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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 109 records · Page 6
All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

Minimizing thickness variation in monolithic U-10Mo fuel foil and Zr interlayer during hot rolling: A microstructure-based finite element method analysis

Low-enriched uranium alloyed with 10 wt. % molybdenum (U-10Mo) has been identified as a promising alternative to highly enriched uranium fuel for the United States’ high performance research reactors. The monolithic U-10Mo fuel plate consists of a metallic U-10Mo fuel foil with a 25 µm Zr interlayer and a relatively thick cladding of aluminum alloy 6061. The Zr interlayer is typically applied during the hot co-rolling process, and this process dictates the uniformity of the Zr interlayer. Thickness variation observed in the U-10Mo and Zr interlayer has been attributed to several sources: the initial grain size of the U-10Mo castings, can materials, rolling temperature, inhomogeneous molybdenum content, and porosity in the cast U-10Mo. This thickness variation limits the ability to meet the dimensional specification; thus, a better understanding of the factors causing the nonuniform thickness is needed. In this work, we used a novel, microstructure-based finite element method to model the hot rolling process to address these concerns. Grain microstructures in U-10Mo were tessellated and explicitly considered in the finite element model. Each grain was assigned a random material property to mimic the grain strength variations induced by different grain orientations. Simulations were performed using six steel can thicknesses, four grain sizes, and with or without a Zr interlayer to investigate the influences of those variables on the thickness nonuniformity. The simulation results showed that a thinner steel can and finer U-10Mo grain size reduce thickness variations in both the U-10Mo fuel foil and Zr interlayer. The direct findings from the simulations and analysis can be used to optimize the hot rolling schedule, reduce fabrication defects, and meet the dimensional specifications. The proposed microstructure-based finite element model can be also coupled with experimental microstructure characterization data, images, and models to simulate multi-pass hot rolling.

36 MATERIALS SCIENCE↗
DOE OSTI2014

Simulation of the ultrasonic array response from real branched cracks using an efficient finite element method

A hybrid model to simulate the ultrasonic array response from stress corrosion cracks is presented. These cracks are branched and difficult to detect so the model is required to enable optimization of an array design. An efficient frequency-domain finite element method is described and selected to simulate the ultrasonic scattering. Experimental validation results are presented, followed by an example of the simulated ultrasonic array response from a real stress corrosion crack whose geometry is obtained from an X-ray Computed Tomography image. A simulation-assisted array design methodology, which includes the model and use of real crack geometries, is proposed.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
DOE OSTI2024

Efficient sensitivity analysis of the thermal profile in powder bed fusion of metals using hypercomplex automatic differentiation finite element method

Rapid cyclic temperature fluctuation occurring in powder bed fusion of metals using a laser beam (PBF-LB/M) influences the formation of flaws in printed parts. Consequently, there is a pressing need to enhance the quality of printed parts by developing innovative methodologies that can predict thermal histories and help uncover the intricate relationships between process parameters and thermal profiles. Sensitivity Analysis (SA) emerges as an essential tool for this, offering the potential for process optimization and enhanced quality control. Nonetheless, conventional SA methodologies often incur in excessive computational costs and potential numerical approximation errors. Here, to address this technical challenge, we present a novel method for SA that integrates the HYPercomplex-based Automatic Differentiation (HYPAD) technique with transient thermal simulations conducted via the finite element method (FEM). Leveraging this methodology, we efficiently and accurately perform SA for PBF-LB/M processes in a post-processing step. Compared to traditional methods like Finite Differences (FD), HYPAD-FEM required 96 % less computational time for obtaining sensitivities for 22 process parameters, under a comparative study conducted within the context of the 2018–02 AM benchmark of the National Institute of Standards and Technology. In summary, HYPAD-FEM offers superior efficiency and accuracy in SA over conventional methods, delivering the best sensitivity of a model without the need for step-size selection and problem or parameter-based implementations.

