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At least 91 records · Page 5

Solar Proton Transport within an ICRU Sphere Surrounded by a Complex Shield: Combinatorial Geometry

The 3DHZETRN code, with improved neutron and light ion (Z (is) less than 2) transport procedures, was recently developed and compared to Monte Carlo (MC) simulations using simplified spherical geometries. It was shown that 3DHZETRN agrees with the MC codes to the extent they agree with each other. In the present report, the 3DHZETRN code is extended to enable analysis in general combinatorial geometry. A more complex shielding structure with internal parts surrounding a tissue sphere is considered and compared against MC simulations. It is shown that even in the more complex geometry, 3DHZETRN agrees well with the MC codes and maintains a high degree of computational efficiency.

Wilson, John W.↗

MOOSE Reactor Module Meshing Enhancements to Support Reactor Physics Analysis

The U.S. Department of Energy Office of Nuclear Energy Advanced Modeling and Simulation (NEAMS) program develops an integrated suite of advanced reactor physics tools built upon the Multiphysics Object-Oriented Simulation Environment (MOOSE) framework. Each code generally requires an input finite element mesh on which the physics solution is calculated, reported, and transferred to other physics codes. The meshing process is often burdensome for the complex geometries present in reactors due to lack of easy-to-use, open-source meshing tools. To address the bottleneck associated with meshing complex geometries found in nuclear reactors, NEAMS initiated the development of the MOOSE Reactor Module starting in FY21. The Reactor Module builds off the existing MOOSE Mesh System to include targeted meshing capabilities such as the ability to generate hexagonal pin cells, assemblies with ducts, rotating control drums, cores, peripheral zones around a core, as well as the automatic labeling (“reporting IDs”) of pin, assembly, and planar zones to simplify post-processing of results. As a Physics Module in MOOSE, the Reactor Module is open-source, available with any MOOSE installation, directly compatible with MOOSE-based tools, and can be invoked from MOOSEbased applications to generate meshes. Functionality from the Reactor Module has been applied to several advanced reactor concepts to demonstrate user workflow improvements and accuracy. The primary objective of the Reactor Module is to improve useability of MOOSEbased tools by streamlining mesh generation and output inspection processes. During FY22, the functionality of the Reactor Module (and accompanying Mesh System) has been expanded based on user needs. First, the Reactor Geometry Mesh Builder capability developed primarily in FY21 has been refactored and merged to the public MOOSE repository. This capability wraps underlying Reactor Module mesh generators into a “Pin – Assembly – Core” workflow appropriate for conventional Cartesian and hexagonal geometries, and notably assigns material IDs during mesh generation stage and generates only the minimal number of blocks needed in order to reduce computational burden. Biasing and boundary layer options have been added to the base mesh generators as required by thermal hydraulics solvers. The reporting ID functionality has been expanded to differentiate ring-wise and azimuthal sectors within a pin for use with depletion algorithms, and VectorPostProcessor and Reporter objects are now available to integrate solution variables across zones based on ID combinations. Functionality to trim hexagonal meshes along the center or periphery has been developed so users may leverage symmetry and reflective boundary conditions to reduce the mesh size. A flexible and powerful tool to fill the space between two sidesets has been introduced to the framework and can be used for transition layers such as stitching two assemblies together with different numbers of pins, or for complex geometries which do not follow conventional Cartesian/hexagonal patterns. Finally, additional verification problems were performed with NEAMS physics tools in complement with existing NEAMS work.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

A Tailored Convolutional Neural Network for Nonlinear Manifold Learning of Computational Physics Data Using Unstructured Spatial Discretizations

In this work, we propose a nonlinear manifold learning technique based on deep convolutional autoencoders that is appropriate for model order reduction of physical systems in complex geometries. Convolutional neural networks have proven to be highly advantageous for compressing data arising from systems demonstrating a slow-decaying Kolmogorov n-width. However, these networks are restricted to data on structured meshes. Unstructured meshes are often required for performing analyses of real systems with complex geometry. Our custom graph convolution operators based on the available differential operators for a given spatial discretization effectively extend the application space of deep convolutional autoencoders to systems with arbitrarily complex geometry that are typically discretized using unstructured meshes. We propose sets of convolution operators based on the spatial derivative operators for the underlying spatial discretization, making the method particularly well suited to data arising from the solution of partial differential equations. We demonstrate the method using examples from heat transfer and fluid mechanics and show better than an order of magnitude improvement in accuracy over linear methods.

