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DOE OSTI2025

Advancing material modeling in hydrocodes using a concurrent finite-element and molecular dynamics multiscale framework

We present a multiscale simulation framework that couples the finite-element method with molecular dynamics. Bypassing traditional equations of state (EOS) by using in-line atomistic simulations, the method offers the advantage of incorporating detailed microscale physics not easily represented with coarse-grained models. Coupling consistency with the continuum code is ensured through the use of lifting and restriction operators, in line with heterogeneous multiscale methods. The concurrent continuum-atomistic framework is validated through comparison with experimental results and conventional EOS models, and demonstrated in a shock-driven hydrodynamic flow simulation under extreme conditions. We further evaluate the framework's usability by comparing it to state-of-the-art EOS models of deuterium. A computational performance study reveals that the atomistic EOS evaluation is a feasible alternative to conventional approaches, and demonstrates a weak scaling of 99% efficiency. These results highlight the framework's potential for large-scale multiscale modeling across a broad range of materials and conditions.

Computer science↗

DOE OSTI2023

Genetic Algorithm-Based Commutation Angle Control for Torque Ripple Mitigation in Switched Reluctance Motor Drives

This work addresses the application of the Genetic Algorithm (GA) technique to optimize the commutation angles of a 2 kW 8/6 switched reluctance machine (SRM). The primary goal is to reduce the well-known drawback of SRMs: the torque ripple. Firstly, the machine was modeled in Matlab /Simulink ® using lookup tables obtained via finite element method (FEM) simulations. Subsequently, the model was used to perform the GA routine aiming to find the optimal phase commutation angles that minimize the torque ripple factor. Notably, the torque performance of the SRM was significantly affected by the commutation angles during the search for the optimal solution. Afterwards, the GA results for four different operation points were verified experimentally through a developed drive platform with digital signal processor-based (DSP) control and an asymmetric bridge converter. As showed by the experiments, the proposed approach was suitable to reduce the torque ripple by more than 50% for one of the evaluated operating points. Furthermore, it was confirmed that the torque ripple mitigation led to acoustic noise improvement.

42 ENGINEERING↗

DOE OSTI2025

Flexible PCB Windings Size Optimization for Winding AC Resistance Minimization Under the Sinusoidal Voltage Regime

In this paper, optimization of the winding AC resistance of the flexible printed circuit board (FPCB) wire windings is performed. A one-dimensional model of the FPCB winding is introduced and an equation for the FPCB winding AC resistance and its low and medium frequency approximation are derived. The approximate FPCB winding AC resistance equation is used to derive optimum thickness of the FPCB winding conductor thickness at which minimum of winding AC resistance (global optimum) is achieved. The Finite Element Method analysis and experimental verification of derived equations (winding resistance, impedance, power loss, and temperature measurements) is performed in order validate derived model and winding resistance equation.

42 ENGINEERING↗

DOE OSTI2023

Additively Manufactured Copper Windings with Hilbert Structure

In this paper, finite element method simulations and frequency analysis of additively manufactured windings with a Hilbert–cross section pattern were performed over a wide frequency range. The current density distributions for the proposed winding conductor and for a square-wire winding conductor at selected frequencies were compared. An approximately 25% winding loss reduction at higher frequencies and an approximately 5% increase at low frequencies were observed for the analyzed Hilbert structure.

Wojda, Rafal↗

DOE OSTI2023

Mechanical Analysis of Carbon Fiber Retaining Sleeve for A High-speed Outer Rotor SPM Electric Motor Design

Outer rotor motors can be designed with a larger airgap diameter than inner rotor motors for the same overall diameter and therefore provide higher torque which makes them ideal for high torque space constrained applications. This advantage fits well with the increasing demand of high-speed electric machines in many applications due to their inherent high-power density. However, increasing the motor speed results in significant centrifugal loads for the outer rotor motor design. Layers of carbon fiber sleeve winding on the rotor outer surface is necessary to guarantee its structural integrity without introducing too much weight on the motor itself. In this paper, we studied the mechanical stress of a carbon fiber retaining sleeve in a surface permanent magnet outer rotor motor that spins up to 20,000 RPM. Analytical results from finite element method (FEM) confirmed that the maximum stress experienced by the carbon fiber sleeve was under the material’s yield strength. The proposed sleeve will allow this outer rotor motor to operate at high speeds.

