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NASA NTRS2003

Development of a Dynamically Configurable, Object-Oriented Framework for Distributed, Multi-modal Computational Aerospace Systems Simulation: Second Year Progress Report

Mesh generation has long been recognized as a bottleneck in the CFD process. While much research on automating the volume mesh generation process have been relatively successful,these methods rely on appropriate initial surface triangulation to work properly. Surface discretization has been one of the least automated steps in computational simulation due to its dependence on implicitly defined CAD surfaces and curves. Differences in CAD peometry engines manifest themselves in discrepancies in their interpretation of the same entities. This lack of "good" geometry causes significant problems for mesh generators, requiring users to "repair" the CAD geometry before mesh generation. The problem is exacerbated when CAD geometry is translated to other forms (e.g., IGES )which do not include important topological and construction information in addition to entity geometry. One technique to avoid these problems is to access the CAD geometry directly from the mesh generating software, rather than through files. By accessing the geometry model (not a discretized version) in its native environment, t h s a proach avoids translation to a format which can deplete the model of topological information. Our approach to enable models developed in the Denali software environment to directly access CAD geometry and functions is through an Application Programming Interface (API) known as CAPRI. CAPRI provides a layer of indirection through which CAD-specific data may be accessed by an application program using CAD-system neutral C and FORTRAN language function calls. CAPRI supports a general set of CAD operations such as truth testing, geometry construction and entity queries.

Afjeh, Abdollah A.↗

NASA NTRS1998

Measurement of heat conduction through stacked screens

This paper describes the experimental apparatus for the measurement of heat conduction through stacked screens as well as some experimental results taken with the apparatus. Screens are stacked in a fiberglass-epoxy cylinder, which is 24.4 mm in diameter and 55 mm in length. The cold end of the stacked screens is cooled by a Gifford-McMahon (GM) cryocooler at cryogenic temperature, and the hot end is maintained at room temperature. Heat conduction through the screens is determined from the temperature gradient in a calibrated heat flow sensor mounted between the cold end of the stacked screens and the GM cryocooler. The samples used for these experiments consisted of 400-mesh stainless steel screens, 400-mesh phosphor bronze screens, and two different porosities of 325-mesh stainless steel screens. The wire diameter of the 400-mesh stainless steel and phosphor bronze screens was 25.4 micrometers and the 325-mesh stainless steel screen wire diameters were 22.9 micrometers and 27.9 micrometers. Standard porosity values were used for the experimental data with additional porosity values used on selected experiments. The experimental results showed that the helium gas between each screen enhanced the heat conduction through the stacked screens by several orders of magnitude compared to that in vacuum. The conduction degradation factor is the ratio of actual heat conduction to the heat conduction where the regenerator material is assumed to be a solid rod of the same cross sectional area as the metal fraction of the screen. This factor was about 0.1 for the stainless steel and 0.022 for the phosphor bronze, and almost constant for the temperature range of 40 to 80 K at the cold end.