36 MATERIALS SCIENCE↗
DOE OSTI2014

Finite volume and finite element methods applied to 3D laminar and turbulent channel flows

The work deals with numerical simulations of incompressible flow in channels with rectangular cross section. The rectangular cross section itself leads to development of various secondary flow patterns, where accuracy of simulation is influenced by numerical viscosity of the scheme and by turbulence modeling. In this work some developments of stabilized finite element method are presented. Its results are compared with those of an implicit finite volume method also described, in laminar and turbulent flows. It is shown that numerical viscosity can cause errors of same magnitude as different turbulence models. The finite volume method is also applied to 3D turbulent flow around backward facing step and good agreement with 3D experimental results is obtained.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
DOE OSTI2019

Acceleration of tensor-product operations for high-order finite element methods

This article is devoted to graphics processing unit (GPU) kernel optimization and performance analysis of three tensor-product operations arising in finite element methods. We provide a mathematical background to these operations and implementation details. Achieving close to peak performance for these operators requires extensive optimization because of the operators’ properties: low arithmetic intensity, tiered structure, and the need to store intermediate results during the kernel execution. We give a guided overview of optimization strategies and we present a performance model that allows us to compare the efficacy of these optimizations against an empirically calibrated roofline.

Świrydowicz, Kasia↗
DOE OSTI2023

COUPLING SMOOTHED PARTICLE HYDRODYNAMICS WITH FINITE ELEMENT METHOD TO SIMULATE RESIDUAL STRESSES FROM FRICTION STIR PROCESSING

Friction stir processing (FSP) is a solid-state material processing technique that locally modifies the microstructure but also induces undesirable residual stresses. A robust numerical model for the FSP can help in mitigating these residual stresses. Heat source models within a finite element method (FEM) framework suffer from inaccuracies. In contrast, smoothed particle hydrodynamics (SPH) model that explicitly captures the material flow near the tool and the associated heat generation are accurate. However, the computational expense of SPH simulations can be prohibitive. In this work, we propose a coupled SPH-FEM framework. SPH is used to model the heat generation accurately near the tool and which is then inserted into to the FEM model as a heat source. To verify this proposed coupling approach, a test case is set up with typical FSP conditions and it is modeled in both SPH and SPH-FEM. The temperatures profiles were compared after the simulations have reached steady-state temperatures. The similarity of the temperature profiles from SPH-FEA and SPH validated the proposed coupling approach. This proposed approach achieves the accuracy of the SPH method while potentially retaining the low computational expense of FEM.

smoothed particle hydrodynamics, Finite Element Me↗
DOE OSTI2014

Full wave simulation of waves in ECRIS plasmas based on the finite element method

This paper describes the modeling and the full wave numerical simulation of electromagnetic waves propagation and absorption in an anisotropic magnetized plasma filling the resonant cavity of an electron cyclotron resonance ion source (ECRIS). The model assumes inhomogeneous, dispersive and tensorial constitutive relations. Maxwell's equations are solved by the finite element method (FEM), using the COMSOL Multiphysics{sup ®} suite. All the relevant details have been considered in the model, including the non uniform external magnetostatic field used for plasma confinement, the local electron density profile resulting in the full-3D non uniform magnetized plasma complex dielectric tensor. The more accurate plasma simulations clearly show the importance of cavity effect on wave propagation and the effects of a resonant surface. These studies are the pillars for an improved ECRIS plasma modeling, that is mandatory to optimize the ion source output (beam intensity distribution and charge state, especially). Any new project concerning the advanced ECRIS design will take benefit by an adequate modeling of self-consistent wave absorption simulations.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
DOE OSTI2019

Thermal analysis of VCSEL arrays based on first principle theory and finite element method

Al{sub x}Ga{sub 1−x}As is a main epitaxial material of 850-nm VCSEL. In order to analyze lattice match and heat production, the band gap of Al{sub x}Ga{sub 1−x}As was built, using the first-principles calculation theory. In addition, based on thermoelectric coupling three-dimensional (3D) finite element method, details on the surface temperature distributions of different 850-nm VCSEL arrays were analyzed. Array spacing and array form have an effect on heat dissipation of VCSEL arrays. The diamond array with 18 light emitting units shows the best thermal stability among others.

77 NANOSCIENCE AND NANOTECHNOLOGY↗
DOE OSTI2012

A Full-wave Model for Wave Propagation and Dissipation in the Inner Magnetosphere Using the Finite Element Method

A wide variety of plasma waves play an important role in the energization and loss of particles in the inner magnetosphere. Our ability to understand and model wave-particle interactions in this region requires improved knowledge of the spatial distribution and properties of these waves as well as improved understanding of how the waves depend on changes in solar wind forcing and/or geomagnetic activity. To this end, we have developed a two-dimensional, finite element code that solves the full wave equations in global magnetospheric geometry. The code describes three-dimensional wave structure including mode conversion when ULF, EMIC, and whistler waves are launched in a two-dimensional axisymmetric background plasma with general magnetic field topology. We illustrate the capabilities of the code by examining the role of plasmaspheric plumes on magnetosonic wave propagation; mode conversion at the ion-ion and Alfven resonances resulting from external, solar wind compressions; and wave structure and mode conversion of electromagnetic ion cyclotron waves launched in the equatorial magnetosphere, which propagate along the magnetic field lines toward the ionosphere. We also discuss advantages of the finite element method for resolving resonant structures, and how the model may be adapted to include nonlocal kinetic effects.

