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Nuclear Materials Packaging, Transportation, and Systems Analysis Group Software Quality Assurance Plan: ANSYS Mechanical Finite Element Analysis Software Version 2023R1

ANSYS Inc. develops and markets engineering simulation software and services used in the aerospace, automotive, manufacturing, electronics, biomedical, energy, defense, and many other industries. ANSYS is dedicated to engineering simulation and is the world’s leading software provider. ANSYS was founded in 1970 and is headquartered in Canonsburg, Pennsylvania. ANSYS provides an engineering analysis tool combining structural, thermal, computational fluid dynamics, acoustic, and electromagnetic simulation capabilities. ANSYS has two main programs, which use the same solvers: (1) Mechanical APDL (ANSYS Design Parametric Language), a Fortran-based coding platform, and (2) ANSYS Workbench, which uses a graphical user interface to aid in finite element analysis implementation. This plan covers both APDL and Workbench. The ANSYS computer program is a large-scale, multipurpose finite element program that can be used to solve several classes of engineering analyses. The analysis capabilities of ANSYS include the ability to solve static and dynamic structural analyses, steady-state and transient heat transfer problems, mode-frequency and buckling eigenvalue problems, static or time-varying magnetic analyses, and various types of field and coupled-field applications. The program contains many special features that allow nonlinearities or secondary effects such as plasticity, large strain, hyperelasticity, creep, swelling, large deflections, contact, stress stiffening, temperature dependency, material anisotropy, and radiation to be included in the solution. As ANSYS has been developed, other special capabilities such as substructuring, submodeling, random vibration, kinetostatics, kinetodynamics, free convection fluid analysis, acoustics, magnetics, piezoelectrics, coupled-field analysis, and design optimization have been added to the program. These capabilities contribute further to making ANSYS a multipurpose analysis tool for varied engineering disciplines. The ANSYS program has been in commercial use for over 50 years and has been used extensively in the aerospace, automotive, construction, electronic, energy services, manufacturing, nuclear, plastics, oil, and steel industries. Additionally, many consulting firms and hundreds of universities have used ANSYS for analysis, research, and educational purposes. ANSYS is recognized worldwide as one of the most widely used and capable programs of its type. Ansys design analysis software is the first created within a quality system with ISO 9001 certification, the internationally accepted quality standard. Product development, testing, maintenance and support processes also meet the United States Nuclear Regulatory Commission's quality requirements, as they have for nearly four decades. The Quality Assurance Service Agreement is suitable for the customers working in the nuclear industry who need to meet specific federal regulations including 10CRF50 Appendix B and provisions of 10CFR21. ANSYS has retained its original International Organization for Standardization (ISO) 9001 accreditation certificate since1995-05-04, It’s current certificate is valid until 2027-05-29.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Software Quality Assurance Plan ANSYS LSDYNA Version 2023R1

