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Development and Operations of the Astrophysics Data System

The ADS was represented at the AAS meeting with 3 poster papers and a demonstration booth. We have setup a mirror site of the Vizier data base system at the CDS. functionality of the ADC at Goddard. This will replace the Preparations for the APS and LPSC meetings in March started. We will have demonstrations at both meetings. Preparations for the APS and LPSC meetings in March continued. We will have demonstrations at both meetings. The ADS was represented with a poster at the joint AGUEGU meeting in Nice, France. Discussions about the on-going collaboration between the ADS and the CDS in Strasbourg, France were held in Strasbourg. The ADS was invited to organize a session about the ADS and its mirror sites at the next United Nations Workshop on Basic Space Sciences in the Developing World. Efforts are under way to enter the tables of contents of all conference proceedings in the SA0 library into the ADS. This requires copying the tables of contents from all volumes in the library and have them typed in. This will greatly enhance the coverage of the literature in the ADS. We started the development of a search system for the full text of all scanned material in the ADS. This will eventually allow our users search capabilities that so far do not exist in any form. I order to enable the full text searching, we have purchased OCR software and are in the process of OCRing the scanned pages in the ADS. Efforts are in progress to handle the inclusion of data set identifiers in article manuscripts. The ADS will be the central system that will allow the journals to verify data set identifiers. The "master verifier" has been implemented in prototype form at the ADS. We started to include more journals in Geosciences/Geophysics in the ADS. The Royal astronomical Society has decided to archive their on-line journals in the ADS three years after publication. We have started to process these older on-line articles in order to archive them in the ADS. Our mirror site in Korea now has a full article mirror. We developed XML output capability in the ADS. This will make it easier to exchange data with other data systems. We started the development of new indexing software that will eventually reduce the indexing time for a database from days to hours or less. The ADS was represented at the IAU General Assembly with a poster. Discussions with the IAU management were held about extending the ADS IAU collaborations.

Murray, Stephen S.↗

Curation of Antarctic Meteorites at NASA Johnson Space Center

The U.S. Antarctic meteorite program began in the 1970 s and has provided more than 18,000 samples in over three decades. The program is based on a three agency agreement between NASA, the National Science Foundation, and the Smithsonian Institution. The collection, stored at the Johnson Space Center and the Smithsonian, is one of the largest collections of meteorites in the world and features samples from the moon and Mars, asteroids, and material from the early solar system. A brief consideration of the collection shows that it contains 92.2% ordinary chondrites, 3.2% carbonaceous chondrites, 3.7% achondrites (1.7% HED), as well as many puzzling ungrouped meteorites. JSC has sent splits of nearly 20,000 meteorite samples to more than 500 scientists around the world since 1977. After the meteorites are collected in Antarctica, they are shipped frozen to JSC in Houston, usually arriving in April following the field season. The Astromaterials Curation Office at JSC is responsible for: - receiving the frozen meteorites. - staging: repackaging and changing the samples field identification numbers with official names. - submitting the names to the Nomenclature Committee of the Meteoritical Society for approval as new meteorites. - initial processing: weighing, measuring, describing and photographing the sample and providing a chip for classification to the Smithsonian Institution staff. - the issuing of two newsletters per year, announcing hundreds of new meteorites. - the handling of requests from the scientific community and the allocation of those requests that are approved. - providing supplies and tools for the field team such as teflon bags and tape, aluminum foil, clean tweezers and tongs. - maintaining the meteorite database with more than 76,000 sample splits. - making petrographic thin and thick sections for the JSC library and scientific investigators. - providing storage and handling of the meteorites in a class 10,000 clean room. Samples that have not been requested for three years are sent to the Smithsonian for permanent storage. There have been several seasons in recent years with two field teams, increasing the number of acquired samples (>1000 in a few seasons). We have recently increased our storage space and additional staff to better serve the scientific community.