Lin, Lianshan↗

DOE OSTI2024

Rotordynamic Analysis and Comparative Study of High-Speed Outer Rotor Permanent Magnet Motor Designs

High–power density electric motor designs are a requirement in aerospace and automotive applications. Outer rotor permanent magnet motors can offer high power density but have mechanical challenges such as structural stability and rotodynamic issues. In this work, a rotodynamic study was performed for two outer rotor permanent magnet motor designs. The first design was a cantilever design in which the rotor was suspended at one end, supported by four bearings; in the second design, the rotor was simply supported by two bearings in each end. Two different finite element method–based approaches, solid rotor and beam rotor methods, were used to extract the critical speed.

Barua, Himel↗

DOE OSTI2021

Solder Bond Fatigue is Insensitive to Module Size

In this article, we explore the influence of module size on the rate of interconnecting solder bond thermomechanical fatigue (TMF) damage. Structural mechanics models of crystalline silicon PV models are created to solve with the finite-element method. Results conclusively demonstrate that the rate of solder bond TMF damage is independent of module size, interconnect location across the cell and cell location across the module.

14 SOLAR ENERGY↗

DOE OSTI2020

Electronic Scanning Strategies in Adaptive Electrical Capacitance Volume Tomography: Tradeoffs and Prospects

Electrical Capacitance Volume Tomography (ECVT) has been applied for imaging of multiphase flows found in industrial applications. The ill-posed nature of the image reconstruction problem in ECVT and the consequent low resolution can be alleviated by employing electronic scanning enabled by electrode segmentation and reconfiguration during data acquisition. Here we study electronic scanning strategies that mimic physical rotation and shifting of the sensor along its symmetry axis. First, we study the feasibility of electronic scanning by analyzing the capacitance transducer circuit in SPICE. Then, we simulate electronic scanning using the finite element method for different electrode shapes, for which we compare the image reconstruction results and acquisition time. We find a noticeable improvement in image resolution for the scanning cases over conventional ECVT. Lastly, among the scanning cases, we emphasize a particular electrode shape that provides the best image resolution along with the minimal amount of acquisition time.

47 OTHER INSTRUMENTATION↗

DOE OSTI2021

Representative Modules for Accelerated Thermal Cycling and Static Load Testing

In this work, we explore the influence of module size on the rate of interconnect solder bond thermomechanical fatigue (TMF) damage and the probability of cell fracture. For the solder bond TMF damage evaluation, structural mechanics models of crystalline silicon PV models are created to solve with the Finite Element Method. For the probability of cell fracture evaluation, Weibull analysis and weakest link theory are employed to resolve the probability of crystalline silicon PV cell fracture when measured as bare cells and when stressed in reduced- and full-sized modules. Results conclusively demonstrate that the rate of solder bond TMF damage is independent of module size, interconnect location across the cell and cell location across the module and that smaller, representative, modules must be loaded to a much higher level than their parent full-sized modules to achieve an equivalent driving force for cell fracture.

accelerated testing↗

DOE OSTI2025

Structural Analysis of Multilayer Tapered Canted-Cosine-Theta Superconducting Magnet for the Interaction Region of Electron Ion Collider