NASA Discipline Environmental Health↗

NASA NTRS2004

Adjoint Algorithm for CAD-Based Shape Optimization Using a Cartesian Method

Adjoint solutions of the governing flow equations are becoming increasingly important for the development of efficient analysis and optimization algorithms. A well-known use of the adjoint method is gradient-based shape optimization. Given an objective function that defines some measure of performance, such as the lift and drag functionals, its gradient is computed at a cost that is essentially independent of the number of design variables (geometric parameters that control the shape). More recently, emerging adjoint applications focus on the analysis problem, where the adjoint solution is used to drive mesh adaptation, as well as to provide estimates of functional error bounds and corrections. The attractive feature of this approach is that the mesh-adaptation procedure targets a specific functional, thereby localizing the mesh refinement and reducing computational cost. Our focus is on the development of adjoint-based optimization techniques for a Cartesian method with embedded boundaries.12 In contrast t o implementations on structured and unstructured grids, Cartesian methods decouple the surface discretization from the volume mesh. This feature makes Cartesian methods well suited for the automated analysis of complex geometry problems, and consequently a promising approach to aerodynamic optimization. Melvin et developed an adjoint formulation for the TRANAIR code, which is based on the full-potential equation with viscous corrections. More recently, Dadone and Grossman presented an adjoint formulation for the Euler equations. In both approaches, a boundary condition is introduced to approximate the effects of the evolving surface shape that results in accurate gradient computation. Central to automated shape optimization algorithms is the issue of geometry modeling and control. The need to optimize complex, "real-life" geometry provides a strong incentive for the use of parametric-CAD systems within the optimization procedure. In previous work, we presented an effective optimization framework that incorporates a direct-CAD interface. In this work, we enhance the capabilities of this framework with efficient gradient computations using the discrete adjoint method. We present details of the adjoint numerical implementation, which reuses the domain decomposition, multigrid, and time-marching schemes of the flow solver. Furthermore, we explain and demonstrate the use of CAD in conjunction with the Cartesian adjoint approach. The final paper will contain a number of complex geometry, industrially relevant examples with many design variables to demonstrate the effectiveness of the adjoint method on Cartesian meshes.

Nemec, Marian↗

NASA NTRS2006

Numerical Issues for Circulation Control Calculations

Steady-state and time-accurate two-dimensional solutions of the compressible Reynolds-averaged Navier- Stokes equations are obtained for flow over the Lockheed circulation control (CC) airfoil and the General Aviation CC (GACC) airfoil. Numerical issues in computing circulation control flows such as the effects of grid resolution, boundary and initial conditions, and unsteadiness are addressed. For the Lockheed CC airfoil computed solutions are compared with detailed experimental data, which include velocity and Reynolds stress profiles. Three turbulence models, having either one or two transport equations, are considered. Solutions are obtained on a sequence of meshes, with mesh refinement primarily concentrated on the airfoil circular trailing edge. Several effects related to mesh refinement are identified. For example, sometimes sufficient mesh resolution can exclude nonphysical solutions, which can occur in CC airfoil calculations. Also, sensitivities of the turbulence models with mesh refinement are discussed. In the case of the GACC airfoil the focus is on the difference between steady-state and time-accurate solutions. A specific objective is to determine if there is self-excited vortex shedding from the jet slot lip.

Swanson, Roy C., Jr.↗

NASA NTRS2010

Offset Compound Gear Drive

The Offset Compound Gear Drive is an in-line, discrete, two-speed device utilizing a special offset compound gear that has both an internal tooth configuration on the input end and external tooth configuration on the output end, thus allowing it to mesh in series, simultaneously, with both a smaller external tooth input gear and a larger internal tooth output gear. This unique geometry and offset axis permits the compound gear to mesh with the smaller diameter input gear and the larger diameter output gear, both of which are on the same central, or primary, centerline. This configuration results in a compact in-line reduction gear set consisting of fewer gears and bearings than a conventional planetary gear train. Switching between the two output ratios is accomplished through a main control clutch and sprag. Power flow to the above is transmitted through concentric power paths. Low-speed operation is accomplished in two meshes. For the purpose of illustrating the low-speed output operation, the following example pitch diameters are given. A 5.0 pitch diameter (PD) input gear to 7.50 PD (internal tooth) intermediate gear (0.667 reduction mesh), and a 7.50 PD (external tooth) intermediate gear to a 10.00 PD output gear (0.750 reduction mesh). Note that it is not required that the intermediate gears on the offset axis be of the same diameter. For this example, the resultant low-speed ratio is 2:1 (output speed = 0.500; product of stage one 0.667 reduction and stage two 0.750 stage reduction). The design is not restricted to the example pitch diameters, or output ratio. From the output gear, power is transmitted through a hollow drive shaft, which, in turn, drives a sprag during which time the main clutch is disengaged.