McBride, K. M.↗

Demonstration of Capability to Simulate Particle Irregular Shape and Poly-Disperse Mixtures Within Lunar Lander Plume-Surface Interaction

Plume-Surface Interaction (PSI) between lander engine plumes and regolith soil creates hazards in obscuration and contamination by particle clouds, high-energy ejecta streams, and landing area cratering damage. The MSFC Fluid Dynamics Branch is developing simulation tools to offer a predictive PSI capability to NASA customers such as the Human Lander System (HLS) and Commercial Lunar Payload Services (CLPS). The Gas-Granular Flow Solver (GGFS) is the main application tool for coupled gas-particle two-phase flow simulations to predict the range of PSI effects from onset of surface erosion to deep crater formation. GGFS features an Eulerian-Eulerian modeling approach, treating both gas and granular material as interacting continuum phases. Modeling the lunar regolith granular material fluidic characteristics poses special challenges due to complex particle shapes and mixture composition. The lunar regolith is poorly sorted with broad particle size distributions and large fines content. It has significant cohesion, due to interlocking jagged particle shapes. Eulerian granular material flow modeling requires closure formulations for the granular material constitutive models (stress, friction, collisional and kinetic energy dissipation, drag, etc.). While closure models for spherical particles are available from particle kinetic theory, closure models for realistic non-spherical particles must be extracted from unit physics Discrete Element Model (DEM) particle interaction simulations and provided in the form of tabular datasets. The effects of particle irregular shape (non-spherical shape factors, angular particle surface roughness, and interlocking features) are simulated by approximating the particle features in the form of grouped elemental spheres to form composite particles in the DEM simulations. The effects of the wide range of regolith mixture particle sizes and the strong effects of the presence of the small particle sizes results in high cohesion and low porosity of the regolith mixture. The range of particle sizes is simulated by binning the particle sizes into an appropriate finite number of particle-size species and solving the problem as a species mixture. Combining these two modeling approaches enables simulations to capture both, the contributions of the irregular particle shape and the particle size distribution. The integration and maturation of the DEM-based constitutive model database generation process and poly-disperse mixture binning approach into the GGFS simulation framework are proceeding under funding by the NASA Game Changing Development program. The status of current capabilities will be presented in comparisons of crater characteristics resulting for spherical and irregular shape particles, and for mono-, bi-, and tri-disperse mixture simulations of Apollo LM plume-surface interaction. The computational results confirm the significance of including the particle shape and mixture effects. Going forward plans for the full implementation of the general poly-disperse regolith modeling capability and maturation towards NASA project application readiness under the GCD program will be presented.

Peter A Liever↗

Demonstration of Capability to Simulate Particle Irregular Shape and Poly-Disperse Mixtures Within Lunar Lander Plume-Surface Interaction

Plume-Surface Interaction (PSI) between lander engine plumes and regolith soil creates hazards in obscuration and contamination by particle clouds, high-energy ejecta streams, and landing area cratering damage. The MSFC Fluid Dynamics Branch is developing simulation tools to offer a predictive PSI capability to NASA customers such as the Human Lander System (HLS) and Commercial Lunar Payload Services (CLPS). The Gas-Granular Flow Solver (GGFS) is the main application tool for coupled gas-particle two-phase flow simulations to predict the range of PSI effects from onset of surface erosion to deep crater formation. GGFS features an Eulerian-Eulerian modeling approach, treating both gas and granular material as interacting continuum phases. Modeling the lunar regolith granular material fluidic characteristics poses special challenges due to complex particle shapes and mixture composition. The lunar regolith is poorly sorted with broad particle size distributions and large fines content. It has significant cohesion, due to interlocking jagged particle shapes. Eulerian granular material flow modeling requires closure formulations for the granular material constitutive models (stress, friction, collisional and kinetic energy dissipation, drag, etc.). While closure models for spherical particles are available from particle kinetic theory, closure models for realistic non-spherical particles must be extracted from unit physics Discrete Element Model (DEM) particle interaction simulations and provided in the form of tabular datasets. The effects of particle irregular shape (non-spherical shape factors, angular particle surface roughness, and interlocking features) are simulated by approximating the particle features in the form of grouped elemental spheres to form composite particles in the DEM simulations. The effects of the wide range of regolith mixture particle sizes and the strong effects of the presence of the small particle sizes results in high cohesion and low porosity of the regolith mixture. The range of particle sizes is simulated by binning the particle sizes into an appropriate finite number of particle-size species and solving the problem as a species mixture. Combining these two modeling approaches enables simulations to capture both, the contributions of the irregular particle shape and the particle size distribution. The integration and maturation of the DEM-based constitutive model database generation process and poly-disperse mixture binning approach into the GGFS simulation framework are proceeding under funding by the NASA Game Changing Development program. The status of current capabilities will be presented in comparisons of crater characteristics resulting for spherical and irregular shape particles, and for mono-, bi-, and tri-disperse mixture simulations of Apollo LM plume-surface interaction. The computational results confirm the significance of including the particle shape and mixture effects. Going forward plans for the full implementation of the general poly-disperse regolith modeling capability and maturation towards NASA project application readiness under the GCD program will be presented.