ANSYS Inc. develops and markets engineering simulation software and services used in the aerospace, automotive, manufacturing, electronics, biomedical, energy, defense, and many other industries. ANSYS is dedicated to engineering simulation and is the world’s leading software provider. ANSYS was founded in 1970 and is headquartered in Canonsburg, Pennsylvania. ANSYS provides an engineering analysis tool combining structural, thermal, computational fluid dynamics, acoustic and electromagnetic simulation capabilities. ANSYS LS-DYNA is the most used explicit simulation program capable of simulating the response of materials to short periods of severe loading. Its many elements, contact formulations, material models, and other controls can be used to simulate complex models with control over all the details of the problem. ANSYS LS-DYNA has a vast array of capabilities to simulate extreme deformation problems using its explicit solver. Engineers can tackle simulations involving material failure and look at how the failure progresses through a part or through a system. Models with large amounts of parts or surfaces interacting with each other are also easily handled, and the interactions and load passing between complex behaviors are modeled accurately. Using computers with higher numbers of CPU cores can drastically reduce solution times. In addition, many consulting firms and hundreds of universities use ANSYS for analysis, research, and educational purposes. ANSYS is recognized worldwide as one of the most widely used and capable programs of its type. ANSYS has successfully passed over 100 customer quality system audits against American Society of Mechanical Engineers (ASME) NQA-1 and 10 CFR Part 50, Appendix B, since the company was founded, over 60 of which have been since 1997. ANSYS has successfully passed over 100 International Organization for Standardization (ISO) 9001 assessments. ANSYS design analysis software is the first created within a quality system with ISO 9001 certification, which is the internationally accepted quality standard. Product development, testing, maintenance, and support processes also meet the US Nuclear Regulatory Commission’s (NRC’s) quality requirements, as they have for nearly four decades. ANSYS staff perform more than 60,000 software verification tests before releasing each new product. ASME NQA-1-2012 (Subpart 2.7 is specific to software) is the industry- and NRC-accepted approach (consensus standard) for meeting 10 CFR Part 50, Appendix B, requirements.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Transformer Analysis with ANSYS Maxwell and COMSOL

This is an extension of work described by Rodriguez et al . (2021). It continues analyses of a generic transformer design by Wes Greenwood. In this report, we summarize that work and add comparable results using the ANSYS Maxwell software (henceforward, “ANSYS”), and with COMSOL . We found the ANSYS and COMSOL calculations of inductance agreed well with previous results for simplified coils in air, and with a ferromagnetic core. We then describe the ANSYS and COMSOL approach and show results for a full transformer model based on magnetic field analyses. Finally, we present electrostatic analyses of E field enhancement, once again resolving individual wires. The purpose is to assess the electrostatic fields in order to locate where electric breakdown is likely to originate. We found the maximum enhancement between the secondary and either the primary or the tertiary at the end of the windings with a large potential difference.

42 ENGINEERING↗

Ceramic material life prediction: A program to translate ANSYS results to CARES/LIFE reliability analysis

This manual describes the use of the ANSCARES program to prepare a neutral file of FEM stress results taken from ANSYS Release 5.0, in the format needed by CARES/LIFE ceramics reliability program. It is intended for use by experienced users of ANSYS and CARES. Knowledge of compiling and linking FORTRAN programs is also required. Maximum use is made of existing routines (from other CARES interface programs and ANSYS routines) to extract the finite element results and prepare the neutral file for input to the reliability analysis. FORTRAN and machine language routines as described are used to read the ANSYS results file. Sub-element stresses are computed and written to a neutral file using FORTRAN subroutines which are nearly identical to those used in the NASCARES (MSC/NASTRAN to CARES) interface.

Vonhermann, Pieter↗

Development of the PROTEUS and ANSYS Coupled System for Simulating Heat Pipe Cooled Micro Reactors

The objective of this project is to develop the coupled system of PROTEUS/ANSYS for simulating a heat pipe cooled micro reactor. As an initial effort, while figuring out controlling ANSYS Mechanical with Workbench, the coupled system of PROTEUS/FLUENT in the CORBA environment were tried to demonstrate the coupled simulation for a transient problem of a heat pipe cooled micro reactor. Finally, the coupled system of PROTEUS/ANSYS was constructed using APDL commands in the CORBA environment, instead of ANSYS Workbench, since we found that ANSYS with the current version of Workbench Python scripting did not provide capabilities necessary for simulating a transient problem.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

Finite element meshing of ANSYS (trademark) solid models

A large scale, general purpose finite element computer program, ANSYS, developed and marketed by Swanson Analysis Systems, Inc. is discussed. ANSYS was perhaps the first commercially available program to offer truly interactive finite element model generation. ANSYS's purpose is for solid modeling. This application is briefly discussed and illustrated.

