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83 records · Page 5

Material flow behavior and microstructural refinement of AA6061 alloy during friction extrusion

In this work we used friction extrusion (FE), a solid phase processing technique, to produce dense, fully consolidated 5?mm rods of aluminum alloy 6061 (AA6061). The combination of large shear stresses and high temperatures at the tool-billet interface during extrusion produced equiaxed, dynamically recrystallized grains and finely distributed precipitates. Texture and microstructure evolution during extrusion was investigated in detail using scanning electron microscopy, electron backscatter diffraction, and transmission electron microscopy. Smoothed particle hydrodynamics simulation was performed to study complex material flow during extrusion. Simulation results suggest spiral material flow during extrusion which corroborated experimental results. Advantages of friction extruded microstructure over conventionally extruded counterparts are also explored using flash annealing for solution treatment followed by artificial aging. Mechanical properties of the as-friction extruded, and the artificially aged specimens were evaluated using tensile testing and compared with conventional extruded material properties.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

TEAMER Technical Support of Ramboll's for Numerical Modeling of WECs to Support OES Task 10: Cooperative Research and Development (Final Report)

National Technology & Engineering Solutions of Sandia, LLC (NTESS) in collaboration with the National Renewable Energy Laboratory (NREL), and with guidance from Ramboll, will perform fluid dynamics simulations to support of The Ocean Energy Systems (OES) Energy Technology Collaboration Program Task 10 Wave Energy Converters (WEC) Modelling Verification and Validation effort. Specific numerical simulations include the fixed device wave impingement studies to benchmark the performance of simulation techniques against physical testing results.

16 TIDAL AND WAVE POWER↗

Multiscale and Multiphysics Modeling of Additive Manufacturing of Advanced Materials

The objective of this proposed project is to research and develop a prediction tool for advanced additive manufacturing (AAM) processes for advanced materials and develop experimental methods to provide fundamental properties and establish validation data. Aircraft structures and engines demand materials that are stronger, useable at much higher temperatures, provide less acoustic transmission, and enable more aeroelastic tailoring than those currently used. Significant improvements in properties can only be achieved by processing the materials under nonequilibrium conditions, such as AAM processes. AAM processes encompass a class of processes that use a focused heat source to create a melt pool on a substrate. Examples include Electron Beam Freeform Fabrication and Direct Metal Deposition. These types of additive processes enable fabrication of parts directly from CAD drawings. To achieve the desired material properties and geometries of the final structure, assessing the impact of process parameters and predicting optimized conditions with numerical modeling as an effective prediction tool is necessary. The targets for the processing are multiple and at different spatial scales, and the physical phenomena associated occur in multiphysics and multiscale. In this project, the research work has been developed to model AAM processes in a multiscale and multiphysics approach. A macroscale model was developed to investigate the residual stresses and distortion in AAM processes. A sequentially coupled, thermomechanical, finite element model was developed and validated experimentally. The results showed the temperature distribution, residual stress, and deformation within the formed deposits and substrates. A mesoscale model was developed to include heat transfer, phase change with mushy zone, incompressible free surface flow, solute redistribution, and surface tension. Because of excessive computing time needed, a parallel computing approach was also tested. In addition, after investigating various methods, a Smoothed Particle Hydrodynamics Model (SPH Model) was developed to model wire feeding process. Its computational efficiency and simple architecture makes it more robust and flexible than other models. More research on material properties may be needed to realistically model the AAM processes. A microscale model was developed to investigate heterogeneous nucleation, dendritic grain growth, epitaxial growth of columnar grains, columnar-to-equiaxed transition, grain transport in melt, and other properties. The orientations of the columnar grains were almost perpendicular to the laser motion's direction. Compared to the similar studies in the literature, the multiple grain morphology modeling result is in the same order of magnitude as optical morphologies in the experiment. Experimental work was conducted to validate different models. An infrared camera was incorporated as a process monitoring and validating tool to identify the solidus and mushy zones during deposition. The images were successfully processed to identify these regions. This research project has investigated multiscale and multiphysics of the complex AAM processes thus leading to advanced understanding of these processes. The project has also developed several modeling tools and experimental validation tools that will be very critical in the future of AAM process qualification and certification.