Peter A. Liever↗

BISON Fuel Fragmentation Relocation and Dispersal (FFRD) Assessment Database for Eventual Use in Bayesian Calibration

Existing light-water reactor (LWR) fuel vendors have been interested in seeking increased discharge burnups of nuclear fuel rods for improved economics for quite a few years. With increased burnups come additional challenges that must be addressed. It has been experimentally observed that average burnups higher than the current regulatory limit of 62 MWd/kgU may undergo fuel fragmentation, relocation, and dispersal (FFRD) during a loss-of-coolant accident (LOCA). Industry must demonstrate approaches to mitigate FFRD. In an effort to support industry, the Nuclear Energy Advanced Modeling and Simulation (NEAMS) program within the U.S. Department of Energy (DOE) has for several years invested in developing multiscale models and creating a validation/assessment database for these models to study the mechanisms driving FFRD. This report provides an update on changes made to the assessment database and new models added to BISON to support the study of fuel rod behavior during FFRD. An effort has been initiated this year to begin adding dedicated inputs to the publicly available Virtual Test Bed (VTB) repository for industry use. A section of this report details the efforts made in this area. NEAMS has recently developed new capabilities in the Multiphysics Object-Oriented Simulation Environment (MOOSE) framework’s stochastic tools module for calibration using Bayesian inference. The goal in the future is to use these capabilities to calibrate and identify weaknesses in the existing BISON models for FFRD. The report concludes with a discussion on the models most likely to benefit the most from such calibration.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

A Vacuum Drying Study of Simulated Failed Nuclear Fuel (FY23)

This report documents work performed under the Office of Spent Fuel and Waste Disposition’s (SFWD’s) Spent Fuel and Waste Science and Technology program for the US Department of Energy (DOE) Office of Nuclear Energy (NE). This work was performed to fulfill Level 4 milestone M4SF-23OR010203013. Over the 70 years of light-water reactor (LWR) operation, fuel rod failures have occurred during reactor operation. Based on the Unified Database that SFWD maintains, there are ~5,400 LWR fuel rods that developed leaks during reactor operation of the >19 million rods operated. The Unified Database indicates that ~4,200 of these rods remain in the spent fuel pool, and ~1,200 are in dry storage canisters. It is expected that all failed rods are “waterlogged” in the spent fuel pool, meaning the inside of the rods contain some volume of water. There are two related objectives of this work. The first is to develop a simple and inexpensive experiment to better understand removal of water from inside failed spent nuclear fuel (SNF) rods, and the second is to develop a model to predict drying of simulated failed fuel in the simple experiment. Once a model captures the phenomenon in the simple experiment, it can be extended to predict drying under more prototypical conditions.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Chemical degradation of fly ash blended concrete with the seasonal variation of rainwater in a radioactive waste repository: A thermodynamic modeling approach

Highlights: • The thermodynamic model for the cementitious system was successfully developed. • The chemical degradation of concrete was greatly affected by rainwater types. • Inorganic carbon species in rainwater reduced the chemical resistance of concrete. • The durability of concrete to rainwater decreased with increasing fly ash content. This study presents a long-term degradation behavior of fly ash blended concrete in a vault type low- and intermediate-level radioactive waste (LILW) repository by thermodynamic equilibrium calculations using PHREEQC combined with CEMDATA18 database. Since rainwater plays a predominant role as leachate for the concrete waste container in the repository, the effect of chemical properties of seasonal rainwater on the chemical degradation of concrete was analyzed. In addition, the impact of the blending with fly ash on the chemical degradation was evaluated through a gradual replacement of ordinary Portland cement (OPC) by fly ash. Regardless of the replacement level, autumn rainwater showed the greatest influence on the concrete degradation owing to the presence of inorganic carbon species, which induce the carbonation. The resistance of concrete to chemical degradation by rainwater was persistently reduced due to the decreasing formation of portlandite and calcium silicate hydrate (C-S-H) with increasing replacement level.