Kelley, F. S.↗

Comparison of the performance of TLD, OSL and RPL personal dosimetry systems to the American National Standard Institute (ANSI) test categories

The Laboratory Accreditation Program (LAP) tests the capability and performance of the United States Department of Energy's (USDOE) facilities to accurately measure and quantify the whole-body and extremity radiation equivalent doses to the occupational workers. The dosimetry methods used in personal dosimetry can be Thermoluminescence (TL), Optically Stimulated Luminescence (OSL) and Radiophotoluminescence (RPL), among other techniques available. Currently, the TL (LiF:Mg,Ti) and OSL (Al 2 O 3 :C) dosimetry systems are DOELAP-accredited for occupational dose measurements and regulatory reporting. In this study, the performance of a beryllium oxide (BeO) OSL dosimetry system and of a silver-doped phosphate glass RPL dosimetry system is compared against the performance of an accredited LiF:Mg,Ti TL dosimetry system. The bias and standard deviation in each of the performance test categories are compared between these three systems for exposures to photons, beta, and mixed radiation fields with the criteria established by the American National Standard Institute (ANSI) and Health Physics Society (HPS) N13.11-2022 standard. The practical implementation of the dosimetry program and its equivalency to the occupational personal equivalent dose H p (0.07) and H p (10) measurements were evaluated. The TL, OSL and RPL dosimetry systems passed the ANSI performance test criteria for H p (0.07) and H p (10) occupational dose measurements and met the DOELAP accreditation requirements.

61 RADIATION PROTECTION AND DOSIMETRY↗

Application of Benchmark Examples to Assess the Single and Mixed-Mode Static Delamination Propagation Capabilities in ANSYS

The application of benchmark examples for the assessment of quasi-static delamination propagation capabilities is demonstrated for ANSYS. The examples are independent of the analysis software used and allow the assessment of the automated delamination propagation in commercial finite element codes based on the virtual crack closure technique (VCCT). The examples selected are based on two-dimensional finite element models of Double Cantilever Beam (DCB), End-Notched Flexure (ENF), Mixed-Mode Bending (MMB) and Single Leg Bending (SLB) specimens. First, the quasi-static benchmark examples were recreated for each specimen using the current implementation of VCCT in ANSYS . Second, the delamination was allowed to propagate under quasi-static loading from its initial location using the automated procedure implemented in the finite element software. Third, the load-displacement relationship from a propagation analysis and the benchmark results were compared, and good agreement could be achieved by selecting the appropriate input parameters. The benchmarking procedure proved valuable by highlighting the issues associated with choosing the input parameters of the particular implementation. Overall the results are encouraging, but further assessment for three-dimensional solid models is required.

Krueger, Ronald↗

Microwave Cavity Simulation Using Ansys HFSS

The design of microwave cavity detectors for axion dark matter research is often accomplished using advanced full-wave electromagnetic simulation software tools. These tools provide a cost-effective approach to evaluate a wide variety of cavity configurations, frequency tuning mechanisms, and conductive or dielectric materials and coatings. One simulation software package used for this application is Ansys High Frequency Structure Simulator (HFSS), which is based upon the well-established finite element method. HFSS includes numerous features useful for microwave cavity design such as parametric geometry modeling, adaptive meshing algorithm, curvilinear mesh elements, driven modal and eigenmode matrix solvers, and optimization algorithms. This paper describes the use of the HFSS software to simulate microwave cavities for axion haloscope detectors, with an example tutorial for a cylindrical cavity. Excellent agreement between the simulated and analytical results is shown for the resonant frequency, quality factor, and form factor.

