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At least 145 records · Page 8

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DOE OSTI2020

A Bezier Curve Informed Melt Pool Geometry to Model Additive Manufacturing Microstructures Using SPPARKS

Additive manufacturing is a transformative technology with the potential to manufacture designs which traditional subtractive machining methods cannot. Additive manufacturing offers fast builds at near final desired geometry; however, material properties and variability from part to part remain a challenge for certification and qualification of metallic components. AM induced metallic microstructures are spatially heterogeneous and highly process dependent. Engineering properties such as strength and toughness are significantly affected by microstructure morphologies resulting from the manufacturing process Linking process parameters to microstructures and ultimately to the dynamic response of AM materials is critical to certifying and qualifying AM built parts and components and improving the performance of AM materials. The AM fabrication process is characterized by building parts layer by layer using a selective laser melt process guided by a computer. A laser selectively scans and melts metal according to a designated geometry. As the laser scans, metal melts, fuses, and solidifies forming the final geometry in a layerwise fashion. As the laser heat source moves away, the metal cools and solidifies forming metallic microstructures. This work describes a microstructure modeling application implemented in the SPPARKS kinetic Monte Carlo computational framework for simulating the resulting microstructures. The application uses Bzier curves and surfaces to model the melt pool surface and spatial temperature profile induced by moving the laser heat source; it simulates the melting and fusing of metal at the laser hot spot and microstructure formation and evolution when the laser moves away. The geometry of the melt pool is quite flexible and we explore effects of variances in model parameters on simulated microstructures.

36 MATERIALS SCIENCE↗

DOE OSTI2025

A Block-Structured Adaptive Mesh Framework to Solve Radiation Transfer Equation in Irregular Embedded Geometries

Radiation transport arises in various scientific, industrial, and medical fields, and understanding its effect in applications is needed to make accurate predictions, safety assessments and performance optimizations. Solving the Radiation Transport Equation (RTE) is challenging due to its integro-differential nature, which involves both differential and integral terms. The differential term describes the change in radiation intensity due to absorption and emission, while the integral term accounts for scattering. The accurate modeling of radiation is further complicated in many applications due to the complex, irregular geometries. Various methods exist for solving the RTE, including the zonal, Monte Carlo, spherical harmonics, discrete ordinates, and finite volume methods. Traditional mesh-based approaches, which rely on structured or unstructured meshes, struggle with irregular geometries due to: a) the difficulty of conforming structured grids to irregular domains, b) challenges in enforcing boundary conditions correctly, and c) the additional computational cost of unstructured mesh methods. This work presents a second-order accurate method for solving the RTE in irregular geometries. The radiation intensity is discretized using the finite-volume method in both spatial and angular directions on regular Cartesian grid blocks. Leveraging the block-structured adaptive mesh refinement (AMR) framework provided by AMReX, our method refines the grid locally to reduce spatial discretization error, ensuring a converged numerical solution while minimizing computational costs elsewhere. A two-stage deferred correction approach is employed: First, a first-order discretization on grid blocks is solved using an algebraic multigrid method in HYPRE. Second, a correction term is applied explicitly to achieve second-order accuracy. The correction term is calculated by approximating the radiation flux on cell faces using a Total Variation Diminishing (TVD) scheme. This approach ensures quick convergence of the multigrid method while preserving higher-order accuracy of the numerical solution. Irregular geometries are resolved as embedded boundaries (EB), resulting in both cut cells and regular cells. In cut cells, we modify the fluxes using face fractions and incorporate additional contributions from EB boundary conditions. To ensure higher-order convergence near the EB interface, the correction term is modified by interpolating the radiation intensity to fictitious ghost points. The implementation takes advantage of modern supercomputers by leveraging AMReX’sMPI/X parallelization strategy where X can be MPI or a GPU accelerator including CUDA, HIP and DPC++. We validate our solver using classical test cases, both with and without EB, demonstrating accuracy and efficiency. Additionally, we analyze the impact of adaptive mesh refinement on solution accuracy and computational cost, highlighting the advantages of our approach for high-resolution radiation transport simulations.

computational fluid dynamics (CFD)↗

DOE OSTI2025

Understanding Geometry and Microstructure Interactions In LPBF By Linking Lab Scale Studies To Real Part Case Examples