36 MATERIALS SCIENCE↗

Data-driven analysis of neutron diffraction line profiles: application to plastically deformed Ta

Abstract Non-destructive evaluation of plastically deformed metals, particularly diffraction line profile analysis (DLPA), is valuable both to estimate dislocation densities and arrangements and to validate microstructure-aware constitutive models. To date, the interpretation of whole line diffraction profiles relies on the use of semi-analytical models such as the extended convolutional multiple whole profile (eCMWP) method. This study introduces and validates two data-driven DLPA models to extract dislocation densities from experimentally gathered whole line diffraction profiles. Using two distinct virtual diffraction models accounting for both strain and instrument induced broadening, a database of virtual diffraction whole line profiles of Ta single crystals is generated using discrete dislocation dynamics. The databases are mined to create Gaussian process regression-based surrogate models, allowing dislocation densities to be extracted from experimental profiles. The method is validated against 11 experimentally gathered whole line diffraction profiles from plastically deformed Ta polycrystals. The newly proposed model predicts dislocation densities consistent with estimates from eCMWP. Advantageously, this data driven LPA model can distinguish broadening originating from the instrument and from the dislocation content even at low dislocation densities. Finally, the data-driven model is used to explore the effect of heterogeneous dislocation densities in microstructures containing grains, which may lead to more accurate data-driven predictions of dislocation density in plastically deformed polycrystals.

36 MATERIALS SCIENCE↗

Evaluation of Reduced Order Model for HT-9 Creep and Modifications to Current HT-9 Creep Model in BISON

In order to leverage existing reduced order models (ROM) for the modeling of LANL-developed HT-9 cladding constitutive behavior, mechanistic-based models have been implemented into BISON. It is posited that the increased fidelity of the ROM will show improvement over engineering-scale models in terms of comparison against experimental measurements. INL will assist LANL in implementing an HT9 ROM in BISON. Once the HT-9 mechanistic constitutive model can be leveraged in nuclear performance simulations, the numerical results of fast reactor models will be analyzed and compared against the Fuels Irradiation & Physics Database (FIPD) and separate effects tests to attempt a validation process. INL and LANL will work together to perform any necessary improvement that is identified during the implementation and use processes. Successful completion of the milestone will enable the general use of validated mechanistic ROMs for HT-9 cladding in BISON. This report provides a brief introduction to the Los Alamos Reduced Order Model Applied to Nonlinear Constitutive Equations (LAROMANCE) code, mechanical testing used to illustrate its creep and plastic deformation predictions for HT-9 cladding, and a comparison with existing models implemented into BISON. Current models have been modified to more appropriately account for primary thermal creep and results for corresponding testing are included in this report.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Use of Historical EM Practices and Policies for Management of Cleanup Program and Address GAO Concerns - 20222

As Department of Energy (DOE) Environmental Management (EM) program policies and management practices are revised over time, it might be useful to periodically reflect on the DOE EM program's past to identify practices that have worked and those that might be appropriate for possible reuse in the future. An added impetus to examine alternative approaches is the recent Government Accountability Office (GAO) report entitled 'Nuclear Waste Cleanup - DOE Could Improve Program and Project Management by Better Classifying Work and Following Leading Practices.' The February 2019 GAO report states that EM categorizes most of its work in a way that does not adequately involve independent experts and DOE senior leadership. It also noted that EM has not followed leading practices for program and project management that could help keep the cleanup efforts on schedule and control costs. The GAO report recommended that EM, working with DOE Office of Project Management (PM): - Establish requirements and then assess EM's ongoing operations activities to determine if some activities should be reclassified as capital asset projects based on these newly established requirements. - Review and revise EM's 2017 cleanup policy to include program management leading practices related to scope, cost, schedule performance, and independent reviews. - Update the cleanup policy to require that earned value management (EVM) systems be maintained and used in a way that follows EVM best practices. - Develop a policy to ensure that work is categorized as level of effort (LOE) only in appropriate, specified circumstances, such as when work is not measurable or when measurement is impractical. - Integrate EVM data into EM's performance metrics for operations activities. To assist with improving program performance and implementing audit recommendations, this paper reviewed past successful cleanups such as Weldon Springs, Rocky Flats, Fernald, Ashtabula, Battelle Columbus (abs, and other historical resources and people with experience during the early years of EM program. As such, there are several past practices which may well be suited for reuse today. Some of these practices include: - In 1990's, as the DOE EM cleanup program, known as Environmental Restoration came into effect, the known cleanup scope at each geographic location or site was organized into four levels ranging from overall site-wide cleanup effort to the individual 'release sites', providing high granularity to the program. - The cleanup program was organized by geography (Northwest, Southwest, Eastern Area Programs, etc.). These 'sub-program' managers provided a degree of Headquarters oversight and management allowing upper management (EM-1, 2, and 3) to focus on major decisions and issues. - Budget levels at selected cleanup sites were funded above 'minimum-safety' levels to accelerate actual cleanup work. - Past practice utilized EVM techniques and uniform EM oversight over all discrete project-like activities, providing for a coordinated cleanup effort. - EM managed LOE activities using benchmarking and best in class management practice techniques to help manage costs. - EM managed and reviewed entire site cleanup baselines, not only individual projects, focusing on a successful overall outcome. - Sites had a 'Road map' or 'Management Action Plan' that provided the overall strategy or plan for that site's cleanup - this helped with understanding and coordination of efforts. - EM had a robust lessons-learned program and database to capture and transmit worthy ideas. - EM had well-structured cleanup baseline change control policies to control cost and schedule changes, at the contractor and higher Headquarters levels. Finally, some of the GAO observations may be valid, however it is not clear as to their extent. For example, for some operation types of work, the use of the Level of Effort (LOE) earned value method to track progress may be appropriate. Also, to ensure independence of thought, and to obtain useful insight on past practices, it may be suitable to have former EM employees to assist with understanding past practices or to verify that activities have been properly identified. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