Ansys HFSS, Cavity simulation, finite element mode↗

Implementation of tritium transport in a gas-liquid contactor CFD simulation of tritium extraction from lead-lithium in ANSYS fluent

Modifications to the Computational Fluid Dynamic (CFD) software ANSYS Fluent were done to quantify and characterize tritium transport in Gas-Liquid Contactors (GLCs). A double-slit, Ergun-like equation was employed for the porous media model, with Ergun coefficients validated with Sulzer’s Sulcol software. Tritium transport from PbLi within the GLC was verified against analytical models. The geometry of the CFD model was based on the MELODIE GLC experiment. The hydrodynamic CFD pressure drop results align well with SulCol estimations and fall between the predictions of the analytical Delft-Olujic and Billet & Schultes models. In terms of mass transfer efficiency, traditional mass transfer models showed a significant deviation from experimental results when using varying values of H solubility in PbLi. A saturation phenomenon occurred when utilizing high solubility values for hydrogen in PbLi. In conclusion, a modified film theory mass transfer coefficient, incorporating either the Delft-Olujic or Billet & Schultes wettability model, yielded CFD-predicted extraction efficiencies that closely matched experimental measurements.

70 - PLASMA PHYSICS AND FUSION TECHNOLOGY↗

Calculating Average Hot Water Mixes of Residential Plumbing Fittings Using the ANSI 301-2019 Hot Water Draw Model and National Residential Data to Estimate Hot Water Use in Showerheads and Lavatory Faucets

Available studies of hot water use percentages may not necessarily be generalized to a national level given regional differences, varying methodological approaches, and limited sample sizes. While some publicly available usage data, reports, and surveys estimate actual household usage, a lack of water use data specific to end uses make more precise savings calculations difficult. Additionally, most hot water draw models tend to focus on overall household use and may not readily estimate lavatory fixture use. However, reviewing more recent studies and standards enables the U.S. Environmental Protection Agency’s WaterSense program to update its estimates for hot water use and consumers’ corresponding energy and monetary savings to better reflect realworld conditions. This report specifically focuses on improving hot water use and savings estimates of lavatory faucets and showerheads. To estimate the hot water use of lavatory faucets and showerheads, we employed the 2015 Residential Energy Consumption Surveys (RECS) microdata alongside the ANSI 301-2019 Hot Water Draw Model. These estimates account for regional differences in hot water use, including regional cold water inlet temperatures. As a result, the refinements presented in this report are more robust, more recent, and better describe the geographic variation than previous inputs used by the WaterSense program. In addition, the approach described in this paper can be updated over time or tailored to regionally specific needs given available inputs. We conclude that hot water percentages for showers and faucets calculated using publicly available national data are close to the percentages found by regional studies and are consistent with household-level models of water use.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

Translators between CADD and section 5 of the ANSI Y14.26M standard

The American National Standard, Engineering Drawing and Related Documentation Practices, Digital Representation for Communication of Product Definition Data (ANSI Y14.26M-1981) comprises an introduction, three sections corresponding to IGES (Initial Graphics Exchange Specification) Version 1.0, and Section 5, a constructive, relational, language-based representation for geometric and topological entities. This presentation discusses the design and development of two-way translators between Section 5 (herein, ANSI5) and CADD (Computer-Aided Design Drafting).

Emnett, R. F.↗

USSAERO version D computer program development using ANSI standard FORTRAN 77 and DI-3000 graphics

The D version of the Unified Subsonic Supersonic Aerodynamic Analysis (USSAERO) program is the result of numerous modifications and enhancements to the B01 version. These changes include conversion to ANSI standard FORTRAN 77; use of the DI-3000 graphics package; removal of the overlay structure; a revised input format; the addition of an input data analysis routine; and increasing the number of aeronautical components allowed.

Wiese, M. R.↗

ANSYS duplicate finite-element checker routine

An ANSYS finite-element code routine to check for duplicated elements within the volume of a three-dimensional (3D) finite-element mesh was developed. The routine developed is used for checking floating elements within a mesh, identically duplicated elements, and intersecting elements with a common face. A space shuttle main engine alternate turbopump development high pressure oxidizer turbopump finite-element model check using the developed subroutine is discussed. Finally, recommendations are provided for duplicate element checking of 3D finite-element models.

Ortega, R.↗