Liou, Frank↗

Embedded smoothed particle hydrodynamics

In this paper, a hybrid method for embedding a meshfree smoothed particle hydrodynamics into mesh-based ALE hydro schemes is presented. The method relies on the embedded mesh framework presented in Puso et al. (2015, 2012) and utilizes SPH (Owen, 2010) in the solid foreground; when an appropriate damage or failure model is used with SPH, it becomes a natural way to model material fracture and cracking in high-explosive driven experiments. Overall, we provide various examples which validate the coupling between SPH and the embedded mesh method.

42 ENGINEERING↗

Some cautionary remarks about smoothed particle hydrodynamics

Potential difficulties with smoothed particle hydrodynamics are discussed. In particular, empirical tests are used to demonstrate that the errors resulting from the use of variable smoothing can be much larger than commonly believed. Fortunately, however, these errors, which are normally small, do not appear to promote instability on small scales, such as fragmentation in self-gravitating fluids. Still, while SPH remains a useful tool for many problems of astrophysical interest, a rigorous formulation of it, which is adaptive but still satisfies conservation properties, is clearly wanting.

Hernquist, Lars↗

Coupling of Sph and Finite Element Codes for Multi-Layer Orbital Debris Shield Design

Particle-based hydrodynamics models offer distinct advantages over Eulerian and Lagrangian hydrocodes in particular shock physics applications. Particle models are designed to avoid the mesh distortion and state variable diffusion problems which can hinder the effective use of Lagrangian and Eulerian codes respectively. However conventional particle-in-cell and smooth particle hydrodynamics methods employ particles which are actually moving interpolation points. A new particle-based modeling methodology, termed Hamiltonian particle hydrodynamics, was developed by Fahrenthold and Koo (1997) to provide an alternative, fully Lagrangian, energy-based approach to shock physics simulations. This alternative formulation avoids the tensile and boundary instabilities associated with standard smooth particle hydrodynamics formulations and the diffusive grid- to-particle mapping schemes characteristic of particle-in-cell methods. In the work described herein, the method of Fahrenthold and Koo has been extended, by coupling the aforementioned hydrodynamic particle model to a hexahedral finite element based description of the continuum dynamics. The resulting continuum model retains all of the features (including general contact-impact effects) of Hamiltonian particle hydrodynamics, while in addition accounting for tensile strength, plasticity, and damage effects important in the simulation of hypervelocity impact on orbital debris shielding. A three dimensional, vectorized, and autotasked implementation of the extended particle method described here has been coded for application to orbital debris shielding design. Source code for the pre-processor (PREP), analysis code (EXOS), post-processor (POST), and rezoner (ZONE), have been delivered separately, along with a User's Guide describing installation and application of the software.

Fahrenthold, Eric P.↗

FSISPH: An SPH formulation for impacts between dissimilar materials

Here, we present an SPH formulation with several new features designed to better model the fully-compressible interaction of dissimilar materials. We developed the new method to simulate the atmospheric entry and break-up of small celestial bodies in planetary atmospheres. The formulation uses a unity-based, density-energy discretization of the hydrodynamic conservation laws with linear-corrected kernel gradients. To account for variations in compressibility, we use an HLLC approximate Riemann solver to adjust the velocity gradient at material interfaces. To handle large transverse velocity discontinuities, we introduce a simple slip interface model that limits the artificial viscosity at material interfaces. Diffusion is optionally applied through the velocity gradient and this allows the density and specific thermal energy to evolve in a manner more consistent with the first law of thermodynamics in comparison to other more direct diffusion schemes. We also introduce a material-local second-order artificial conduction scheme used to smooth the specific thermal energy field. Material damage fits neatly under this framework by treating the damage front as a material interface. The method has been implemented as a solver, FSISPH, within the code, Spheral++, and is publicly available on github. We test our new solver on a number of classic shock, mixing, and multi-material problem. The components we outline can significantly improve accuracy of SPH for problems with sharp contact discontinuities.