The electron ion collider (EIC) will collide high energy and highly polarized hadron and electron beams with luminosities up to 10 34 cm -2 s -1 . The magnet designs at the interaction region (IR) are challenging due to the close proximity of the hadron and electron beams. A canted cosine theta (CCT) quadrupole magnet was designed due to the space restrictions at the IR. The CCT magnet has a tapered aperture, which allows higher gradients at the interaction point (IP) side of the magnet. The tapered geometry makes the magnet not symmetrical along the axial direction. In conclusion, to validate the design in terms of the mechanical strength and the allowed deformations, a detailed structural mechanical analysis for the tapered CCT quadrupole magnet has been carried out using the finite element method (FEM) considering both the shrinking due to cool down and the electromagnetic force on the conductors.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗

DOE OSTI2025

Structural Analysis of a Serpentine Superconducting Magnet for the Interaction Region of the Electron Ion Collider

The electron ion collider (EIC) is under design to collide the high energy and highly polarized hadron with electron beams with luminosities up to 10 34 cm −2 s −1 . The superconducting magnet designs at the interaction region (IR) are quite challenging due to the close proximity of the hadron and electron beams. Several serpentine types of superconducting magnets have been designed due to the space restrictions at the IR. Here, to validate the designs in terms of the mechanical strength, structural integrity, as well as the allowed deformations, a detailed structural mechanical analysis for a 12-layer superconducting quadrupole serpentine magnet (Q1BpR) in the rear side hadron beams has been carried out using the finite element method (FEM) considering the pretension stress, shrinking due to cool down, and the electromagnetic force on the conductors. Anisotropy material properties and individual roving tension have been considered. The electro-magnetic (EM) simulations were performed using COMSOL, confirmed with RAT, the structural mechanical analysis were performed using COMSOL by considering the contact elements.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗

DOE OSTI2020

Efficient and Flexible Sensitivity Matrix Computation for Adaptive Electrical Capacitance Volume Tomography

Electrical capacitance tomography is a widely used sensor modality for flow imaging in many industrial settings. Adaptive Electrical Capacitance Volume Tomography (AECVT) extends the capabilities of traditional ECT by enabling direct volumetric imaging and an improved resolution. Construction of the sensitivity matrix is a necessary step to obtain flow images. This step requires computation of the electric field inside the sensing domain, which is done via a typical field solver such as the finite element method. In this work, we present an efficient and flexible method to construct the sensitivity matrix for Adaptive Electrical Capacitance Volume Tomography (AECVT) based on individual electrode segment excitations and their judicious combination to form desired matrix elements. We illustrate how the proposed method yields the same sensitivity matrix as the traditional method but at a much lower computational cost. Once all segment contributions are obtained, we also indicate how the proposed method, unlike the traditional approach, can generate the sensitivity matrix on demand for an arbitrary combination of synthetic electrodes and obviating the need for any additional field computations. Finally, we present image reconstruction results for two different experimental scenarios where the mutual capacitance data and the corresponding sensitivity vectors are obtained through the proposed measurement combination scheme.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

DOE OSTI2025

Deep Neural Network Assisted Distributed Strain and Temperature Fiber Sensor System for Natural Gas Pipeline Monitoring

Natural gas pipeline integrity monitoring is crucial to detect potential leaks, find structural issues, and prevent environmental damage. This article presents a system of natural gas pipeline monitoring that uses a specialized double Brillouin peak sensing fiber along with the Brillouin optical time domain analysis (BOTDAs) technique. The calibrated sensing fiber coefficients for strain and temperature are 41.8 kHz/ με and 0.9 MHz/°C for peak 1; and 47.2 kHz/ με , and 1.11 MHz/°C for peak 2, respectively. Initially, lab tests were performed by installing a short section of double Brillouin peak fiber (DBPF) on a 1-in steel pipe under pressure up to 1000 per square inch (psi) at elevated temperatures. Simultaneous distributed measurements of temperature and pressure-induced hoop strain were successfully measured. Considering the long processing speed to extract Brillouin frequency shift (BFS), we employ a novel probabilistic deep neural network (PDNN) framework for rapid BFS prediction. Additionally, using the Finite Element Method, the effects of the pipeline pressure on hoop strain were modeled and compared to the experimental hoop strain under the same set of pipeline conditions. Finally, an actual 4-in outer diameter steel natural gas pipeline was used for pilot-scale tests, where hoop strain was measured at various pressure levels. Leaks were simulated to demonstrate accurate pipeline integrity monitoring. At an internal pipe pressure of 1000 psi, hoop strain of approximately 300 με was observed, and the sensitivity was calculated as 0.28 με /psi. The results of this pilot-scale study demonstrated that the system is capable of performing distributed monitoring sufficient to detect pipeline pressure and the presence of leaks to ensure the safe operation of gas pipelines in the field.