The mechanical properties derived from simple tensile tests are uniquely important in the design and qualification of load bearing metallic components. The tensile properties in standards for wrought metallic materials are generally accessible for design and simulation engineers, but this is not the case for additively manufactured metals. This work investigates the influence of tensile specimen geometry on the mechanical properties of laser powder bed fusion (LPBF) additively manufactured Ti-6Al-4V, particularly in relation to properties measured from specimens excised from an exemplar part. A comprehensive analysis was conducted across various specimen geometries, considering factors such as thermal history, cross-sectional area, shape, and surface roughness. Key findings reveal that sample size, particularly cross-sectional area, significantly affects reported tensile properties, with ASTM E8 flat and round specimens exhibiting differences in elastic modulus (13%), yield strength (17%), ultimate tensile strength (UTS) (14%), and elongation to failure (11%). Additionally, surface roughness was found to have a limited impact on ASTM round geometries, but it becomes critical in thin-walled and small high-throughput samples. The ASTM flat samples closely matched the properties of samples excised from the exemplar part, underscoring the necessity of testing witness samples that accurately represent end-use conditions. Furthermore, mechanical properties of samples built within the stitch zone of the exemplar part demonstrated reduced ductility, highlighting the importance of laser alignment and qualification in multi-laser additive manufacturing processes. Overall, this study emphasizes the need for careful consideration of specimen geometry and testing conditions to ensure accurate reporting of mechanical properties in LPBF Ti-6Al-4V.

36 MATERIALS SCIENCE↗

DOE OSTI2022

Altering the Supply of Shielding Gases to Fabricate Distinct Geometry in GMA Additive Manufacturing

Wire arc additive manufacturing (WAAM) is the process by which large, metallic structures are built, layer-by-layer, using a welding arc to melt wire feedstock. In this process, the proper selection of the shielding gas plays a vital role in the achievement of structurally acceptable part geometries and quality surface finishes. In this study, the authors used either a ternary mix (He, Ar and CO 2 ) or a binary mix (Ar and CO 2 ) of shielding gases to deposit wall geometries using an open loop-controlled WAAM system developed at Oak Ridge National Laboratory’s Manufacturing Demonstration Facility. The binary blend produced a wider and shorter geometry, while the ternary blend resulted in a narrower build that was more equivalent to the CAD geometry. The data indicated that the binary blend provided a higher oxygen concentration in the weld as compared to that of the ternary blend. The results imply that the arc characteristics and heat input had a significantly higher impact on the weld penetration than the surface tension effect of surface active elements. This was further verified by developing and applying a high-fidelity computational fluid dynamics (CFD) model of the thermophysical properties of gas mixtures. The results from the model showed that, while the influence of increased oxygen concentration on the surface tension for the binary blend led to a deeper penetration, the ternary blend gave rise to heat flux to the workpiece.

36 MATERIALS SCIENCE↗

NASA NTRS1973

A study of engine variable geometry systems for an advanced high subsonic long range commercial aircraft

Several variable geometry high Mach inlet concepts, aimed at meeting a system noise objective of 15 EPNdB below FAR part 36, for a long range, Mach 0.9 advanced commercial transport are assessed and compared to a fixed geometry inlet with multiple splitters. The effects of a variable exhaust nozzle (mixed exhaust engine) on noise, inlet geometry requirements, and economics are also presented. The best variable geometry inlet configuration identified is a variable cowl design which relies on a high throat Mach number for additional inlet noise suppression only at takeoff, and depends entirely on inlet wall treatment for noise suppression at approach power. Relative economic penalties as a function of noise level are also presented.

Compagnon, M. A.↗

NASA NTRS1979

Interfacial geometry and D-variation effects in two-phase systems

Numerical solutions of the governing diffusion equation for two-phase concentration dependent diffusion coefficients are examined. Solutions were also calculated for planar, cylindrical, and spherical geometries to compare the effect of interface geometries with those caused by concentration-dependent diffusion coefficients, and two methods of averaging D were considered to determine the best averaging method for different types of D-variations. The effects of interface-location criteria on mass conservation and convergence of interface location, diffusion coefficient variation in the alpha and beta-phases of a two-phase binary alloy system, effect of D(alpha) variation in a cylindrical couple on beta-phase thickness, and geometry and D-variation effects on the degree of homogenization were determined. It is concluded that typical D(alpha)-variations can have a greater influence on the kinetics of interdiffusion than the geometry.

Tenney, D. R.↗

NASA NTRS1982

Aircraft geometry verification with enhanced computer generated displays

A method for visual verification of aerodynamic geometries using computer generated, color shaded images is described. The mathematical models representing aircraft geometries are created for use in theoretical aerodynamic analyses and in computer aided manufacturing. The aerodynamic shapes are defined using parametric bi-cubic splined patches. This mathematical representation is then used as input to an algorithm that generates a color shaded image of the geometry. A discussion of the techniques used in the mathematical representation of the geometry and in the rendering of the color shaded display is presented. The results include examples of color shaded displays, which are contrasted with wire frame type displays. The examples also show the use of mapped surface pressures in terms of color shaded images of V/STOL fighter/attack aircraft and advanced turboprop aircraft.