97 MATHEMATICS AND COMPUTING↗

Numerical Modeling of a Vortex Stabilized Arcjet

Arcjet thrusters are being actively considered for use in Earth orbit maneuvering applications. Experimental studies are currently the chief means of determining an optimal thruster configuration. Earlier numerical studies have failed to include all of the effects found in typical arcjets including complex geometries, viscosity, and swirling flow. Arcjet geometries are large area ratio converging nozzles with centerbodies in the subsonic portion of the nozzle. The nozzle walls serve as the anode while the centerbody functions as the cathode. Viscous effects are important because the Reynolds number, based on the throat radius, is typically less than 1,000. Experimental studies have shown that a swirl or circumferential velocity component stabilizes a constricted arc. This dissertation describes the equations governing flow through a constricted arcjet thruster. An assumption that the flowfield is in local thermodynamic equilibrium leads to a single fluid plasma temperature model. An order of magnitude analysis reveals the governing fluid mechanics equations are uncoupled from the electromagnetic field equations. A numerical method is developed to solve the governing fluid mechanics equations, the Thin Layer Navier-Stokes equations. A coordinate transformation is employed in deriving the governing equations to simplify the application of boundary conditions in complex geometries. An axisymmetric formulation is employed to include the swirl velocity component as well as the axial and radial velocity components. The numerical method is an implicit finite-volume technique and allows for large time steps to reach a converged steady-state solution. The inviscid fluxes are flux-split, and Gauss-Seidel line relaxation is used to accelerate convergence. Converging-diverging nozzles with exit-to-throat area ratios up to 100:1 and annular nozzles were examined. Quantities examined included Mach number and static wall pressure distributions, and oblique shock structures. As the level of swirl and viscosity in the flowfield increased the mass flow rate and thrust decreased. The technique was used to predict the flow through a typical arcjet thruster geometry. Results indicate swirl and viscosity play an important role in the complex geometry of an arcjet.

Pawlas, Gary E.↗

LAVA Voronoi Mesher for Wall-Modeled Large-Eddy Simulations

The unstructured Voronoi mesher currently being developed within the Launch, Ascent, and Vehicle Aerodynamics (LAVA) software framework at NASA Ames Research Center is described in detail. The discussions include, but are not limited to, the strategies used in the seeding and smoothing phases to ensure a high-quality mesh for Wall-Modeled Large-Eddy Simulations (WMLES), the methods behind the cell clipping algorithm responsible for conforming the mesh to a complex geometry, and the approach to create a global mesh from the distinct Voronoi cells. Applications and benefits of the Voronoi meshing approach are also presented. The automated meshing paradigm introduced was able to significantly reduce the time necessary to create a high-quality mesh around a complex geometry when compared against the current LAVA curvilinear overset meshing standard. For example, the task of generating a single mesh around the high-lift common research model requires the full dedication of a mesh generation expert for a period between one and two months. A family of meshes with different refinement levels up to six hundred million cells can be generated by a single engineer in a day or two. This technology has the potential for decreasing the turnaround time for conducting WMLES around complex geometries, as well as facilitating comprehensive mesh refinement studies.

Victor C B Sousa↗

Aspects of Unstructured Grids and Finite-Volume Solvers for the Euler and Navier-Stokes Equations

One of the major achievements in engineering science has been the development of computer algorithms for solving nonlinear differential equations such as the Navier-Stokes equations. These algorithms are now used in the practical engineering design of devices such as cars and airplanes as well as theoretical studies of complex phenomena such as fluid turbulence. In past years, limited computer resources have motivated the development of efficient numerical methods in computational fluid dynamics (CFD) utilizing structured meshes. These meshes are comprised of systematic arrays of quadrilateral or hexahedral cells. The use of structured meshes greatly simplifies the implementation of CFD algorithms on conventional computers. Structured meshes also permit the use of highly efficient solution techniques such as alternating direction implicit (ADI) iteration schemes or multigrid. Following the dramatic improvement in computing speed in recent years, emphasis has shifted towards the design of algorithms capable of treating complex geometries. The automatic generation of structured grids about complex geometries is problematic. Unstructured grids offer one promising alternative technique for treating these general geometries. Unstructured meshes have irregular connectivity and usually contain triangles and/or quadrilaterals in two dimensions and tetrahedra and/or hexahedra in three dimensions. The generation and use of unstructured grids poses new challenges in computational fluid dynamics. This is true for both grid generation as well as for the design of algorithms for flow solution. The purpose of these notes is to present recent developments in the unstructured grid generation and flow solution technology.

