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At least 1,747 records · Page 97

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DOE OSTI2022

Microstructure-Sensitive modeling of surface roughness and notch effects on extreme value fatigue response

Fatigue life knockdown due to surface roughness induces local stress concentrations. Physical fatigue experiments are crucial to qualify materials for use but are limited in their capability to examine the mechanisms underlying the fatigue crack formation driving force due to these stress concentrations. Microstructure-sensitive computational models can aid in this regard and are employed in this work to examine the effects of surface roughness in Al 7075-T6. Digital microstructure models are subjected to crystal plasticity finite element method (CPFEM) simulations to examine the combined effects of microstructure and grain scale asperities on the driving force for fatigue crack formation. Following elastic–plastic shakedown, mesoscale volume-averaged fatigue indicator parameters (FIPs) are computed within fatigue damage process zones of grains. An increase in the intensity of realistic surface roughness profiles corresponds accordingly to larger FIPs but it is difficult to precisely interpret the mechanisms and effects of this intensification. We thus parametrically investigate surface asperities that couple with microstructure and lack of constraint on slip at the free surface to describe microstructure-sensitive surface roughness knockdown effects on fatigue resistance. The depth of a single valley (i.e., notch) due to surface roughness is found to be more detrimental to fatigue resistance than the radius (i.e., notch width, not to be confused with notch acuity). Finally, we also find that different crystallographic textures, grain morphologies, and number of sampled grains have a limited effect on the depth of influence of these notches.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Simulated effect of defect volume and location on very high cycle fatigue of laser beam powder bed fused AlSi10Mg

This study quantifies the interaction between volumetric defect location and size on the very high cycle fatigue (VHCF) of laser beam powder bed fused (LB-PBF) AlSi10Mg. Crystal plasticity finite element method (CPFEM) simulations were used to investigate the effects of defect location and size on the driving force for crack initiation. The CPFEM model was calibrated against uniaxial and cyclic experimental data of LB-PBF AlSi10Mg. Defect characteristics were informed by experimental data from the specimens produced in various geometries to create realistic representative volume elements (RVEs) with equivalent volume fractions of defects. By embedding defects of varying sizes and locations within the RVEs, fatigue indicator parameters (FIPs) were calculated to analyze the impact of defects’ characteristics on fatigue performance. Different combinations of defect volume and locations were generated for various microstructure instantiations, providing insight into extreme value fatigue responses. Larger defect volumes located on free surfaces consistently generated the highest FIPs, suggesting defect size and boundary proximity intensify stress concentration effects. RVEs with multiple smaller defects produced lower FIPs than those with single large critical defects. These findings underscore the critical role of defect characteristics on fatigue life, providing a foundation for future predictive modeling in fatigue-sensitive AM applications.

AlSi10Mg↗

DOE OSTI2014

Uncertainty quantification for the impact of injection rate fluctuation on the geomechanical response of geological carbon sequestration

We present an analysis of the geomechanical effects of injection rate fluctuations for geological sequestration of carbon dioxide (CO2). Initially, we present analytical solutions for the effects of injection rate fluctuations on CO2 fluid pressure spatial distribution and temporal evolution for a typical injection scenario. Numerical calculations are performed using a finite element method to investigate the effects of injection rate fluctuations on geomechanical deformation, stresses, and potential failure of the aquifer and caprock layers. The numerical method was first validated by the fluid pressure distribution’s good agreement with the analytical solution. It was shown that for any Gaussian fluctuations of injection rate Q with given mean Q and variance ε_Q, the coefficients of variance for fluid pressure (ϵ_p=ε_p ), deformation (ϵ_u=ε_u ), and stresses (ϵ_σ=ε_σ ) increase linearly with the coefficient of variance for injection rate (ϵ_Q=ε_Q ). The proportional constants are identified, and the fluctuations have the most pronounced effect on the geomechanical stresses, and, therefore, on the potential failure of the aquifer and caprock layers. Instead of expensive computational simulation, this study provides an efficient tool to estimate the geomechanical response variance to injection rate fluctuation. A failure analysis was presented based on the numerical results, where probability of failure was estimated for fluctuating injection rates with different mean and variance during the entire injection period. It was found that with increasing injection rate fluctuation, the failure probability increases significantly. Therefore, the risk associated with injection rate fluctuations should be carefully evaluated.