Stevens, Mark A.↗

NASA NTRS2005

Semiautomated, Reproducible Batch Processing of Soy

A computer-controlled apparatus processes batches of soybeans into one or more of a variety of food products, under conditions that can be chosen by the user and reproduced from batch to batch. Examples of products include soy milk, tofu, okara (an insoluble protein and fiber byproduct of soy milk), and whey. Most processing steps take place without intervention by the user. This apparatus was developed for use in research on processing of soy. It is also a prototype of other soy-processing apparatuses for research, industrial, and home use. Prior soy-processing equipment includes household devices that automatically produce soy milk but do not automatically produce tofu. The designs of prior soy-processing equipment require users to manually transfer intermediate solid soy products and to press them manually and, hence, under conditions that are not consistent from batch to batch. Prior designs do not afford choices of processing conditions: Users cannot use previously developed soy-processing equipment to investigate the effects of variations of techniques used to produce soy milk (e.g., cold grinding, hot grinding, and pre-cook blanching) and of such process parameters as cooking times and temperatures, grinding times, soaking times and temperatures, rinsing conditions, and sizes of particles generated by grinding. In contrast, the present apparatus is amenable to such investigations. The apparatus (see figure) includes a processing tank and a jacketed holding or coagulation tank. The processing tank can be capped by either of two different heads and can contain either of two different insertable mesh baskets. The first head includes a grinding blade and heating elements. The second head includes an automated press piston. One mesh basket, designated the okara basket, has oblong holes with a size equivalent to about 40 mesh [40 openings per inch (.16 openings per centimeter)]. The second mesh basket, designated the tofu basket, has holes of 70 mesh [70 openings per inch (.28 openings per centimeter)] and is used in conjunction with the press-piston head. Supporting equipment includes a soy-milk heat exchanger for maintaining selected coagulation temperatures, a filter system for separating okara from other particulate matter and from soy milk, two pumps, and various thermocouples, flowmeters, level indicators, pressure sensors, valves, tubes, and sample ports

Thoerne, Mary↗

NASA NTRS2011

A Generalized Framework for Constrained Design Optimization of General Supersonic Configurations Using Adjoint Based Sensitivity Derivatives

The Aeronautics Research Mission Directorate (ARMD) sent out an NASA Research Announcement (NRA) for proposals soliciting research and technical development. The proposed research program was aimed at addressing the desired milestones and outcomes of ROA (ROA-2006) Subtopic A.4.1.1 Advanced Computational Methods. The second milestone, SUP.1.06.02 Robust, validated mesh adaptation and error quantification for near field Computational Fluid Dynamics (CFD), was addressed by the proposed research. Additional research utilizing the direct links to geometry through a CAD interface enabled by this work will allow for geometric constraints to be applied and address the final milestone, SUP2.07.06 Constrained low-drag supersonic aerodynamic design capability. The original product of the proposed research program was an integrated system of tools that can be used for the mesh mechanics required for rapid high fidelity analysis and for design of supersonic cruise vehicles. These Euler and Navier-Stokes volume grid manipulation tools were proposed to efficiently use parallel processing. The mesh adaptation provides a systematic approach for achieving demonstrated levels of accuracy in the solutions. NASA chose to fund only the mesh generation/adaptation portion of the proposal. So this report describes the completion of the proposed tasks for mesh creation, manipulation and adaptation as it pertains to sonic boom prediction of supersonic configurations.

Karman, Steve L., Jr.↗

NASA NTRS2012

Blocking Filters with Enhanced Throughput for X-Ray Microcalorimetry

New and improved blocking filters (see figure) have been developed for microcalorimeters on several mission payloads, made of high-transmission polyimide support mesh, that can replace the nickel mesh used in previous blocking filter flight designs. To realize the resolution and signal sensitivity of today s x-ray microcalorimeters, significant improvements in the blocking filter stack are needed. Using high-transmission polyimide support mesh, it is possible to improve overall throughput on a typical microcalorimeter such as Suzaku s X-ray Spectrometer by 11%, compared to previous flight designs. Using polyimide to replace standard metal mesh means the mesh will be transparent to energies 3 keV and higher. Incorporating polyimide s advantageous strength-to-weight ratio, thermal stability, and transmission characteristics permits thinner filter materials, significantly enhancing through - put. A prototype contamination blocking filter for ASTRO-H has passed QT-level acoustic testing. Resistive traces can also be incorporated to provide decontamination capability to actively restore filter performance in orbit.