79 ASTRONOMY AND ASTROPHYSICS↗

Modeling the Compression of Merged Compact Toroids by Multiple Plasma Jets

A fusion propulsion scheme has been proposed that makes use of the merging of a spherical distribution of plasma jets to dynamically form a gaseous liner. The gaseous liner is used to implode a magnetized target to produce the fusion reaction in a standoff manner. In this paper, the merging of the plasma jets to form the gaseous liner is investigated numerically. The Los Alamos SPHINX code, based on the smoothed particle hydrodynamics method is used to model the interaction of the jets. 2-D and 3-D simulations have been performed to study the characteristics of the resulting flow when these jets collide. The results show that the jets merge to form a plasma liner that converge radially which may be used to compress the central plasma to fusion conditions. Details of the computational model and the SPH numerical methods will be presented together with the numerical results.

Thio, Y. C. Francis↗

Validation of SPH code Spheral to model interacting solid bodies in a supersonic flow

Contemporary discussions of planetary defense involve analyzing the risks posed by smaller sized, 20 to 200 m diameter, asteroids which are capable of breaking up in the atmosphere and generating a blast wave. Consequence assessments for this size class of asteroids are performed through fast-running analytic or semi-analytic models which are informed by high-fidelity hydrocode simulations of asteroid entry and breakup. However, insufficient historical data necessitates validating the independent physical processes which dominate airburst events. Here, the Fluid Solid Interface Smoothed Particle Hydrodynamics solver was previously used by Pearl et al. in 2023 to model the Chelyabinsk airburst and is used here to perform a series of validation simulations. The first effort involves modeling a cylinder in a hypersonic flow and comparing the bow shock geometry to that predicted by analytic theory. The second effort involves modeling the separation of two spherical bodies in supersonic flow and validating against experimental footage. Combined, these exercises demonstrate the ability of the code to model the flight-path of interacting solid bodies in a hypersonic flow.

Airburst↗

Nonaxisymmetric evolution in protostellar disks

We present a two-dimensional, multigridded hydrodynamical simulation of the collapse of an axisymmetric, rotating, 1 solar mass protostellar cloud, which forms a resolved, hydrotastic disk. The code includes the effects of physical viscosity, radiative transfer and radiative acceleration but not magnetic fields. We examine how the disk is affected by the inclusion of turbulent viscosity by comparing a viscous simulation with an inviscid model evolved from the same initial conditions, and we derive a disk evolutionary timescale on the order of 300,000 years if alpha = 0.01. Effects arising from non-axisymmetric gravitational instabilities in the protostellar disk are followed with a three-dimensional SPH code, starting from the two-dimensional structure. We find that the disk is prone to a series of spiral instabilities with primary azimulthal mode number m = 1 and m = 2. The torques induced by these nonaxisymmetric structures elicit material transport of angular momentum and mass through the disk, readjusting the surface density profile toward more stable configurations. We present a series of analyses which characterize both the development and the likely source of the instabilities. We speculate that an evolving disk which maintains a minimum Toomre Q-value approximately 1.4 will have a total evolutionary span of several times 10(exp 5) years, comparable to, but somewhat shorter than the evolutionary timescale resulting from viscous turbulence alone. We compare the evolution resulting from nonaxisymmetric instabilities with solutions of a one-dimensional viscous diffusion equation applied to the initial surface density and temperature profile. We find that an effective alpha-value of 0.03 is a good fit to the results of the simulation. However, the effective alpha will depend on the minimum Q in the disk at the time the instability is activated. We argue that the major fraction of the transport characterized by the value of alpha is due to the action of gravitational torques, and does not arise from inherent viscosity within the smoothed particle hydrodynamics method.

Laughlin, Gregory↗