58 GEOSCIENCES↗

DOE OSTI2020

Composite Structured Surfaces for Durable Dropwise Condensation

Dropwise condensation of steam on hydrophobic substrates has a 10X higher heat transfer coefficient compared to filmwise condensation. To promote dropwise condensation, low surface energy hydrophobic coatings (polymers) are typically utilized. The low intrinsic thermal conductivity (k < 1 W/(m · K)) of polymers, coupled with high heat transfer coefficient of dropwise condensation (100 kW/(m 2 · K)), necessitates that the coating be thin (< 1µm) in order to avoid reducing the overall heat exchanger conductance. However, thin polymeric films easily degrade. The two opposing requirements result in the need for optimization between the durability (thick coating) and the heat transfer (thin coating). To enable high thermal conductivity in thicker coatings, we develop metal-polymer structured surfaces. By using porous structures as inter-connected heat-conducting backbones that are filled with hydrophobic materials, we enable tuning of the coating effective thermal conductivity and surface energy. Three metal structures were studied; micro/nanowires, inverse opals, and sintered spheres. Heat transfer performance was calculated using three-dimensional finite element method simulations with two distinct boundary conditions; convection at the walls and isothermal walls. Interestingly, the overall conductance shows up to 40% difference depending on the boundary condition used in calculating the composite coating effective thermal conductivity. We use our model to predict the heat transfer performance as a function of metal fraction by volume and by surface area for condensation. By coupling our thermal simulations with a previously verified analytical model for predicting wetting behavior on heterogeneous surfaces, we propose a regime map to predict dropwise-to-filmwise transition. Furthermore, our work not only forms a starting point for the development of durable dropwise condensing surfaces, it identifies important considerations needed for computing effective thermal conductivity of composites.

42 ENGINEERING↗

DOE OSTI2020

Modeling The Effects of Loading Scenario and Thermal Expansion Coefficient on Potential Failure of Cryo-compressed Hydrogen Vessels

A multiscale thermomechanical model for a simplified Type-3 cryogenic compressed hydrogen (H2) storage vessel is developed in this paper. The model accounts for the temperature-dependent elastic-plastic behavior of the vessel carbon/epoxy composite overwrap and aluminum alloy liner. The homogenized thermo-elastic-plastic behavior for the individual laminas of the vessel layup is obtained by an incremental Eshelby-Mori-Tanka approach associated with a micromechanical failure criterion to predict lamina failure while a standard elastic-plastic constitutive model is used to describe the behavior of a typical aluminum alloy assumed for the liner. The vessel response to external loadings is achieved by a finite element method. Four loading scenarios representing four thermomechanical cycles applied to the vessel are analyzed to evaluate constituent and lamina stresses as well as the associate failure criterion during the cycle according to these scenarios. The model can provide helpful guidance to mitigate thermal stresses by an adequate selection of loading scenario, optimizing the layup and by tailoring thermomechanical properties of the resin matrix.

36 MATERIALS SCIENCE↗

DOE OSTI2020

Experimental verification of a crystal plasticity-based simulation framework for predicting microstructure and geometric shape changes: Application to bending and Taylor impact testing of Zr