Grove, David↗

NASA NTRS2012

Extension of the Time-Spectral Approach to Overset Solvers for Arbitrary Motion

Forced periodic flows arise in a broad range of aerodynamic applications such as rotorcraft, turbomachinery, and flapping wing configurations. Standard practice involves solving the unsteady flow equations forward in time until the initial transient exits the domain and a statistically stationary flow is achieved. It is often required to simulate through several periods to remove the initial transient making unsteady design optimization prohibitively expensive for most realistic problems. An effort to reduce the computational cost of these calculations led to the development of the Harmonic Balance method [1, 2] which capitalizes on the periodic nature of the solution. The approach exploits the fact that forced temporally periodic flow, while varying in the time domain, is invariant in the frequency domain. Expanding the temporal variation at each spatial node into a Fourier series transforms the unsteady governing equations into a steady set of equations in integer harmonics that can be tackled with the acceleration techniques afforded to steady-state flow solvers. Other similar approaches, such as the Nonlinear Frequency Domain [3,4,5], Reduced Frequency [6] and Time-Spectral [7, 8, 9] methods, were developed shortly thereafter. Additionally, adjoint-based optimization techniques can be applied [10, 11] as well as frequency-adaptive methods [12, 13, 14] to provide even more flexibility to the method. The Fourier temporal basis functions imply spectral convergence as the number of harmonic modes, and correspondingly number of time samples, N, is increased. Some elect to solve the equations in the frequency domain directly, while others choose to transform the equations back into the time domain to simplify the process of adding this capability to existing solvers, but each harnesses the underlying steady solution in the frequency domain. These temporal projection methods will herein be collectively referred to as Time-Spectral methods. Time-Spectral methods have demonstrated marked success in reducing the computational costs associated with simulating periodic forced flows, but have yet to be fully applied to overset or Cartesian solvers for arbitrary motion with dynamic hole-cutting. Overset and Cartesian grid methodologies are versatile techniques capable of handling complex geometry configurations in practical engineering applications, and the combination of the Time-Spectral approach with this general capability potentially provides an enabling new design and analysis tool. In an arbitrary moving-body scenario for these approaches, a Lagrangian body moves through a fixed Eulerian mesh and mesh points in the Eulerian mesh interior to the solid body are removed (cut or blanked), leaving a hole in the Eulerian mesh. During the dynamic motion some gridpoints in the domain are blanked and do not have a complete set of time-samples preventing a direct implementation of the Time-Spectral method. Murman[6] demonstrated the Time-Spectral approach for a Cartesian solver with a rigid domain motion, wherein the hole cutting remains constant. Similarly, Custer et al. [15, 16] used the NASA overset OVERFLOW solver and limited the amount of relative motion to ensure static hole-cutting and interpolation. Recently, Mavriplis and Mundis[17] demonstrated a qualitative method for applying the Time-Spectral approach to an unstructured overset solver for arbitrary motion. The goal of the current work is to develop a robust and general method for handling arbitrary motion with the Time-Spectral approach within an overset or Cartesian mesh method, while still approaching the spectral convergence rate of the original Time-Spectral approach. The viscous OVERFLOW solver will be augmented with the new Time-Spectral algorithm and the capability of the method for benchmark problems in rotorcraft and turbomachinery will be demonstrated. This abstract begins with a brief synopsis of the Time-Spectral approach for overset grids and provides details of e current approach to allow for arbitrary motion. Model problem results in one and two dimensions are included to demonstrate the viability of the method and the convergence properties. Section IV briefly outlines the implementation into the OVERFLOW solver, and the abstract closes with a description of the benchmark test cases which will be included in the final paper.

