Flight Campaign

The study of solidification microstructure formation is of utmost importance for materials design and processing, as solid-liquid interface patterns largely govern mechanical and physical properties. Pattern selection occurs under dynamic conditions of growth in which the initial morphological instability evolves nonlinearly and undergoes a reorganization process. The dynamic and nonlinear nature of this instability renders in situ observation of the interface an invaluable tool to gain knowledge on the time-evolution of the interface pattern. Transparent organic analogs, which solidify like metallic alloys, allow direct visualization of interface dynamics. Extensive ground-based studies of both metallic and organic bulk samples have established the presence of significant convection during solidification processes that alters the formation of interfacial microstructures. A reduced-gravity environment is therefore mandatory for fluid flow elimination in bulk samples. In the framework of the CNES project MISOL3D (MIcrostrutures de SOLidification 3D) and the NASA projects DSIP (Dynamical Selection of 3D Interface Patterns), SPADES (SPAtiotemporal Evolution of three-dimensional DEndritic array Structures) and CAMUS (ComputAtional Studies of MicrostrUcture Formation During Alloy Solidification in Microgravity), we participated in the development of the Directional Solidification Insert (DSI) of the DEvice for the study of Critical Liquids and Crystallization (DECLIC). The DECLIC-DSI is dedicated to in situ and real-time characterization of solid-liquid interface patterns during directional solidification of transparent alloys in diffusive transport regime. Between April 2010 and March 2011, the first ISS campaign (DSI) explored the entire range of microstructures resulting in unprecedented observations. A second campaign (DSI-R), performed between October 2017 and December 2018, in which the insert contained an alloy of higher solute concentration, allowed to complete the benchmark database. The increase of solute concentration resulted in well-developed dendritic patterns at lower velocities (lower interface curvature and larger tip radius). The microstructure resulting from dendritic growth is dominant in metallurgy so that it is fundamental to understand the mechanisms of its formation. The main aims of this experimental campaign are to understand: the mechanisms of the cell to dendrite transition, the fundamental mechanisms of sidebranching formation, the dependence of dendrite tip shapes on growth conditions, the interaction of primary array and secondary sidebranches, and the influence of subgrain boundaries on the spatiotemporal organization of the array structure. Preparation, analysis and interpretation of the experiments performed onboard ISS are considerably enhanced by experiments performed on ground using thin-samples (Pr. Trivedi’s group) and phase-field simulations of microstructure formation in a diffuse growth regime (Pr. Karma’s group). In this summary, we will present an initial assessment of the results obtained during the DSI-R campaign. Nomenclature Vp: pulling velocity G: thermal gradient L: solidified length rtip: tip curvature radius Acronyms/Abbreviations CADMOS: Centre d'Aide au Développement des activités en Micro-pesanteur et des Opérations Spatiales CNES: Centre National d’Études Spatiales DECLIC: Device for the study of Critical LIquids and Crystallization DSI: Directional Solidification Insert DSI-R: Directional Solidification Insert - Refurbish ISS: International Space Station NASA: National Aeronautics and Space Administration PF: phase-field SCN: Succinonitrile 3D: three-dimensional

Mota, F.L.↗