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DOE OSTI2022

A gauge-compatible Hamiltonian splitting algorithm for particle-in-cell simulations using finite element exterior calculus

A particle-in-cell algorithm is derived with a canonical Poisson structure in the formalism of finite element exterior calculus. The resulting method belongs to the class of gauge-compatible splitting algorithms, which exactly preserve gauge symmetries and their associated conservation laws via the momentum map. We numerically demonstrate this time invariance of the momentum map and its usefulness in establishing precise initial conditions with a desired initial electric field and fixed background charge. The restriction of this canonical, finite element Poisson structure to the 1X2P $1\frac {1}{2}$ -dimensional phase space is also considered and simulated numerically.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2022

Instrumented Photovoltaic Modules for Environmental Characterization and Simulation Model Validation

Photovoltaic modules are subjected to various mechanical stressors in their deployment environments, ranging from installation handling to wind and snow loads. Damage incurred during these mechanical events has the potential to initiate subsequent degradation mechanisms, reducing useful module lifespan. Thus, characterizing the mechanical state of photovoltaic modules is pertinent to the development of reliable packaging designs. In this work, photovoltaic modules with strain gauges directly incorporated into the module laminate were fabricated and subjected to mechanical loading to characterize internal strains within the module when under load. These experimental measurements were then compared against results obtained by high-fidelity finite-element simulations. The simulation results showed reasonable agreement in the strain values over time; however, there were large discrepancies in the magnitudes of these strains. Both the instrumentation technique and the finite-element simulations have areas where they can improve. These areas of improvement have been documented. Despite the observed discrepancies between the experimental and simulated results, the module instrumentation proved to be a useful gauge in monitoring and characterizing the mechanical state. With some process improvements, this method could potentially be applied to other environments that a photovoltaic module will encounter in its lifetime that are known to cause damage and degrade performance.

14 SOLAR ENERGY↗

DOE OSTI2026

Inverse design of hypoeutectoid pearlite steel microstructures using a deep learning and genetic algorithm optimization framework

Goal-oriented microstructure design in metallic materials is a challenging task due to complex structure-property relationships. Traditional experimental and computational approaches are time-intensive and economically inefficient, limiting their applicability for large-scale design space exploration. Here, in this work, we propose an end-to-end framework that integrates deep learning models with genetic optimization to design microstructures with targeted mechanical properties. Deep learning models enable accurate forward design, while their integration with genetic optimization enables efficient inverse design within a few hours, compared to days or weeks using conventional finite element simulations. The framework combines experimental characterization and finite element modeling to analyze the influence of microstructural features on the mechanical behavior of hypoeutectoid steels. Data from both experiments and simulations are used to train the deep learning models. To demonstrate its effectiveness, we apply the framework to 0.63% carbon steel with proeutectoid ferrite and pearlite phases, commonly used in industrial applications. In this study, 2D microstructures were used for modeling, selected primarily for computational efficiency and to establish proof of concept. The framework successfully optimizes microstructures for targeted yield strength, ultimate strength, and stress concentration factors while significantly reducing computational time. Beyond hypoeutectoid steels, this scalable framework can be extended to other material systems and integrated with additive manufacturing, offering an efficient approach for accelerating microstructure design for specific engineering applications.

ConvLSTM↗

DOE OSTI2021

In situ characterization of laser-generated melt pools using synchronized ultrasound and high-speed X-ray imaging

Metal additive manufacturing is a fabrication method that forms a part by fusing layers of powder to one another. An energy source, such as a laser, is commonly used to heat the metal powder sufficiently to cause a molten pool to form, which is known as the melt pool. The melt pool can exist in the conduction or the keyhole mode where the material begins to rapidly evaporate. The interaction between the laser and the material is physically complex and difficult to predict or measure. Here, high-speed X-ray imaging was combined with immersion ultrasound to obtain synchronized measurements of stationary laser-generated melt pools. Furthermore, two-dimensional and three-dimensional finite-element simulations were conducted to help explain the ultrasonic response in the experiments. In particular, the time-of-flight and amplitude in pulse-echo configuration were observed to have a linear relationship to the depth of the melt pool. These results are promising for the use of ultrasound to characterize the melt pool behavior and for finite-element simulations to aid in interpretation.