Leffell, Joshua Isaac↗

NASA NTRS2012

Membrane Shell Reflector Segment Antenna

The mesh reflector is the only type of large, in-space deployable antenna that has successfully flown in space. However, state-of-the-art large deployable mesh antenna systems are RF-frequency-limited by both global shape accuracy and local surface quality. The limitations of mesh reflectors stem from two factors. First, at higher frequencies, the porosity and surface roughness of the mesh results in loss and scattering of the signal. Second, the mesh material does not have any bending stiffness and thus cannot be formed into true parabolic (or other desired) shapes. To advance the deployable reflector technology at high RF frequencies from the current state-of-the-art, significant improvements need to be made in three major aspects: a high-stability and highprecision deployable truss; a continuously curved RF reflecting surface (the function of the surface as well as its first derivative are both continuous); and the RF reflecting surface should be made of a continuous material. To meet these three requirements, the Membrane Shell Reflector Segment (MSRS) antenna was developed.

Fang, Houfei↗

NASA NTRS2014

Cart3D Simulations for the First AIAA Sonic Boom Prediction Workshop

Simulation results for the First AIAA Sonic Boom Prediction Workshop (LBW1) are presented using an inviscid, embedded-boundary Cartesian mesh method. The method employs adjoint-based error estimation and adaptive meshing to automatically determine resolution requirements of the computational domain. Results are presented for both mandatory and optional test cases. These include an axisymmetric body of revolution, a 69deg delta wing model and a complete model of the Lockheed N+2 supersonic tri-jet with V-tail and flow through nacelles. In addition to formal mesh refinement studies and examination of the adjoint-based error estimates, mesh convergence is assessed by presenting simulation results for meshes at several resolutions which are comparable in size to the unstructured grids distributed by the workshop organizers. Data provided includes both the pressure signals required by the workshop and information on code performance in both memory and processing time. Various enhanced techniques offering improved simulation efficiency will be demonstrated and discussed.

Predictions↗

NASA NTRS2015

Full-Carpet Design of a Low-Boom Demonstrator Concept

The Cart3D adjoint-based design framework is used to mitigate the undesirable o -track sonic boom properties of a demonstrator concept designed for low-boom directly under the flight path. First, the requirements of a Cart3D design mesh are determined using a high-fidelity mesh adapted to minimize the discretization error of the CFD analysis. Low-boom equivalent area targets are then generated at the under-track and one off-track azimuthal position for the baseline configuration. The under-track target is generated using a trim- feasible low-boom target generation process, ensuring that the final design is not only low-boom, but also trimmed at the specified flight condition. The o -track equivalent area target is generated by minimizing the A-weighted loudness using an efficient adjoint-based approach. The configuration outer mold line is then parameterized and optimized to match the off-body pressure distributions prescribed by the low-boom targets. The numerical optimizer uses design gradients which are calculated using the Cart3D adjoint- based design capability. Optimization constraints are placed on the geometry to satisfy structural feasibility. The low-boom properties of the final design are verified using the adaptive meshing approach. This analysis quantifies the error associated with the CFD mesh that is used for design. Finally, an alternate mesh construction and target positioning approach offering greater computational efficiency is demonstrated and verified.

Ordaz, Irian↗

NASA NTRS2018

LAVA Simulations for the 3rd AIAA CFD High Lift Prediction Workshop with Body Fitted Grids

In response to the 3rd AIAA CFD High Lift Prediction Workshop, the workshop cases were analyzed using Reynolds-averaged Navier-Stokes flow solvers within the Launch Ascent and Vehicle Aerodynamics (LAVA) solver framework. For the workshop cases the advantages and limitations of both overset-structured an unstructured polyhedral meshes were assessed. The workshop included 3 cases: a 2D airfoil validation case, a mesh convergence study using the High Lift Common Research Model, and a nacelle/pylon integration study using the JAXA (Japan Aerospace Exploration Agency) Standard Model. The 2D airfoil case from the workshop is used to verify the implementation of the Spalart-Allmaras turbulence model along with some of its variants within the solver. The High Lift Common Research Model case is used to assess solver performance and accuracy at varying mesh resolutions, as well as identify the minimum mesh fidelity required for LAVA on this class of problem. The JAXA Standard Model case is used to assess the solver's sensitivity to the turbulence model and to compare the structured and unstructured mesh paradigms. These workshop cases have helped establish best practices for high lift flow configurations for the LAVA solver.