43 PARTICLE ACCELERATORS↗
DOE OSTI2023

A finite element method for angular discretization of the radiation transport equation on spherical geodesic grids

Discrete ordinate (S N ) and filtered spherical harmonics (FP N ) based schemes have been proven to be robust and accurate in solving the Boltzmann transport equation but they have their own strengths and weaknesses in different physical scenarios. We present a new method based on a finite element approach in angle that combines the strengths of both methods and mitigates their disadvantages. The angular variables are specified on a spherical geodesic grid with functions on the sphere being represented using a finite element basis. A positivity-preserving limiting strategy is employed to prevent non-physical values from appearing in the solutions. Here, the resulting method is then compared with both S N and FP N schemes using four test problems and is found to perform well when one of the other methods fail.

79 ASTRONOMY AND ASTROPHYSICS↗
DOE OSTI2026

Full-wave modeling of RF waves in fusion plasmas with finite element method: Progress in past decades and its future role

This paper reviews the progress in computing radio frequency (RF) wave fields in fusion plasmas, specifically focusing on simulations utilizing the finite element method (FEM) over the past few decades. Computing RF wave fields in fusion plasmas presents unique challenges due to large simulation domains, complex antenna structures, non-local dielectric properties, and wide ranges of spatial scales. It highlights key developments and outlines future directions, primarily addressing waves in the ion cyclotron (IC) to lower hybrid (LH) frequency range. We begin with briefly revisiting earlier developments before the widespread availability of modern computer-aided engineering (CAE) software based on FEM. This historical perspective illuminates early progress and the physics difficulties that motivated ongoing work within the community. Modern wave simulations for RF antennas based on FEM are characterized by the use of detailed 3D antenna model geometry generated from engineering CAD software and localized wave dielectric model. Significant advancements have also been made in improving physics models to include phenomena such as RF sheath rectification and wave scattering. FEM-based RF simulations have also been applied to compute wave propagation in the core region, where the inclusion of non-local dielectric response is crucial. This is a challenging goal, and several promising approaches have been proposed in this area. Additionally, RF simulation development initiatives based on open-source libraries have gained popularity, demonstrating scalability and flexibility in extending physics models. This paper will discuss the advantages and disadvantages of using such a publicly available FEM library.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2014

A finite elements method to solve the Bloch–Torrey equation applied to diffusion magnetic resonance imaging

The complex transverse water proton magnetization subject to diffusion-encoding magnetic field gradient pulses in a heterogeneous medium can be modeled by the multiple compartment Bloch–Torrey partial differential equation (PDE). In addition, steady-state Laplace PDEs can be formulated to produce the homogenized diffusion tensor that describes the diffusion characteristics of the medium in the long time limit. In spatial domains that model biological tissues at the cellular level, these two types of PDEs have to be completed with permeability conditions on the cellular interfaces. To solve these PDEs, we implemented a finite elements method that allows jumps in the solution at the cell interfaces by using double nodes. Using a transformation of the Bloch–Torrey PDE we reduced oscillations in the searched-for solution and simplified the implementation of the boundary conditions. The spatial discretization was then coupled to the adaptive explicit Runge–Kutta–Chebyshev time-stepping method. Our proposed method is second order accurate in space and second order accurate in time. We implemented this method on the FEniCS C++ platform and show time and spatial convergence results. Finally, this method is applied to study some relevant questions in diffusion MRI.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
DOE OSTI2024

Creep and Creep Fracture Modeling with Surrogate Creep Models and the Extended Finite Element Method

Alloy components in advanced nuclear reactors will be subjected to environmental conditions that could include high temperatures, irradiation, and exposure to corrosive salts. These conditions could lead to the formation of crack-like defects, which could grow over time in a mechanism known as creep crack growth (CCG). Predicting growth rates of these defects is important for assessing the safe operating life of advanced reactors. This project documents progress toward developing and testing next-generation data-driven constitutive models for deformation creep. It also documents the application of the extended finite element method in conjunction with surrogate creep models to predict CCG parameters under a variety of conditions. These important incremental developments contribute to the longer-term objective of developing microstructure-aware constitutive models that can be used for predicting creep deformation and CCG at the component scale with improved accuracy.