Review of the Nuclear Energy Agency (NEA) Ancillary Thermodynamic Database (TDB) Volume (DRAFT REV. 0)

The Nuclear Energy Agency (NEA) Ancillary data volume comprises thermodynamic data of mineral and aqueous species that, in addition to Auxiliary Data (as referred to in previous NEA thermodynamic data volumes), is necessary to calculations of chemical interactions relevant to radioactive waste management and nuclear energy. This SAND report is a review of the NEA Ancillary data critical reviews volume of thermodynamic data parameters. The review given in this report mainly involves data comparison with other thermodynamic data assessments, analysis of thermodynamic parameters, and examination of data sources. Only new and updated data parameters were considered in this review. Overall, no major inconsistencies or errors were found as allowed by the comparisons conducted in this review. Some remarks were noted, for example, on the consideration of relevant studies and/or comparisons on the analysis and retrieval of thermodynamic data parameters not cited in the respective sections.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Survey of Aging and Monitoring Concerns for Cables and Splices Due to Cable Repair and Replacement

The purpose of this report is to survey aging and monitoring concerns for electrical cable splices in nuclear power plants (NPPs) in long term operation. As portions of existing electrical cable runs in nuclear are replaced over time due to localized events, the total number of splices in NPPs is expected to increase. Relative to cables, the body of knowledge regarding aging of splices and splices in combination with aging cables in nuclear service environments in long-term operations is low. A few reports have considered the aging of cable system components other than cables (Jacobus 1990; Nelson 1998; Villaran and Lofaro 2002), but the nuclear industry has two decades of operating experience since these were published to further enlighten this issue. Herein we discuss electrical cables and splices commonly found in U.S. nuclear power plants, their qualification in safety-related application, and methods for monitoring their health condition. Common environmental stresses that can give rise to cable and splice failure are discussed. The Nuclear Regulatory Commission (NRC) Licensee Event Reports (LER) database was used to identify documented issues of cable and splice failure. The trend in the resultant data over time is considered to see if failures are increasing as plants age. Observations and conclusions of this work include: 1. Cables and splices are highly reliable components. Occurrence rates for events of interest were low and nearly constant over the last 20 years. 2. Common-cause failure for evaluated cable events of interest was observed to primarily be associated with loose connections, which may manifest associated with workmanship issues, thermal cycling, and/or vibration. 3. Replacement of cables is more common than repair, leading to an increase in proportion of new generation cables in the plant over time. 4. Splices on degraded cables have been observed to be problematic. Due to aging NPP infrastructure, including electrical cables, it is expected that such issues will continue to increase. 5. Condition monitoring approaches, while shown to be fruitful for cables, have been shown to be insensitive to degradation of splice sleeves, which are critical to the continued performance of splices. Additional condition monitoring (CM) work is needed to evaluate methods which are sensitive to the degradation of splice components. 6. Extended Material Degradation Assessment (EMDA) knowledge gaps for electrical cables (Bernstein et al. 2014) have not been investigated for splices but may represent similar concerns such as for the accelerated aging process historically used in environmental qualification.