LAVA↗

DOE OSTI2015

Three-dimensional local ALE-FEM method for fluid flow in domains containing moving boundaries/objects interfaces

A three-dimensional finite element method for the numerical simulations of fluid flow in domains containing moving rigid objects or boundaries is developed. The method falls into the general category of Arbitrary Lagrangian Eulerian methods; it is based on a fixed mesh that is locally adapted in the immediate vicinity of the moving interfaces and reverts to its original shape once the moving interfaces go past the elements. The moving interfaces are defined by separate sets of marker points so that the global mesh is independent of interface movement and the possibility of mesh entanglement is eliminated. The results is a fully robust formulation capable of calculating on domains of complex geometry with moving boundaries or devises that can also have a complex geometry without danger of the mesh becoming unsuitable due to its continuous deformation thus eliminating the need for repeated re-meshing and interpolation. Moreover, the boundary conditions on the interfaces are imposed exactly. This work is intended to support the internal combustion engines simulator KIVA developed at Los Alamos National Laboratories. The model's capabilities are illustrated through application to incompressible flows in different geometrical settings that show the robustness and flexibility of the technique to perform simulations involving moving boundaries in a three-dimensional domain.

16 TIDAL AND WAVE POWER↗

DOE OSTI2014

Redwing: A MOOSE application for coupling MPACT and BISON

Fuel performance and whole core neutron transport programs are often used to analyze fuel behavior as it is depleted in a reactor. For fuel performance programs, internal models provide the local intra-pin power density, fast neutron flux, burnup, and fission rate density, which are needed for a fuel performance analysis. The fuel performance internal models have a number of limitations. These include effects on the intra-pin power distribution by nearby assembly elements, such as water channels and control rods, and the further limitation of applicability to a specified fuel type such as low enriched UO2. In addition, whole core neutron transport codes need an accurate intra-pin temperature distribution in order to calculate neutron cross sections. Fuel performance simulations are able to model the intra-pin fuel displacement as the fuel expands and densifies. These displacements must be accurately modeled in order to capture the eventual mechanical contact of the fuel and the clad; the correct radial gap width is needed for an accurate calculation of the temperature distribution of the fuel rod. Redwing is a MOOSE-based application that enables coupling between MPACT and BISON for transport and fuel performance coupling. MPACT is a 3D neutron transport and reactor core simulator based on the method of characteristics (MOC). The development of MPACT began at the University of Michigan (UM) and now is under the joint development of ORNL and UM as part of the DOE CASL Simulation Hub. MPACT is able to model the effects of local assembly elements and is able calculate intra-pin quantities such as the local power density on a volumetric mesh for any fuel type. BISON is a fuel performance application of Multi-physics Object Oriented Simulation Environment (MOOSE), which is under development at Idaho National Laboratory. BISON is able to solve the nonlinearly coupled mechanical deformation and heat transfer finite element equations that model a fuel element as it is depleted in a nuclear reactor. Redwing couples BISON and MPACT in a single application. Redwing maps and transfers the individual intra-pin quantities such as fission rate density, power density, and fast neutron flux from the MPACT volumetric mesh to the individual BISON finite element meshes. For a two-way coupling Redwing maps and transfers the individual pin temperature field and axially dependent coolant densities from the BISON mesh to the MPACT volumetric mesh. Details of the mapping are given. Redwing advances the simulation with the MPACT solution for each depletion time step and then advances the multiple BISON simulations for fuel performance calculations. Sub-cycle advancement can be applied to the individual BISON simulations and allows multiple time steps to be applied to the fuel performance simulations. Currently, only loose coupling where data from a previous time step is applied to the current time step is performed.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2017