This paper is concerned with experimental verification of a recently developed multi-scale simulation framework for plastic deformation of metallic materials from quasi-static to impact deformation conditions. The framework is a visco-plastic self-consistent (VPSC) polycrystalline model embedded in an implicit finite element method (FE-VPSC) to provide a microstructure-sensitive constitutive response at each material point. Each material point of the FEM model is a polycrystalline aggregate with crystallographic deformation mechanisms operating at the single crystal scale with their evolving activity based on a dislocation density-based hardening law and texture. Four beams and three cylinders machined in different orientations from a textured plate of high-purity zirconium are tested quasi-statically in 4-point bending and at speeds of 100 m/s, 170 m/s and 243 m/s during Taylor impact tests, respectively. The variation in dimensional changes resulting from different sample orientations in the plate with respect to loading directions is measured for each sample. Moreover, texture and twinning characterization is performed using electron backscattered diffraction (EBSD). The deformation processes and underlying evolution of microstructure are successfully simulated using the FE-VPSC framework. In doing so, the model parameters are optimized and validated across a broad range of strain rates and temperatures. Simulation results in terms of geometrical changes and microstructural evolution are compared with the experimental measurements. The model predicts anisotropic material flow resulting from the hard-to-deform crystallographic directions, the development of gradients in texture and twinning through the geometries, tension–compression asymmetry, as well as the extent of plasticity under impact.

42 ENGINEERING↗

DOE OSTI2018

FEM modeling of plastic flow and strain-induced phase transformation in BN under high pressure and large shear in a rotational diamond anvil cell

In this study, combined three-dimensional plastic flow and strain-induced phase transformation (PT) in boron nitride (BN) under high pressure and large shear in a rotational diamond anvil cell (rotational DAC or RDAC) are investigated. Geometrically nonlinear frameworks including finite elastic, transformational, and plastic deformations and finite element method (FEM) are utilized. Quantitative information is obtained on the evolutions of the stress tensor, plastic strain, volume fraction of phases in the entire sample, and slip-cohesion transitions, all during torsion under a fixed compressive load in RDAC. The effects of the applied compressive stress and the sample radius on PT and plastic flow are discussed. In comparison with DAC, the same amount of the high-pressure phase can be obtained at a much lower pressure in RDAC, which reduces the required force and the risk of diamond fracture. Also, RDAC has a potential to complete PT during torsion under pressure close to the minimum possible. A quasi-homogeneous pressure can be obtained in a transforming sample in RDAC under a proper choice of properties and parameters of a gasket. A number of experimental phenomena, including the pressure self-multiplication and quasi-homogeneous pressures in DAC and RDAC, are reproduced and interpreted. Finally, the simulation results provide a significant insight into coupled PTs and plastic flow in material in RDAC, and are important for the optimum design of experiments and the extraction of material parameters for PT, as well as for the optimization and control of PTs by the variation of various parameters.

36 MATERIALS SCIENCE↗

DOE OSTI2020

Constitutive modeling of δ-phase zircaloy hydride based on strain rate dependent nanoindentation and nano-scale impact dataset

In this work, a constitutive model for zircaloy-4 embedded with δ-phase hydride rim/blister structures (δ-phase zircaloy hydride) is presented. Nanoindentation and nano-scale impact experiments were performed on the δ-hydride blisters as a function of temperature in order to obtain strain rate dependent location specific constitutive response. A power law viscoplastic constitutive model was chosen to represent the strain rate dependent behavior. The strength coefficient and the strain hardening exponent in the power law relation were found to decrease with increase in temperature indicating softening behavior at higher temperatures. The strain rate exponent remained constant with increase in temperature indicating that the rate dependent ductility does not change significantly at higher temperatures. A finite element method based model was created to analyze the failure behavior and the ductile to brittle transition in zircaloy hydride. The model predicted that fracture strength of δ-phase zircaloy hydride decreases linearly with increase in temperature.