Barth, T. J.↗

Freeform thermoelectrics in single-step manufacturing: additive manufacturing of bismuth-telluride thermoelectrics

The project succeeded in producing crack-free Bismuth Telluride thermoelectric parts with density exceeding 98% through laser powder bed fusion (LPBF) additive manufacturing (AM). This greatly exceeded the highest previously reported density of 88% and is the highest among all semiconducting materials processed by LPBF. The additively manufactured material shows comparable Seebeck coefficient as conventional form and can be made into complex geometries with reduced material loss. On the other hand, measured properties are dramatically sensitive to the AM process parameters used, such that with identical composition, the Seebeck coefficient can be controllably tuned from +120 µV/K to -207 µV/K, which means the material switches between an n-type to a p-type semiconductor depending on processing. These changes are accompanied by significant differences in the as-processed microstructure due to rapid solidification. A machine learning protocol was developed and greatly reduced the experimental burden of the project, reducing the typical process optimization period of 2 years to 6 months. The project was fully successful in the objective of producing defect-free, complex geometry of bismuth-telluride parts through LPBF, but only partially successful in achieving performance goals. First, cost reduction of manufacturing, as measured by material waste, was successfully reduced by up to 70% compared to conventional manufacturing methods. This exceeded the proposed 30% reduction in materials waste needed to reach the 20% cost reduction goal of the project. On the other hand, the device performance, as measured by Seebeck coefficient, failed to reach the 40% improvement in efficiency. Rather, we observe comparable Seebeck coefficient between AM samples and conventionally processed counterparts. The device-level efficiency improvement does exceed 40% for complex geometry samples due to shape-induced increase in temperature gradients, but this was not the originally proposed metric. The machine learning approach developed in this project greatly accelerated the process optimization and can be adopted for fast development of AM processing parameters for other brittle and otherwise difficult-to-print materials. For the public, we deliver an efficient and widely adoptable process for incorporating waste-heat harvesting thermoelectric devices in both industrial and commercial heat exchangers. The geometric flexibility allows the capturing device to conform to the shape of the heat source to improve the system-level conversion efficiency. The technique can be deployed on any commercial LBPF systems with zero modifications, thus poses minimal adoption barrier for any manufacturer that already employed AM technology. Beyond bismuth-telluride, the machine-learning guided optimization protocol can be used in the future to reduce both the time and cost of process development for AM of other energy conversion and harvesting materials.

36 MATERIALS SCIENCE↗

A comparative study of turbulence models for overset grids

The implementation of two different types of turbulence models for a flow solver using the Chimera overset grid method is examined. Various turbulence model characteristics, such as length scale determination and transition modeling, are found to have a significant impact on the computed pressure distribution for a multielement airfoil case. No inherent problem is found with using either algebraic or one-equation turbulence models with an overset grid scheme, but simulation of turbulence for multiple-body or complex geometry flows is very difficult regardless of the gridding method. For complex geometry flowfields, modification of the Baldwin-Lomax turbulence model is necessary to select the appropriate length scale in wall-bounded regions. The overset grid approach presents no obstacle to use of a one- or two-equation turbulence model. Both Baldwin-Lomax and Baldwin-Barth models have problems providing accurate eddy viscosity levels for complex multiple-body flowfields such as those involving the Space Shuttle.

Renze, Kevin J.↗

Methods of treating complex space vehicle geometry for charged particle radiation transport

Current methods of treating complex geometry models for space radiation transport calculations are reviewed. The geometric techniques used in three computer codes are outlined. Evaluations of geometric capability and speed are provided for these codes. Although no code development work is included several suggestions for significantly improving complex geometry codes are offered.