Gas reservoir and a method to supply gas to plasma tubes

A reservoir for storing and supplying a portion of a reservoir gas into a gas-filled tube is presented. The reservoir includes a first vessel having a thermally conductive surface, a meshed vessel having a lid, and placed inside the first vessel to form a cavity between the meshed vessel and the first vessel, at least one tray placed inside the meshed vessel to divide an inner space of the meshed vessel into a plurality of compartments, a sorbent material placed inside the plurality of compartments in the meshed vessel, a temperature control device positioned such that a first portion of the temperature control device is in physical contact with at least a portion of the thermally conductive surface, and a change in the temperature of the temperature control device changes the temperature of the sorbent material, wherein the reservoir gas is retained by the sorbent material at the storage temperature.

36 MATERIALS SCIENCE↗

DOE OSTI2016

Pellet Cladding Mechanical Interaction Modeling Using the Extended Finite Element Method

As a brittle material, the ceramic UO2 used as light water reactor fuel experiences significant fracturing throughout its life, beginning with the first rise to power of fresh fuel. This has multiple effects on the thermal and mechanical response of the fuel/cladding system. One such effect that is particularly important is that when there is mechanical contact between the fuel and cladding, cracks that extending from the outer surface of the fuel into the volume of the fuel cause elevated stresses in the adjacent cladding, which can potentially lead to cladding failure. Modeling the thermal and mechanical response of the cladding in the vicinity of these surface-breaking cracks in the fuel can provide important insights into this behavior to help avoid operating conditions that could lead to cladding failure. Such modeling has traditionally been done in the context of finite-element-based fuel performance analysis by modifying the fuel mesh to introduce discrete cracks. While this approach is effective in capturing the important behavior at the fuel/cladding interface, there are multiple drawbacks to explicitly incorporating the cracks in the finite element mesh. Because the cracks are incorporated in the original mesh, the mesh must be modified for cracks of specified location and depth, so it is difficult to account for crack propagation and the formation of new cracks at other locations. The extended finite element method (XFEM) has emerged in recent years as a powerful method to represent arbitrary, evolving, discrete discontinuities within the context of the finite element method. Development work is underway by the authors to implement XFEM in the BISON fuel performance code, and this capability has previously been demonstrated in simulations of fracture propagation in ceramic nuclear fuel. These preliminary demonstrations have included only the fuel, and excluded the cladding for simplicity. This paper presents initial results of efforts to apply XFEM to model stress concentrations induced by fuel fractures at the fuel/cladding interface during pellet cladding mechanical interaction (PCMI). This is accomplished by enhancing the thermal and mechanical contact enforcement algorithms employed by BISON to permit their use in conjunction with XFEM. The results from this methodology are demonstrated to be equivalent to those from using meshed discrete cracks. While the results of the two methods are equivalent for the case of a stationary crack, it is demonstrated that XFEM provides the additional flexibility of allowing arbitrary crack initiation and propagation during the analysis, and minimizes model setup effort for cases with stationary cracks.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2019

System, method, and computer program for creating geometry-compliant lattice structures

A system and method of creating a shape-conforming lattice structure for a part formed via additive manufacturing. The method includes receiving a computer model of the part and generating a finite element mesh. A lattice structure including a number of lattice cellular components may also be generated. Some of the mesh elements of the finite element mesh may be deformed so that the finite element mesh conforms to the overall shape of the part. The lattice structure may then be deformed so that the lattice structure has a cellular periodicity corresponding to the finite elements of the finite element mesh. In this way, the part retains the benefits of its overall shape and the benefits of lattice features without introducing structural weak points, directional stresses, and other structural deficiencies.

Vernon, Gregory John↗