42 ENGINEERING↗

Toward a Generalizable Prediction Model of Molten Salt Mixture Density with Chemistry‐Informed Transfer Learning

Optimally designing applications of molten salts requires knowledge of their thermophysical properties over a wide range of temperatures and compositions. There exist significant gaps in existing databases and this data can be challenging to experimentally measure due to high temperatures, salt corrosivity, and salt hygroscopicity. Existing databases have been used to create Redlich–Kister (RK) models for mixture density showing improved accuracy with respect to ideal mixing assumptions, but these models require subcomponent data measurements for each new system, therefore lacking generality. In order to address generalizability and data sparsity, a transfer learning procedure is proposed to train deep neural networks (DNNs) using a combination of semi‐empirical relationships (RK), data from the thermophysical arm of the molten salt thermal properties database and universal ab initio properties of component mixtures taken from the joint automated repository for various integrated simulations (JARVIS) classical force‐field inspired descriptors database to predict density in molten salts. Herein, it is shown that DNNs predict molten salt density with an r 2 over 0.99 and a mean absolute percentage error under 1%, outperforming alternative methods.

inorganic materials↗

Predicting oxidation damage of ultra high-temperature carbide ceramics in extreme environments using machine learning

Determining the oxidation resistance of UHTC carbides in extreme environments is challenging theoretically and experimentally due to the high dimensional complexity of influencing variables and intricate testing setups. Herein we demonstrate the use of machine learning (ML) models trained with experimental literature data to predict the oxide thickness of UHTC carbides exposed to air based on composition, mean grain size, relative densification, holding time, and temperature. A multi-dimensional database with 76 occurrences is created containing experimental results of Hf, Zr, and Ta carbides plus additives. In this study, the preprocessed database is then used to train ML models to predict their oxidation behavior. The trained model predicts the oxidation damage in the form of an average oxide thickness in UHTC carbides with a Mean Absolute Error (MAE) of ±65.45 μm for samples in the testing set that developed thicknesses up to 1000 μm. The model successfully predicted oxidation damage for a recession rate lower than 60 μm/min. It is noticed that the ensemble method MAE is increased to ±134.34 μm while forecasting the oxidation of samples with a recession rate higher than the threshold. The unprecedented approach is a novel way to predict the damage through the oxidation of carbide compounds before processing for a smarter design with room for improvement.

36 MATERIALS SCIENCE↗

A Combined Machine Learning and High-Energy X-ray Diffraction Approach to Understanding Liquid and Amorphous Metal Oxides

Determining the structure-property relations of liquid and amorphous metal oxides is challenging, due to their variable short-range order and polyhedral connectivity. To predict chemically realistic structures, we have developed a Machine Learned, Gaussian Approximation Potential (GAP) for HfO 2 , with a focus on enhanced sampling of the training database and accurate density functional theory calculations. By using training datasets for the GAP model at the level of Density Functional Theory-Strongly Constrained and Appropriately Normed (DFT-SCAN) level of theory, our results show that the topology of both the low viscosity liquid and the amorphous form are dominated by edge-shared chains and small corner-shared rings of polyhedra. This topology is shown to be consistent with the structure of other liquid and amorphous transition metal oxides of variable ion size, such as TiO 2 and ZrO 2 . Current limitations of the ML-GAP modeling method for obtaining glass structures and future perspectives are also discussed.

36 MATERIALS SCIENCE↗

Fluorescence Visualization of Hypersonic Flow Past Triangular and Rectangular Boundary-layer Trips

Planar laser-induced fluorescence (PLIF) flow visualization has been used to investigate the hypersonic flow of air over surface protrusions that are sized to force laminar-to-turbulent boundary layer transition. These trips were selected to simulate protruding Space Shuttle Orbiter heat shield gap-filler material. Experiments were performed in the NASA Langley Research Center 31-Inch Mach 10 Air Wind Tunnel, which is an electrically-heated, blowdown facility. Two-mm high by 8-mm wide triangular and rectangular trips were attached to a flat plate and were oriented at an angle of 45 degrees with respect to the oncoming flow. Upstream of these trips, nitric oxide (NO) was seeded into the boundary layer. PLIF visualization of this NO allowed observation of both laminar and turbulent boundary layer flow downstream of the trips for varying flow conditions as the flat plate angle of attack was varied. By varying the angle of attack, the Mach number above the boundary layer was varied between 4.2 and 9.8, according to analytical oblique-shock calculations. Computational Fluid Dynamics (CFD) simulations of the flowfield with a laminar boundary layer were also performed to better understand the flow environment. The PLIF images of the tripped boundary layer flow were compared to a case with no trip for which the flow remained laminar over the entire angle-of-attack range studied. Qualitative agreement is found between the present observed transition measurements and a previous experimental roughness-induced transition database determined by other means, which is used by the shuttle return-to-flight program.