03 NATURAL GAS↗

DOE OSTI2020

Heat Flux Analysis From IR Imaging on Proto-MPEX

The Prototype Material Plasma Exposure eXperiment (Proto-MPEX) is a linear device used to develop the source and heating concept for MPEX, an experiment to study plasma–material interactions for future fusion reactors. This paper highlights recent analysis and results on Proto-MPEX using an infrared (IR) camera, a key tool for imaging heat fluxes measured at the material target. The target heat fluxes are crucial to understanding the source and heating concepts. The recent analysis includes the application of homography and 3-D finite-element methods to provide between-shot measurements of the 2-D target heat flux profile. The IR camera inferred heat flux is shown to correlate with Langmuir probe inferred heat fluxes for a range of parameters in helicon only and helicon + electron cyclotron heated discharges. Results show both desirable central and undesirable edge heat flux for helicon source and electron heating on the target. These heat flux measurements are shown to be important for better understanding of the source and heating physics.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2021

Computational Evaluation of Thermal Response of Open-Cell Foam With Circular Pore (Computional Evaluation of Thermal Response of Open-Cell Foam with Circular Pore)

The evaluation of effective material properties in heterogeneous materials (e.g., composites or multicomponent structures) critically relevant to a wide spectrum of applications, including nuclear power, electronic packaging, flame retardants, hypersonics, and gas turbine power. The work described in this paper is centered around the numerical assessment of the thermal behavior of porous materials obtained from finite element thermal modeling and simulation. Here, two-dimensional, steady state analyses were performed on unit cells with centered, circular pores using a second order accurate Galerkin finite element method (FEM). The effective thermal conductivities of the porous systems were examined, encompassing a range of porosities from 4.9% to 60.1%. The geometries of the models were generated based on ordered circular pores for each modeled porosity level. The system response quantity (SRQ) under investigation was the dimensionless effective thermal conductivity across the unit cell. The dimensionless effective thermal conductivity was compared across all simulated cases, producing a trend between porosity and effective thermal conductivity. In the presented investigation, the method of manufactured solutions (MMS) was used to perform code verification, and the grid convergence index (GCI) was employed to estimate discretization uncertainty as solution verification. Code verification concluded an approximately second order accurate Galerkin FEM solver. It was found that the introduction of porosity to the unit cell material structure reduces effective thermal conductivity, as anticipated. Numerical results obtained in this study are compared to an analytical solution and to a sample of empirical data.

36 MATERIALS SCIENCE↗

DOE OSTI2024

Efficient mapping between void shapes and stress fields using Deep Convolutional Neural Networks with sparse data