36 MATERIALS SCIENCE↗

DOE OSTI2022

Weight function procedure for reduced order fracture analysis of arbitrary flaws in cylindrical pressure vessels

Fracture mechanics calculations using the finite element method can be computationally expensive, which makes them challenging to use in engineering evaluations of flaws in pressure vessels. The weight function (WF) technique is a reduced order fracture modeling method that is widely used to greatly reduce these computational costs. Its computational efficiency is essential for use in probabilistic fracture mechanics evaluations of embrittled nuclear reactor pressure vessels (RPVs), due to the large number of sampled flaws that must be evaluated. Although the WF technique is general, it is typically used only for axis-aligned flaws. Recent discoveries of off-axis flaws in operating nuclear reactors have necessitated detailed simulations of such flaws and the interactions between neighboring flaws. This paper presents a generalized WF approach applicable for analyzing arbitrary flaw geometries in thick-walled cylindrical vessels, including surface-breaking and subsurface flaws, which can either axis-aligned or off-axis, and can account for interactions with other flaws. Herein, this approach is demonstrated on representative simulations of multiple flaw geometries in a RPV subjected to transient loading conditions. In all cases, the WF technique gives good comparison with benchmark results from direct simulation with greatly reduced computational effort.

42 ENGINEERING↗

DOE OSTI2019

Assessing the reliability of fast Fourier transform-based crystal plasticity simulations of a polycrystalline material near a crack tip

Crystal plasticity simulations enable a physically-based description of the micromechanical fields associated with microstructural attributes in polycrystalline materials. Fast Fourier transforms implementation of crystal plasticity (CP-FFT) in periodic unit cells offers increased computational efficiency compared to traditional finite element methods (CP-FEM). Albeit, questions may arise concerning the accuracy of the CP-FFT approach given its underlying spectral framework, specifically in regards to: potential artifacts due to violating the traction-free conditions at internal free surface within the unit cell, Gibbs phenomenon near regions with sharp changes in local mechanical properties, and representation of free surfaces under the constraints imposed by the requirement of periodicity of the unit cell. This paper presents a custom massively parallelized implementation of CP-FFT. A direct comparison of simulation results for polycrystalline deformation near a crack in a Ti55531 alloy is presented between CP-FEM and CP-FFT. The micromechanical fields and slip system level values are quantified and are similar between the two methods. Up to 10% difference in the stress fields is reported at the crack tip and this value dissipates moving away from the crack tip after 5 voxels (7 µm). In conclusion, the results point towards the reliable use of CP-FFT simulations to model polycrystalline deformation with caveats based on the treatment of the discussed artifacts.

36 MATERIALS SCIENCE↗

DOE OSTI2022

A unified finite strain gradient-enhanced micropolar continuum approach for modeling quasi-brittle failure of cohesive-frictional materials

Here, in this work, a novel framework for modeling quasi-brittle crack propagation and shear band dominated failure of cohesive-frictional materials like concrete, mortar, rock, tough ceramics, energetic materials, but also granular materials like sands or powders in terms of a unified continuum approach is proposed. It is based on a combination of the gradient-enhanced continuum with gradients of internal variables for representing quasi-brittle cracking, and the micropolar continuum, accounting for the deformation of the microstructure. For developing the gradient-enhanced micropolar framework, the set of balance equations and the kinematic relations are derived, and the constitutive relations are established in a general manner. The framework is formulated in a geometrically exact setting, based on the thermodynamically sound theory of hyperelasto-plasticity, and the numerical implementation by means of the finite element method is discussed. For assessing the approach, realizations of this new approach in terms of constitutive models for particular materials are developed. They are applied to numerical benchmark examples, investigating various loading conditions, and the obtained results are validated by means of a comparison with experiments from the literature.

36 MATERIALS SCIENCE↗

DOE OSTI2014

Parareal in time 3D numerical solver for the LWR Benchmark neutron diffusion transient model