Hill, C. W.↗

Athena-I CUBIT Journal Files

The Monte Carlo N-Particle (MCNP)1 transport code version 6 (also known as MCNP6) has the capability for tracking particles on unstructured mesh (UM) geometry models embedded into con structive solid geometry (CSG) cells. This feature has been developed for performing calculations of complex geometry models because manually creating CSG models is a time-consuming and error prone process as the complexities of geometries increase. The UM capability was originally designed to work with UM models created with the Abaqus software and ASCII input files that it generates. The MCNP code version 6.0 and later can process UM models formatted as Abaqus input files. Starting with version 6.3, MCNP can also process HDF5 mesh input files. External codes must be used to generate Abaqus input files for MCNP UM calculations. CUBIT, the Sandia National Laboratory automated mesh generation toolkit, can generate a UM model formatted as an Abaqus input file. However, the Abaqus input files exported from CUBIT cannot be used for MCNP simulations because it lacks the proper syntax. A Python script was developed to convert an Abaqus file created by CUBIT to an Abaqus file format that MCNP can process. Creating UM models for complex geometries is not an easy task. The process of creating UM models in CUBIT for MCNP simulations is detailed in. CUBIT provides several user interface options including a graphical user interface (GUI) and a command line interface. A GUI provides an easy way to use CUBIT without learning the CUBIT command syntax. When using CUBIT with either interface option, command lines are written into an ASCII file known as a journal file; this journal file can be edited and archived so that it can be played back in CUBIT to automatically generate a UM model. This report describes the CUBIT journal files of the UM models developed for Athena-I. The Athena platform, an energy-tuning assembly, was developed to spectrally shape the National Ignition Facility (NIF) deuterium-tritium fusion neutron source to a thermonuclear (fusion) plus prompt fission neutron spectrum with capability to act as a short-pulse neutron source. MCNP6 was used for the Athena experiment design analysis.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗

CAD-Based Aerodynamic Design of Complex Configurations using a Cartesian Method

A modular framework for aerodynamic optimization of complex geometries is developed. By working directly with a parametric CAD system, complex-geometry models are modified nnd tessellated in an automatic fashion. The use of a component-based Cartesian method significantly reduces the demands on the CAD system, and also provides for robust and efficient flowfield analysis. The optimization is controlled using either a genetic or quasi-Newton algorithm. Parallel efficiency of the framework is maintained even when subject to limited CAD resources by dynamically re-allocating the processors of the flow solver. Overall, the resulting framework can explore designs incorporating large shape modifications and changes in topology.

Nemec, Marian↗

Embedded mesh solutions of the Euler equation using a multiple-grid method

New developments make it now possible to obtain solutions to Euler equations for many problems on the basis of acceptable computing times. The possibility of an extension of these methods to more difficult flows and increasingly complex geometries can depend on obtaining suitable grid structures. Thus, an attractive approach to complex geometries involves the recasting of the problem into the framework of a multiple-grid structure. The discrete equations represented on the grid are solved as a simultaneous system. In the present investigation, this is accomplished with the aid of Ni's multiple-grid algorithm. The multiple-grid structure provided in this study represents the first step towards a completely general modular approach to the solution of the complete compressible flow problem. In the presented cases, a fine mesh resolution is obtained within the embedded mesh regions, while preserving the global coarse mesh convergence rates.

Usab, W. J., Jr.↗

Low-cost fin-tube heat exchanger design for building thermal energy storage using phase change material

Heat transfer in phase change materials (PCMs) is complex because the melting and freezing fronts change as functions of stored or released heat. In prior attempts to optimize heat exchangers (HXs) in one or two dimensions, complex geometry has often been used to maximize the melt and freeze front area. This complex geometry is difficult and hence expensive to construct. This paper proposes a multiple-scale 3D finite element modeling approach to design fin-tube HXs for low-cost latent thermal energy storage applications. Further, the optimal fin and tube designs were determined at three scales (unit-scale, medium-scale, and large-scale) by modeling the melt and freeze front in three dimensions and using measured bulk thermal properties. The finite element model was validated by comparing it with the experimental data for a referenced design of a similar type. The results indicate that commercially available organic PCMs with low conductivity (<0.3 W/m·K) can have charge and discharge times appropriate for building thermal energy storage (i.e., 4–5 h) with fin-tube HX designs at costs <$26/kWh, even when the temperature difference (5.56°C) between the heat transfer fluid and the PCM phase change temperature is small. However, as the HX increases in length, the temperature reduction along the tube limits some larger-scale designs.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