42 ENGINEERING↗

DOE OSTI2024

Facile Tensile Testing Platform for In Situ Transmission Electron Microscopy of Nanomaterials

In situ tensile testing using transmission electron microscopy (TEM) is a powerful technique to probe structure-property relationships of materials at the atomic scale. In this work, a facile tensile testing platform for in situ characterization of materials inside a transmission electron microscope is demonstrated. The platform consists of: 1) a commercially available, flexible, electron-transparent substrate (e.g., TEM grid) integrated with a conventional tensile testing holder, and 2) a finite element simulation providing quantification of specimen-applied strain. The flexible substrate (carbon support film of the TEM grid) mitigates strain concentrations usually found in free-standing films and enables in situ straining experiments to be performed on materials that cannot undergo localized thinning or focused ion beam lift-out. The finite element simulation enables direct correlation of holder displacement with sample strain, providing upper and lower bounds of expected strain across the substrate. The tensile testing platform is validated for three disparate material systems: sputtered gold-palladium, few-layer transferred tungsten disulfide, and electrodeposited lithium, by measuring lattice strain from experimentally recorded electron diffraction data. The results show good agreement between experiment and simulation, providing confidence in the ability to transfer strain from holder to sample and relate TEM crystal structural observations with material mechanical properties.

2D materials↗

DOE OSTI2021

Physics-Informed Machine Learning Models for Predicting the Progress of Reactive-Mixing

This paper presents a physics-informed machine learning (ML) framework to construct reduced-order models (ROMs) for reactive-transport quantities of interest (QoIs) based on high-fidelity numerical simu-lations. QoIs include species decay, product yield, and degree of mixing. The ROMs for QoIs are applied to quantify and understand how the chemical species evolve over time. First, high-resolution datasets for constructing ROMs are generated by solving anisotropic reaction-di?usion equations using a non-negative finite element formulation for di?erent input parameters. The reactive-mixing model input parameters are: time-scale associated with flipping of velocity, spatial-scale controlling small/large vortex structures of velocity, perturbation parameter of the vortex-based velocity, anisotropic dispersion strength/contrast, and molecular diffusion. Second, random forests, F-test, and mutual information criterion are used to evaluate the importance of model inputs/features with respect to QoIs. We observed that anisotropic dispersion strength/contrast is the most important feature and time-scale associated with flipping of velocity is the least important feature. Third, Support Vector Machines (SVM) and Support Vector Regression (SVR) are used to construct ROMs based on the model inputs. The constructed SVR-ROMs are then used to predict scaling of QoIs. We also present estimates and inequalities on the QoIs, which inform that the species decay, mix, and produce in an exponential fashion. These inequalities also inform that a radial basis function is the most suitable kernel for the SVM/SVR models for QoIs. It is observed that R2-score for SVR-ROMs on unseen data is greater than 0.9, implying that the SVR-ROMs are able to predict the reaction-diffusion system state reasonably well. Finally, in terms of the computational cost, the proposed SVM-ROMs are O(107) times faster than running a high-fidelity finite element simulation for evaluating QoIs. This makes the proposed ML-based ROMs attractive for reactive-transport sensing and real-time monitoring applications as they are significantly faster yet reasonably accurate.

Mudunuru, Maruti K.↗

DOE OSTI2020

Global System Reduction Order Modeling for Localized Feature Inclusion

The development of reduced-order models remains an active research area, despite advances in computational resources. Here we develop a novel order-reduction approach that is designed to incorporate isolated regions that contain, for example, nonlinearitites or accumulating damage. The approach is designed to use global modes of the overall system response, which are then naturally coupled to the response in the isolated region of interest. Two examples are provided to demonstrate both the accuracy and the computational efficiency of the proposed approach. The performance of this approach is compared to the exact response corresponding to a finite element simulation for the chosen problems. In addition, the accuracy and computational efficiency are shown relative to a standard Galerkin reduction based on the linear normal modes. It is found that the proposed reduction offer computational efficiency comparable to a Galerkin reduction, but more accurately represents the response of the system when both are compared to the finite element simulation.