Establishing fast and accurate structure-to-property relationships is an important component in the design and discovery of advanced materials. Physics-based simulation models like the finite element method (FEM) are often used to predict deformation, stress, and strain fields as a function of material microstructure in material and structural systems. Such models may be computationally expensive and time intensive if the underlying physics of the system is complex. This limits their application to solve inverse design problems and identify structures that maximize performance. In such scenarios, surrogate models are employed to make the forward mapping computationally efficient to evaluate. However, the high dimensionality of the input microstructure and the output field of interest often renders such surrogate models inefficient, especially when dealing with sparse data. Deep convolutional neural network (CNN) based surrogate models have shown great promise in handling such high-dimensional problems. In this paper, a single ellipsoidal void structure under a uniaxial tensile load represented by a linear elastic, high-dimensional and expensive-to-query, FEM model. We consider two deep CNN architectures, a modified convolutional autoencoder framework with a fully connected bottleneck and a UNet CNN, and compare their accuracy in predicting the von Mises stress field for any given input void shape in the FEM model. Additionally, a sensitivity analysis study is performed using the two approaches, where the variation in the prediction accuracy on unseen test data is studied through numerical experiments by varying the number of training samples from 20 to 100.

surrogate modeling; convolutional neural networks;↗

DOE OSTI2022

Computational Modeling of Multi-Pass Rolling Parameters Effect on Resulting Fuel Foil Shape

A focus of the U.S. Department of Energy is to improve production yield and reduce the cost of Low Enriched Uranium (LEU)-molybdenum alloy (U-10Mo) monolithic fuel plates that will be replacing High Enriched Uranium (HEU) oxide dispersion fuels used currently in the United States High Performance Research Reactors (USHPRR). One area of improvement is lowering the high transverse waviness and longitudinal waviness currently present within rolled foils prior to cladding to produce fuel plates. Traditional rolling manufacturing techniques for other metal foils use winders to pull and straighten the foil as it is rolled back and forth to the final thickness. This approach cannot be used to roll thin U-10Mo foils (0.008-0.025” thick) because only small castings can be rolled due to nuclear criticality safety concerns. As a result, the fuel foils are too short (1 m in length) to use traditional winders. Therefore, it is crucial to identify other rolling parameters (i.e., roller friction, axial tension load, roller diameter, and roll pass reduction percent) that might reduce transverse waviness and longitudinal waviness in the rolled fuel foil and develop a high-yield, low-cost multi-pass rolling manufacturing process. This report documents a systematic finite element modeling study to investigate the effects of numerous rolling parameters to reduce resulting transverse waviness and longitudinal waviness in the fuel foil during multi-pass rolling of U-10Mo foils. The rolling of a U-10Mo plate with initial dimensions of 1”x1”x 0.048” is modeled using Abaqus CAE. This rolling is modeled to undergo eight 20% reduction roll passes to a final fuel foil thickness of 0.01”. The elastic-plastic constitutive model of the U-10Mo alloy was input to the fuel foil rolling model. The rollers were modeled as rigid bodies. A comparison of rolling friction coefficients of 0.3 and 0.7 over a wide range of applied axial tension loads were investigated in order to evaluate the effect of using a lubricant during rolling. The effect of roller diameter on the resulting transverse waviness and longitudinal waviness of the fuel foil over a wide range of axial tension loads were also investigated by modeling rollers 7/8” and 3.75” in diameter. The results of this systematic finite element method study will aid manufacturers in producing low transverse waviness and reduced longitudinal waviness in U-10Mo fuel foils.

U-10Mo, FEA, Rolling, Residual Stress, Fuel Foil↗

DOE OSTI2023

Brief Announcement: Communication Optimal Sparse LU Factorization for Planar Matrices

We introduce a new parallel algorithm for solving sparse LU factorization of planar matrices, which commonly arise in the finite element method for 2D PDEs. Existing scalable methods, such as the multifrontal approach with subtree-to-subcube mapping by Gupta et al. [1] and right-looking with 3D mapping by Sao et al. [2] fail to achieve optimal communication costs for these matrices. Our new algorithm combines 3D mapping and subtree-to-subcube mapping to minimize communication costs while allowing trade-offs between extra memory and reduced communication. We demonstrate that our proposed algorithm attains the communication lower bound up to a factor of O(log log n) in the memory-optimal case and up to a factor of O(log P) in the memory-independent case for an n-dimensional planar sparse matrix on P processors.

Sao, Piyush↗