Rapid particle generation from an STL file and related issues in the application of material point methods to complex objects

Abstract In this paper, we focus on three issues related to applications of material point methods (MPMs) to objects with complex geometries. They are material point generation, compatibility of material points with a mesh, and sensitivity to mesh orientation. An efficient method of generating material points from a stereolithography (STL) file is introduced. This material point generation method is independent of the mesh used in MPM calculations. The compatibility between the material points and the mesh is then studied. We also show that the original MPM and the dual domain material point (DDMP) method are sensitive to mesh orientation. These issues are related to the calculation of the internal force and are concerns of the MPMs. They become more prominent when MPMs are applied to complex geometries. Our numerical results show that the recently developed local stress difference (LSD) algorithm (Perez et al. in J Comp Phys 498:112681, 2024) can be used to effectively address them.

36 MATERIALS SCIENCE↗

Influence of topology optimization parameters on the mechanical response of an additively manufactured test structure

Topology Optimization (TO) determines a material distribution within a domain under given conditions and design constraints, and generally generates complex geometries as a result. Complementary to TO, Additive Manufacturing (AM) offers the ability to fabricate complex geometries which may be difficult to manufacture using traditional techniques such as milling. AM has been used in multiple industries including the medical devices area. Hence, TO may be used to create patient-matched devices where the mechanical response is catered to a particular patient. Furthermore, during a medical device regulatory 510(k) pathway, demonstrating that worst-cases are known and tested is critical to the review process. Using TO and AM to predict worst-case designs for subsequent performance testing may be challenging and does not appear to have been thoroughly explored. Investigating the effects of TO input parameters when AM is employed may be the first step in determining the feasibility of predicting these worst-cases.

36 MATERIALS SCIENCE↗

Development of a Nonlinear Probability of Collision Tool for the Earth Observing System

The Earth Observing System (EOS) spacecraft Terra, Aqua, and Aura fly in constellation with several other spacecraft in 705-kilometer mean altitude sun-synchronous orbits. All three spacecraft are operated by the Earth Science Mission Operations (ESMO) Project at Goddard Space Flight Center (GSFC). In 2004, the ESMO project began assessing the probability of collision of the EOS spacecraft with other space objects. In addition to conjunctions with high relative velocities, the collision assessment method for the EOS spacecraft must address conjunctions with low relative velocities during potential collisions between constellation members. Probability of Collision algorithms that are based on assumptions of high relative velocities and linear relative trajectories are not suitable for these situations; therefore an algorithm for handling the nonlinear relative trajectories was developed. This paper describes this algorithm and presents results from its validation for operational use. The probability of collision is typically calculated by integrating a Gaussian probability distribution over the volume swept out by a sphere representing the size of the space objects involved in the conjunction. This sphere is defined as the Hard Body Radius. With the assumption of linear relative trajectories, this volume is a cylinder, which translates into simple limits of integration for the probability calculation. For the case of nonlinear relative trajectories, the volume becomes a complex geometry. However, with an appropriate choice of coordinate systems, the new algorithm breaks down the complex geometry into a series of simple cylinders that have simple limits of integration. This nonlinear algorithm will be discussed in detail in the paper. The nonlinear Probability of Collision algorithm was first verified by showing that, when used in high relative velocity cases, it yields similar answers to existing high relative velocity linear relative trajectory algorithms. The comparison with the existing high velocity/linear theory will also be used to determine at what relative velocity the analysis should use the new nonlinear theory in place of the existing linear theory. The nonlinear algorithm was also compared to a known exact solution for the probability of collision between two objects when the relative motion is strictly circular and the error covariance is spherically symmetric. Figure I shows preliminary results from this comparison by plotting the probabilities calculated from the new algorithm and those from the exact solution versus the Hard Body Radius to Covariance ratio. These results show about 5% error when the Hard Body Radius is equal to one half the spherical covariance magnitude. The algorithm was then combined with a high fidelity orbit state and error covariance propagator into a useful tool for analyzing low relative velocity nonlinear relative trajectories. The high fidelity propagator is capable of using atmospheric drag, central body gravitational, solar radiation, and third body forces to provide accurate prediction of the relative trajectories and covariance evolution. The covariance propagator also includes a process noise model to ensure realistic evolutions of the error covariance. This paper will describe the integration of the nonlinear probability algorithm and the propagators into a useful collision assessment tool. Finally, a hypothetical case study involving a low relative velocity conjunction between members of the Earth Observation System constellation will be presented.