42 ENGINEERING↗

DOE OSTI2020

Iodine Effects on Medical Isotope Producer Delay & Guard Bed Temperature and Performance in Support of NA-23 Program

In support of NA-23’s objective to accelerate the establishment of a reliable commercial United States (U.S.) domestic supply of 99Mo produced without the use of highly enriched uranium (HEU), the Pacific Northwest National Laboratory (PNNL) was tasked with modeling the performance of activated carbon delay and guard beds that may be typical for non-HEU 99Mo production processes. The specific tasks accomplished by PNNL included calculations of long-term effects of iodine on delay bed performance and development of a finite element simulation to better understand delay bed performance under various scenarios specifically with radioxenon and radioiodine decay heating of the delay beds. The main issue of interest in this study is understanding the effect of iodine on the abatement performance of the beds if iodine is not sufficiently removed from gases prior to reaching the delay beds. Finite element simulations of delay bed performance were developed using COMSOL Multiphysics® Software. These simulations are based on partial differential equations that describe xenon and iodine adsorption, heat transfer and decay of radioxenon and radioiodine isotopes. Heat transfer in the activated carbon beds is simulated with a heat source tied to the decay of radioactive xenon and iodine species. These simulations were used to investigate delay bed temperature and hold up time using radioxenon and radioiodine activities and flowrates expected from a non-HEU production process. A bounding case scenario was simulated, where all the iodine was released into the delay beds due to insufficient guarding of the delay beds. In addition, preliminary investigations of the guard beds were conducted.

07 ISOTOPE AND RADIATION SOURCES↗

NASA NTRS1991

FIESTA ROC: A new finite element analysis program for solar cell simulation

The Finite Element Semiconductor Three-dimensional Analyzer by Ralph O. Clark (FIESTA ROC) is a computational tool for investigating in detail the performance of arbitrary solar cell structures. As its name indicates, it uses the finite element technique to solve the fundamental semiconductor equations in the cell. It may be used for predicting the performance (thereby dictating the design parameters) of a proposed cell or for investigating the limiting factors in an established design.

Clark, Ralph O.↗

DOE OSTI2023

Effect of Diphenyl Content on Viscoelasticity of Poly(dimethyl- co -diphenyl)siloxane Melt and Network

Polydimethylsiloxane (PDMS) is one of the most widely used polymeric materials for sealants, adhesives, lubricants, and thermal as well as electrical insulation. At low temperatures, however, PDMS is subject to crystallization that can cause deterioration in mechanical function. A common way to suppress such crystallization is through the incorporation of phenylsiloxane into the backbone of polysiloxane. Nevertheless, the introduction of phenyl components, even in small quantities, could potentially change the properties of the siloxane in a significant way. In this work, a series of mechanical tests and finite element simulations were performed to study the macroscale viscoelasticity of two poly(dimethyl-co-diphenyl)siloxane formulations in order to understand the effects of a few percent diphenyl contents on the viscoelasticity of the polysiloxane material. Here, we utilized the small-angle X-ray scattering to investigate the microscopic structures of the copolymers and broadband dielectric spectroscopy and rheology to probe the chain dynamics at the microscale. The results of these characterizations were used to inform the finite element simulations. We found that the degree of cross-linking does not significantly alter the microstructure but can profoundly affect the viscoelastic response of the copolymer networks. The corresponding hysteretic behavior is interpreted in terms of reptation-like motion and relaxation of the effective free chains in the cured polymer network. The relaxation of the copolymer chains is slowed significantly by even a small increase in the molar ratio of the diphenyl component.

36 MATERIALS SCIENCE↗

NASA NTRSDate not supplied

Evaluation of Human Spaceflight-Related Tissue Weight Relief Using Whole Body Finite Element Model Simulations

Tissue Weight Relief (TWR) is a physiological condition observed in human spaceflight. It not only impacts the injury biomechanics of soft tissue but also the physiological responses of the cardiovascular system both due to fluid redistribution and the effect of tissue-related transmural pressure on the large venous blood vessels. Understanding the effects of tissue weight relief is especially important because of the role it may play in understanding the cause of Space Associated Neuro-Ocular Syndrome (SANS). SANS can be characterized by a number of ocular changes which reduce visual acuity and SANS related symptoms occur in up to 51% of astronauts. A prevailing theory for the causation of SANS is that of headward (cephalad) fluid shift and a prolonged increase of Intracranial Pressure (ICP) similar to intracranial hypertension, which is not fully supported by the experimental data or astronaut symptom reporting. However, it is still believed that SANS is caused by a pressure change in the eye and the surrounding tissues. It has been proposed that TWR plays a substantial role in affecting internal pressures and fluid shifts in microgravity. In this effort, two whole-body Finite Element (FE) models – Elemance and THUMS – are used to ascertain the microgravity-associated TWR of the musculature surrounding the lower body veins. Elemance and THUMS are physics-based computational models that have been validated and verified for several automotive and domestic applications, and as such, can simulate the relief of soft tissue weight due to changes in the gravitation vector. Specifically, the current effort modeled the transition of the gravitational vector from 1G to 0G, applied across the whole-body model in a supine position. For each 1G to 0G transition simulation, the lower body vein’s transmural pressure-time profile was extracted and averaged around the anterior portion of the thigh muscle. The ascertained transmural pressure changes from 1G to 0G transition are given in Figure 1 for the Elemance and the THUMS FE models. The transmural pressure changes of 10 mmHg and 21 mmHg are in the same order of magnitude as Lu’s value of 44 mmHg. It is to be noted that Lu implemented a 0D to 1D lumped parameter model and the Elemance and THUMS are 3D higher order computational models. This proof-of-concept approach demonstrates that TWR pressure can be adequately estimated with in silico techniques however, further in silico investigations need to be conducted to address the unique contributions to the transmural pressure from each of the computational models.