36 MATERIALS SCIENCE↗
DOE OSTI2025

A note on the reliability of goal-oriented error estimates for Galerkin finite element methods with nonlinear functionals

Here, we consider estimating the discretization error in a nonlinear functional J (u) in the setting of an abstract variational problem: find u ϵ $\mathscr{V}$ such that B (u, φ) = L (φ) ∀φ ϵ $\mathscr{V}$, as approximated by a Galerkin finite element method. Here, $\mathscr{V}$ is a Hilbert space, B (. , .) is a bilinear form, and L (∙) is a linear functional. We consider well-known error estimates η of the form J (u) - J (u h ) ≈ η = L (z) - B (u h , z), where u h denotes a finite element approximation to u, and z denotes the solution to an auxiliary adjoint variational problem. We show that there exist nonlinear functionals for which error estimates of this form are not reliable, even in the presence of an exact adjoint solution z. An estimate η is said to be reliable if there exists a constant C ϵ $\mathbb{R}$ >0 independent of u h such that |J (u) - J (u h )| ≤ C|η|. We present several example pairs of bilinear forms and nonlinear functionals where reliability of η is not achieved.

A posteriori↗
DOE OSTI2017

Mechanical and Microstructural Effects of Thermal Aging on Cast Duplex Stainless Steels by Experiment and Finite Element Method

Cast duplex stainless steel piping in light water nuclear reactors expe- rience thermal aging embrittlement during operational service. Interest in extending the operational life to 80 years requires an increased understanding of the microstructural evolution and corresponding changes in mechanical behavior. We analyze the evolution of the microstructure during thermal aging of cast CF-3 and CF-8 stainless steels using electron microscopy and atom probe tomography. The evolution of the mechanical properties is measured concurrently by mechanical methods such as tensile tests, Charpy V-notch tests, and instrumented nanoinden- tation. A microstructure-based finite element method model is developed and uti- lized in conjunction with the characterization results in order to correlate the local stress-strain effects in the microstructure with the bulk measurements. This work is supported by the DOE Nuclear Energy University Programs (NEUP), contract number DE-NE0000724.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Modeling of High-Temperature Corrosion of Zirconium Alloys Using the eXtended Finite Element Method (X-FEM)

Oxidation modeling in modern nuclear fuel performance codes is currently limited by the lack of coupling with mechanics, thus preventing proper description of how high-temperature oxidation impacts mechanical properties. This is mostly due to the fact that the finite difference formalism adopted in corrosion models is incompatible with the direct coupling with mechanics in the finite element modeling employed in modern nuclear fuel performance codes. In this study, a physically based zirconium alloy corrosion model called the Coupled-Current Charge Compensation (C4) model, which was initially developed for operating temperature conditions, has been updated to include high-temperature corrosion in order to provide additional critical information (e.g., oxygen concentration profile) under loss-of-coolant accident (LOCA) conditions—information lacking in existing empirical models. The C4 model was implemented in the MOOSE finite-element framework developed at Idaho National Laboratory, enabling it to be used in the BISON nuclear fuel performance code based on the MOOSE framework. To precisely track the different interfaces at a relatively low computational cost, the eXtended Finite Element Method (X-FEM) was applied in MOOSE. The model’s results were compared to those of existing empirical models as well as metallographic analysis of high-temperature oxidized Zircaloy-4 coupons. Oxygen diffusivities in the a and ß phases resulting from this comparison closely agree with those found in the literature. The C4 model implemented with X-FEM in MOOSE now has the capability to accurately predict oxide, oxygen-stabilized a, and prior ß phase layer growth kinetics under isothermal exposure at high temperature (1000–1500°C). Furthermore, in contrast with the empirical models, the C4 model accounts for the finite thickness of the fuel cladding. It can predict the oxygen concentration profile evolution through the whole cladding, enabling evaluation of the remaining ductile thickness—a crucial variable for modeling the mechanical behavior of the fuel cladding under LOCA. Furthermore, this implementation allows direct coupling with mechanics, at a low computing cost, using finite-element-based nuclear fuel performance codes such as BISON.

36 MATERIALS SCIENCE↗