In this paper we present a time-parallel algorithm for the 3D neutrons calculation of a transient model in a nuclear reactor core. The neutrons calculation consists in numerically solving the time dependent diffusion approximation equation, which is a simplified transport equation. The numerical resolution is done with finite elements method based on a tetrahedral meshing of the computational domain, representing the reactor core, and time discretization is achieved using a θ-scheme. The transient model presents moving control rods during the time of the reaction. Therefore, cross-sections (piecewise constants) are taken into account by interpolations with respect to the velocity of the control rods. The parallelism across the time is achieved by an adequate use of the parareal in time algorithm to the handled problem. This parallel method is a predictor corrector scheme that iteratively combines the use of two kinds of numerical propagators, one coarse and one fine. Our method is made efficient by means of a coarse solver defined with large time step and fixed position control rods model, while the fine propagator is assumed to be a high order numerical approximation of the full model. The parallel implementation of our method provides a good scalability of the algorithm. Numerical results show the efficiency of the parareal method on large light water reactor transient model corresponding to the Langenbuch–Maurer–Werner benchmark.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2016

Scalable algorithms for three-field mixed finite element coupled poromechanics

We introduce a class of block preconditioners for accelerating the iterative solution of coupled poromechanics equations based on a three-field formulation. The use of a displacement/velocity/pressure mixed finite-element method combined with a first order backward difference formula for the approximation of time derivatives produces a sequence of linear systems with a 3 x 3 unsymmetric and indefinite block matrix. The preconditioners are obtained by approximating the two-level Schur complement with the aid of physically-based arguments that can be also generalized in a purely algebraic approach. A theoretical and experimental analysis is presented that provides evidence of the robustness, efficiency and scalability of the proposed algorithm. In conclusion, the performance is also assessed for a real-world challenging consolidation experiment of a shallow formation.

42 ENGINEERING↗

DOE OSTI2017

A scalable nonlinear fluid–structure interaction solver based on a Schwarz preconditioner with isogeometric unstructured coarse spaces in 3D

Nonlinear fluid-structure interaction (FSI) problems on unstructured meshes in 3D appear many applications in science and engineering, such as vibration analysis of aircrafts and patient-specific diagnosis of cardiovascular diseases. In this work, we develop a highly scalable, parallel algorithmic and software framework for FSI problems consisting of a nonlinear fluid system and a nonlinear solid system, that are coupled monolithically. The FSI system is discretized by a stabilized finite element method in space and a fully implicit backward difference scheme in time. To solve the large, sparse system of nonlinear algebraic equations at each time step, we propose an inexact Newton-Krylov method together with a multilevel, smoothed Schwarz preconditioner with isogeometric coarse meshes generated by a geometry preserving coarsening algorithm. Here ''geometry'' includes the boundary of the computational domain and the wet interface between the fluid and the solid. We show numerically that the proposed algorithm and implementation are highly scalable in terms of the number of linear and nonlinear iterations and the total compute time on a supercomputer with more than 10,000 processor cores for several problems with hundreds of millions of unknowns.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2017

Discontinuous Galerkin algorithms for fully kinetic plasmas

Here, we present a new algorithm for the discretization of the non-relativistic Vlasov–Maxwell system of equations for the study of plasmas in the kinetic regime. Using the discontinuous Galerkin finite element method for the spatial discretization, we obtain a high order accurate solution for the plasma's distribution function. Time stepping for the distribution function is done explicitly with a third order strong-stability preserving Runge–Kutta method. Since the Vlasov equation in the Vlasov–Maxwell system is a high dimensional transport equation, up to six dimensions plus time, we take special care to note various features we have implemented to reduce the cost while maintaining the integrity of the solution, including the use of a reduced high-order basis set. A series of benchmarks, from simple wave and shock calculations, to a five dimensional turbulence simulation, are presented to verify the efficacy of our set of numerical methods, as well as demonstrate the power of the implemented features.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2025

Evaluating the bond strength and fracture mechanisms of cold-sprayed zinc coating on AZ91 magnesium substrate via a combined experimental and computational approach