Finite element modeling↗

DOE OSTI2019

AC Resistance Reduction Using Orthogonal Air Gaps in High-Frequency Inductors: Preprint

This paper presents a relatively simple technique to reduce winding losses due to fringing fields in high-frequency inductors. In high-frequency power electronics, ac inductor winding losses are affected by skin and proximity effects, including uneven current distribution due to fringing magnetic fields around airgaps. It is well known how fringing effects can be mitigated using distributed airgaps, at the expense of non-standard core or winding geometry. In planar magnetics, the orthogonal-airgap approach proposed in this paper combines airgaps in core segments parallel with the windings with conventionally placed airgaps in segments perpendicular to the windings. The approach is developed using a 1D analytical framework and validated by 2D finite-element simulations. Analytical guidelines are presented to optimize the airgaps to achieve minimum ac resistance. As a case study, a planar inductor is designed for an 8~kW SiC-based buck converter operating at 250~kHz. It is shown how the orthogonal airgaps result in more than 45\% reduction in ac resistance and substantially reduced inductor losses compared to the design using standard airgaps. The results are verified by loss measurements on an experimental converter prototype.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2020

Ultrasonic waves from radial mode excitation of a piezoelectric disc on the surface of an elastic solid

In this work, we discuss the ultrasonic wave propagation characteristics in an isotropic elastic solid due to the radial mode excitation of a piezoelectric disc actuator bonded to its surface. Finite element simulations using coupled electromechanical modeling is employed to investigate the wave propagation behavior. We find that the radial mode vibrations on the surface of the elastic solid generates all the three types of ultrasonic waves: longitudinal, shear, and surface waves. The waves in the solid are comprised of a central lobe and multiple side lobes based on the frequency of the radial mode excitation. The central lobe is predominantly composed of longitudinal waves and the side lobes are composed of shear waves. While the longitudinal waves have a strong central lobe and weak side lobes that are not fully developed, shear waves consists of fully developed side lobes. In addition, we observe that the longitudinal waves have fewer side lobes inside the solid compared to the shear waves. A semi-analytical approach is presented to explain the above observations. The interface traction boundary condition between the piezoelectric disc and the elastic solid is approximated as a truncated 'Bessel' excitation over the area of the piezoelectric disc in contact with the solid. A Fourier–Bessel series expansion technique is used to investigate the wave propagation behavior from the above traction boundary condition. The results obtained explain the observations from the finite element simulations with regard to the number and distribution of side lobes pertaining to the longitudinal and shear waves generated from the radial modes of the piezoelectric disc. The proposed semi-analytical approach is general and can be applied to any arbitrary axisymmetric excitations on the surface of an elastic solid.

36 MATERIALS SCIENCE↗

DOE OSTI2022

High strain-rate compression behavior of polymeric rod and plate Kelvin lattice structures