Cozzolongo, J. V.↗

NASA NTRS1982

Aircraft geometry verification with enhanced computer-generated displays

A method for visual verification of aerodynamic geometries using computer-generated, color-shaded images is described. The mathematical models representing aircraft geometries are created for use in theoretical aerodynamic analyses and in computer-aided manufacturing. The aerodynamic shapes are defined using parametric bi-cubic splined patches. This mathematical representation is then used as input to an algorithm that generates a color-shaded image of the geometry. A discussion of the techniques used in the mathematical representation of the geometry and in the rendering of the color-shaded display is presented. The results include examples of color-shaded displays, which are contrasted with wire-frame-type displays. The examples also show the use of mapped surface pressures in terms of color-shaded images of V/STOL fighter/attack aircraft and advanced turboprop aircraft.

Cozzolongo, J. V.↗

NASA NTRS1982

Slab-geometry Nd:glass laser performance studies

It is noted that slab-geometry solid-state lasers potentially provide significant performance improvements relative to conventional rod-geometry lasers. Experimental measurements that use an Nd:glass test-bed slab laser are presented. A comparison is made between the results and computer-model predictions of the slab-geometry approach. The computer model calculates and displays the temperature and stress fields in the slab, and on the basis of these predicts birefringence and index-of-refraction distributions. The effect that these distributions have on optical propagation is determined in a polarization-sensitive ray-tracing section of the model. Calculations are also made of stress-induced surface curvature and the resulting focusing effects. The measurements are found to be in good agreement with the computer-model predictions. It is concluded that the slab configuration offers significant laser-performance advantages in comparison with the traditional rod-laser geometry.

Eggleston, J. M.↗

NASA NTRS1983

A variable-geometry combustor used to study primary and secondary zone stoichiometry

A combustion program is underway to evaluate fuel quality effects on gas turbine combustors. A rich-lean variable geometry combustor design was chosen to evaluate fuel quality effects over a wide range of primary and secondary zone equivalence ratios at simulated engine operating conditions. The first task of this effort, was to evaluate the performance of the variable geometry combustor. The combustor incorporates three stations of variable geometry to control primary and secondary zone equivalence ratio and overall pressure loss. Geometry changes could be made while a test was in progress through the use of remote control actuators. The primary zone liner was water cooled to eliminate the concern of liner durability. Emissions and performance data were obtained at simulated engine conditions of 80 percent and full power. Inlet air temperature varied from 611 to 665K, inlet total pressure varied from 1.02 to 1.24 MPa, reference velocity was a constant 1400 K.

Briehl, D.↗

NASA NTRS1984

Interactive graphics for quick-geometry modeling

The QUICK-geometry system is a method for defining configuration shapes in completely analytical form. It was developed for use when the analytical definition of aircraft geometry is advantageous or necessary for the solution of the flow around it. While the QUICK-geometry system provides a convenient and flexible method for generating configurations with completely analytical definitions, experience showed that it can be difficult to match a previously defined configuration with a QUICK-geometry definition. Therefore, the National Aeronautics and Space Administration (NASA) and other users developed computer programs that aid in the generation of QUICK inputs. A NASA-developed set of such programs which recently were upgraded extensively to improve its usability and portability are described.

Townsend, J. C.↗

NASA NTRS1985

Elasticity Solution of an Adhesively Bonded Cover Plate of Various Geometries

The plane strain of adhesively bonded structures consisting of two different isotropic adherends is considered. By expressing the x-y components of the displacements in terms of Fourier integrals and using the corresponding boundary and continuity conditions, the integral equations for the general problem are obtained and solved numerically by applying Gauss-Chebyshev integration scheme. The shear and the normal stresses in the adhesive are calculated for various geometries and material properties for a stiffened plate under uniaxial tension. Numerical results involving the stress intensity factors and the strain energy release rate are presented. The closed-form expressions for the Fredholm kernels are provided to obtain the solution for an arbitrary geometry and material properties. For the general geometry, the contribution of the normal stress is quite significant, while for symmetric geometries, the shear stress is dominant, the normal stress vanishes if the adherends are of the same material and the same thickness.