Magnesium (Mg) alloys are ideal candidates for automotive applications due to their high strength to weight ratio, castability, recyclability etc., however, they lack corrosion and oxidation resistance. Solid-state deposition techniques, such as cold spray, have been demonstrated to enhance their corrosion resistance as it relies on the severe plastic deformation of powder particles upon impact with the substrate to form a metallurgical bond with the substrate and within the coating. At cold sprayed interfaces, a heterogeneous microstructure is formed that includes some porosity, oxides and intermetallics which can significantly affect coating performance. Thus, establishing a direct correlation between the interface microstructure and its properties can aid in designing optimal cold spray parameters. In this study, we investigated the microstructure and mechanical properties of a zinc (Zn) coating deposited on a high pressure die cast (HPDC) AZ91 Mg substrate via high resolution scanning transmission electron microscopy, in situ micro-tensile testing, and finite element method (FEM) modeling. Micro-tensile pillars fabricated using the plasma focused ion beam (PFIB) successfully isolates the coating-substrate interface within the gauge length. The average bond strength of Zn-Mg interface was determined to be ∼140 MPa with failure occurring partially at the interface and mostly into the coatings. A detailed microstructural characterization revealed evidence of a strong metallurgical bonding at the Zn-Mg interface and formation of the C14 MgZn 2 laves phase interlayer resulting in a mixed mode of fracture during the micro-tensile experiments. FEM modeling reveals the stress distribution along the interfaces and suggests that a MgZn 2 layer thickness between 200–400 nm is optimum to increase the bond strength and minimize the triaxiality. Such a site-specific interfacial analysis with correlative computational modeling provides crucial insight into the overall performance of cold spray interfaces.

Bond strength↗

DOE OSTI2019

LaserOrigami (LO) of three-dimensional (3D) components: Experimental analysis and numerical modeling-part II

The present work explores how the choice of the scanning patterns can affect the final shapes of 3D components manufactured by laser-origami with a High-Power Diode Laser (HPDL). The experimental approach allowed the achievement of high bending angles, also avoiding any distortion on the surface of AISI 304 stainless steel workpiece. Optimization of the operational parameters led to the best prototype of the 3D components, with the closest respect of the strictest dimensional and geometrical tolerances. In addition, a thermo-mechanical model to predict the final shape of the 3D components was developed. The numerical model, implemented by Finite Element Method (FEM), was discovered to be a reliable tool in predicting the final shape of the prototypes, matching with a great deal of accuracy the experimental results. Specifically, the model allowed the estimation of the temperature distribution and nodal displacements of the components varying both the setting of the laser parameters and the choice of the scanning patterns.

47 OTHER INSTRUMENTATION↗

DOE OSTI2018

Coupled elasticity, plastic slip, and twinning in single crystal titanium loaded by split-Hopkinson pressure bar

Here coupled elasticity, plastic slip, and twinning in high-purity single crystal titanium loaded by split-Hopkinson pressure bar (SHPB) are investigated, in the framework of large deformation and by utilizing the finite element method (FEM). A thermodynamically consistent system of equations for combined plastic slip and twinning is formulated. Novel kinematics is proposed to develop the driving forces for slip and twinning processes and to consider plastic slip in twins. Dislocation based crystal plasticity is proposed, with an emphasis on the interactions among all slip modes in multi-variant/multiphase heterogeneous materials. A mechanism for dislocation density evolution during twinning is proposed. The impact loading along the [0001] and [1$0\bar{1}$1] directions of single crystal high purity titanium is investigated. The evolution of stress-strain field, dislocation density, and volume fraction for each variant in the sample during the entire loading process are obtained and discussed in detail. Results in simulations show that for the [0001] specimen due to the existence of six symmetry primary twin variants with respect to the loading direction and fifteen different slip systems in each variant, the fields of stress and dislocation density are very homogenous in the sample. The simulation results are compared with experimental data for the [0001] and [1$0\bar{1}$1] specimens. The experimental results are explained and interpreted for both specimens, which include the pole figures, the stress-strain curves, and volume fraction of variants. The simulation results provide an important insight into mechanical responses of high-purity single crystal titanium under high rate loading, and this paper advances the mesoscale modeling and simulations in coupled plastic slip and twinning.

36 MATERIALS SCIENCE↗