The compressive high strain-rate behavior of polymeric Kelvin lattice structures with rod-based or plate-based unit cells was investigated through experimental techniques and finite element simulations. Polymeric lattice structures with 5x5x5 unit cell geometries were manufactured on the millimeter scale using vat polymerization additive manufacturing and tested at low (0.001/s) and high (1000/s) strain-rates. High strain-rate experiments were performed and validated for a viscoelastic split-Hopkinson (Kolsky) pressure bar system (SHPB) coupled with high-speed imaging and digital image correlation (DIC). Experimental results at both low and high strain-rates show the formation of a localized deformation band which was more prevalent in low relative density specimens and low strain-rate experiments. Strain-rate effects of lattice specimens strongly correlate with effects of the base polymer material; both bulk polymer and lattice specimen demonstrated strain-rate hardening, strain-rate stiffening, and decreased fracture strain under dynamic loading. Results show mechanical failure properties and energy absorption depended strongly on the relative density of the lattice specimen and exhibited distinct scaling between relative density and geometry type (rod, plate) and loading rate. High relative density plate-lattices demonstrated inferior mechanical properties to rod-lattices; however, there exists a critical relative density for a given mechanical property (17%- 28%) below which plate-lattices outperform rod-lattices of similar mass. As a result, high strain-rate explicit finite element simulations were performed and showed good agreement with the mechanical failure trends and deformation modes observed in the experiments.

36 MATERIALS SCIENCE↗

NASA NTRS1979

Crash simulation of composite and aluminum helicopter fuselages using a finite-element program

This paper describes a mathematical investigation of the crash-impact responses of an all-composite helicopter cockpit section incorporating an energy absorbing concept and one of conventional aluminum construction, using the Grumman DYCAST finite-element nonlinear structural dynamics computer program. The overall objective of this initial investigation was to explore the application of DYCAST to the design of future helicopter structures. The specific purposes are to assess the value of the finite-element code as a crashworthiness design analysis tool, and to compare the responses of the two fuselage sections. The results indicate that the finite-element simulation is a powerful analysis tool, providing sufficient detail to evaluate individual structural components, and that the crashworthiness of an all-composite cockpit section could be enhanced with energy-absorbing concepts

Winter, R.↗

NASA NTRS1997

Finite Element Aircraft Simulation of Turbulence

A turbulence model has been developed for realtime aircraft simulation that accommodates stochastic turbulence and distributed discrete gusts as a function of the terrain. This model is applicable to conventional aircraft, V/STOL aircraft, and disc rotor model helicopter simulations. Vehicle angular activity in response to turbulence is computed from geometrical and temporal relationships rather than by using the conventional continuum approximations that assume uniform gust immersion and low frequency responses. By using techniques similar to those recently developed for blade-element rotor models, the angular-rate filters of conventional turbulence models are not required. The model produces rotational rates as well as air mass translational velocities in response to both stochastic and deterministic disturbances, where the discrete gusts and turbulence magnitudes may be correlated with significant terrain features or ship models. Assuming isotropy, a two-dimensional vertical turbulence field is created. A novel Gaussian interpolation technique is used to distribute vertical turbulence on the wing span or lateral rotor disc, and this distribution is used to compute roll responses. Air mass velocities are applied at significant centers of pressure in the computation of the aircraft's pitch and roll responses.

McFarland, R. E.↗

NASA NTRS2019

Quadruple Simulations of Thermographic Inspections of Impacted Composites

Thermography has been shown to be a viable technique for inspection of composites. Impact damage in composites typically contains multiple overlapping delaminations at different depths. Understanding the limitations of the thermographic inspection is enhanced by performing simulations of the technique. Most simulations of composite thermographic inspections have focused on simulations of a single delamination at a fixed depth. The quadrupole method has been shown as a viable technique for rapid three-dimensional thermographic simulations of a delamination. This method is expanded to enable rapid simulation of multiple overlapping delaminations at different depths. Quadrupole simulations are compared to finite element simulations of multiple delaminations at different depths. The simulations are also compared to the thermographic measurements on impacted composites where shape and depth of the delaminations are known from x-ray computed tomography data.

Winfree, William P.↗

NASA NTRSDate not supplied

Quadrupole Simulations of Thermographic Responses of Composites

Thermography has been shown to be a viable technique for inspection of composites. The quadrupole method has been shown as a viable technique for rapidedly simulating the thermal repsonse of layered systems. Often, the effort has focused on a one-dimentional models, in particular for improved analysis of thermal data. For composites, the in-plane heat diffusion often significantly impacts the thermal response of defects of interest, therefore three-dimensional simulations are desirable. This paper discusses the extension of the quadrupole methodology to perform simulations of thermographic responses in three-dimensional configuration. This enables the more realistic simulations of the thermal response of delaminiations in composites. The simulations are compared to finite element simulations of the same inspection configurations. The simulations are also compared to the thermographic measurements on composites where shape and depth of the delaminations are known obtained from other sources.

Thermography↗