Aksel, G. N.↗

NASA NTRS1986

Specimen geometry effects on graphite/PMR-15 composites during thermo-oxidative aging

Studies were conducted to establish the effects of specimen geometry on the thermo-oxidative stability and the mechanical properties retention of unidirectional Celion 12000 graphite fiber reinforced PMR-15 polyimide composites. Weight loss, flexural strength and interlaminar shear strength are measured at isothermal aging times as long as 1639 hr at a temperature of 316 C for three different specimen geometries. It is found that the three different types of specimen surfaces exhibit different values of weight loss/unit area. The mechanical properties retention is also found to be dependent on geometry for these composites. The interlaminar shear strength decreases significantly over the complete range of aging times. The flexural strength retention starts showing geometric dependency after about 1000 hr of aging at 316C. Weight loss fluxes, associated with the three different types of exposed surfaces, are calculated and used to develop an empirical mathematical model for predicting the weight loss behavior of unidirectional composites of arbitrary geometries. Data are presented comparing experimentally determined weight loss with weight loss values predicted using the empirical model.

Bowles, K. J.↗

NASA NTRS1986

Geometry definition and grid generation for a complete fighter aircraft

Recent advances in computing power and numerical solution procedures have enabled computational fluid dynamicists to attempt increasingly difficult problems. In particular, efforts are focusing on computations of complex three-dimensional flow fields about realistic aerodynamic bodies. To perform such computations, a very accurate and detailed description of the surface geometry must be provided, and a three-dimensional grid must be generated in the space around the body. The geometry must be supplied in a format compatible with the grid generation requirements, and must be verified to be free of inconsistencies. This paper presents a procedure for performing the geometry definition of a fighter aircraft that makes use of a commercial computer-aided design/computer-aided manufacturing system. Furthermore, visual representations of the geometry are generated using a computer graphics system for verification of the body definition. Finally, the three-dimensional grids for fighter-like aircraft are generated by means of an efficient new parabolic grid generation method. This method exhibits good control of grid quality.

Edwards, T. A.↗

NASA NTRS1986

Geometry definition and grid generation for a complete fighter aircraft

Recent advances in computing power and numerical solution procedures have enabled computational fluid dynamicists to attempt increasingly difficult problems. In particular, efforts are focusing on computations of complex three-dimensional flow fields about realistic aerodynamic bodies. To perform such computations, a very accurate and detailed description of the surface geometry must be provided, and a three-dimensional grid must be generated in the space around the body. The geometry must be supplied in a format compatible with the grid generation requirements, and must be verified to be free of inconsistencies. A procedure for performing the geometry definition of a fighter aircraft that makes use of a commercial computer-aided design/computer-aided manufacturing system is presented. Furthermore, visual representations of the geometry are generated using a computer graphics system for verification of the body definition. Finally, the three-dimensional grids for fighter-like aircraft are generated by means of an efficient new parabolic grid generation method. This method exhibits good control of grid quality.

Edwards, Thomas A.↗

NASA NTRS1986

Specimen geometry effects on graphite/PMR-15 composites during thermo-oxidative aging

Studies were conducted to establish the effects of specimen geometry on the thermo-oxidative stability and the mechanical properties retention of unidirectional Celion 12000 graphite fiber reinforced PMR-15 polyimide composites. Weight loss, flexural strength and interlaminar shear strength are measured at isothermal aging times as long as 1639 hr at a temperature of 316 C for three different specimen geometries. It is found that the three different types of specimen surfaces exhibit different values of weight loss/unit area. The mechanical properties retention is also found to be dependent on geometry for these composites. The interlaminar shear strength decreases significantly over the complete range of aging times. The flexural strength retention starts showing geometric dependency after about 1000 hr of aging at 316 C. Weight loss fluxes, associated with the three different types of exposed surfaces, are calculated and used to develop an empirical mathematical model for predicting the weight loss behavior of unidirectional composites of arbitrary geometries. Data are presented comparing experimentally determined weight loss with weight loss values predicted using the empirical model.

Bowles, K. J.↗

NASA NTRS1988

Surface grid generation for complex three-dimensional geometries

An outline is presented for the creation of surface grids from primitive geometry data such as obtained from CAD/CAM systems. The general procedure is applicable to any geometry including full aircraft with wing, nacelle, and empennage. When developed in an interactive graphics environment, a code based on this procedure is expected to substantially improve the turn around time for generating surface grids on complex geometries. Results are shown for a general hypersonic airplane geometry.

Luh, Raymond Ching-Chung↗

NASA NTRS1988

Surface grid generation for complex three-dimensional geometries

An outline is presented for the creation of surface grids from primitive geometry data such as obtained from CAD/CAM systems. The general procedure is applicable to any geometry including full aircraft with wing, nacelle, and empennage. When developed in an interactive graphics environment, a code base on this procedure is expected to substantially improve the turn around time for generating surface grids on complex geometries. Results are shown for a general hypersonic airplane geometry.

Luh, Raymond Ching-Chung↗