Danehy, Paul M.↗

Harnessing structural stochasticity in the computational discovery and design of microstructures

This paper presents a deep generative model-based design methodology for tailoring the structural stochasticity of microstructures. Although numerous methods have been established for designing deterministic (periodic) or stochastic microstructures, a systematic design approach that allows the unified treatment of both deterministic and stochastic microstructure design domains has yet to be created. The proposed methodology resolves this issue by learning a unified feature space that embodies diverse structural patterns with continuously varying stochasticity levels. A highly diverse microstructure database is established to incorporate various types of deterministic and stochastic microstructure patterns. A property-aware deep generative model is proposed to learn a unified feature space of the structural characteristics, as well as the relationship between structure features and properties of interest. Autoencoder (AE), Variational Autoencoder (VAE), and Adversarial Autoencoder (AAE) are compared to understand their relative merits in the property-aware learning of the unified feature space. Microstructural designs with tailorable stochasticity and properties are obtained by searching the unified feature space. Multiple design cases are presented to demonstrate the capability of designing microstructures for structural stochasticity and properties. Furthermore, the proposed method is employed to create stochastically graded structures, which manipulate the mechanical behaviors by varying the local stochasticity of the structure.

36 MATERIALS SCIENCE↗

Finite Element Models for Electron Beam Freeform Fabrication Process

Electron beam freeform fabrication (EBF3) is a member of an emerging class of direct manufacturing processes known as solid freeform fabrication (SFF); another member of the class is the laser deposition process. Successful application of the EBF3 process requires precise control of a number of process parameters such as the EB power, speed, and metal feed rate in order to ensure thermal management; good fusion between the substrate and the first layer and between successive layers; minimize part distortion and residual stresses; and control the microstructure of the finished product. This is the only effort thus far that has addressed computer simulation of the EBF3 process. The models developed in this effort can assist in reducing the number of trials in the laboratory or on the shop floor while making high-quality parts. With some modifications, their use can be further extended to the simulation of laser, TIG (tungsten inert gas), and other deposition processes. A solid mechanics-based finite element code, ABAQUS, was chosen as the primary engine in developing these models whereas a computational fluid dynamics (CFD) code, Fluent, was used in a support role. Several innovative concepts were developed, some of which are highlighted below. These concepts were implemented in a number of new computer models either in the form of stand-alone programs or as user subroutines for ABAQUS and Fluent codes. A database of thermo-physical, mechanical, fluid, and metallurgical properties of stainless steel 304 was developed. Computing models for Gaussian and raster modes of the electron beam heat input were developed. Also, new schemes were devised to account for the heat sink effect during the deposition process. These innovations, and others, lead to improved models for thermal management and prediction of transient/residual stresses and distortions. Two approaches for the prediction of microstructure were pursued. The first was an empirical approach involving the computation of thermal gradient, solidification rate, and velocity (G,R,V) coupled with the use of a solidification map that should be known a priori. The second approach relies completely on computer simulation. For this purpose a criterion for the prediction of morphology was proposed, which was combined with three alternative models for the prediction of microstructure; one based on solidification kinetics, the second on phase diagram, and the third on differential scanning calorimetry data. The last was found to be the simplest and the most versatile; it can be used with multicomponent alloys and rapid solidification without any additional difficulty. For the purpose of (limited) experimental validation, finite element models developed in this effort were applied to three different shapes made of stainless steel 304 material, designed expressly for this effort with an increasing level of complexity. These finite element models require large computation time, especially when applied to deposits with multiple adjacent beads and layers. This problem can be overcome, to some extent, by the use of fast, multi-core computers. Also, due to their numerical nature coupled with the fact that solid mechanics- based models are being used to represent the material behavior in liquid and vapor phases as well, the models have some inherent approximations that become more pronounced when dealing with multi-bead and multi-layer deposits.

Chandra, Umesh↗