McKinley, David P.↗

Predictive Tools for Customizing Heat Treatment of Additively Manufactured Aerospace Components

Laser-bed powder fusion (LBPF) additive manufacturing is increasingly being used to produce components of complex geometries using the Ni-base superalloy Inconel 718. The composition and the microstructure of the alloy are currently well optimized for wrought components made using conventional manufacturing processes such as rolling, forging, extrusion, etc. The attractive mechanical properties of the alloy result from the underlying austenitic matrix with fine equiaxed grains, and a high density and uniform distribution of the precipitation hardening phase, γ". Heat treatment steps such as homogenization, solutioning and aging are well documented for the wrought alloy. However, when the same wrought alloy compositions are used for the additive manufacturing (AM) processes, the asprocessed microstructure is significantly different, because of the different thermal history associated with LBPF, including rapid solidification and multiple temperature excursions that lead to multiple re-melting and reheating in the solid state. Rapid solidification introduces potential non-equilibrium effects at the moving solid-liquid interfaces that impact the extent of solute segregation, as well as the morphology of the dendritic grains that form. In order to recover the target mechanical properties, AM components have to undergo post-process heat treatments. However, such heat treatments have to be custom designed for the AM process and the component geometry because of the expected vast differences in the microstructure at various locations of a component with complex geometry. The homogenization and precipitation steps should be optimized for the component so that target mechanical properties can be obtained throughout the part. The objective of this research is to utilize High Performance Computing in phase field simulations of microstructure evolution during post-processing of AM components. The physics-based modeling will be beneficial in reducing the experimental effort required for heat treatment process selection, optimization, and certification, thus leading to a significant reduction in energy consumption for AM and post-processing heat treatment. The optimization study will help identify heat treatments steps that are critical for development of a final desired microstructure with the minimum energy input. This combined with shortening of the production cycle (time-to-market) by reducing the number of failed parts (property targets), and reduction in the number of iterations for process optimization, will enable 30-40% savings in the energy costs. Phase field simulations of the degree of homogenization and the effect of local matrix composition on the nucleation and growth of competing precipitating phases were performed using the Microstructure Evolution Using Massively Parallel Phase Field Simulations code developed in-house at the Oak Ridge National Laboratory. The simulations were able to successfully capture the kinetics of nucleation and growth, and morphologies of various precipitating phases as a function of local matrix compositions and composition gradients characteristic of local microstructures arising from location-dependent variations in the thermal conditions. Future work will involve extending the simulations to a length scale consisting of multiple dendrites, so that the effect of homogenization on the coarsening of the dendrites can be simulated and used as an additional input to the optimization of the heat treatment process.

36 MATERIALS SCIENCE↗

CrossLink: General Overview [Slides]

Problem: Traditional mesh generation approaches are labor intensive and have limited robustness when applied to parametric design exploration and optimization of complex geometries. While automatic mesh generation approaches exist, they tend to generate tetrahedral or mixed-hybrid meshes which are generally unsuitable for physics applications with strong shock waves, thin boundary layers, and strong gradients. In addition, simulations sizes in the billions of cells are becoming more common with traditional mesh generation methods quickly reaching scalability limits. Solution: CrossLink offers a topology-based mesh generation approach with unstructured block-filling methods and a scalable mesh generation engine. In addition, CrossLink incorporates a python-based API for seamless workflow integration and robust repeatability of the geometry handling and mesh generation process. This makes it ideal for parametric design study and optimization of complex geometries. Finally, future versions of CrossLink will offer a parametric mesh capability that optimizes a high-order mesh and enables reconstruction of the final mesh in memory by the physics solver.

97 MATHEMATICS AND COMPUTING↗