In this work we employ data-driven homogenization approaches to predict the particular mechanical evolution of polycrystalline aggregates with tens of individual crystals. In these oligocrystals the differences in stress response due to microstructural variation is pronounced. Shell-like structures produced by metal-based additive manufacturing and the like make the prediction of the behavior of oligocrystals technologically relevant. The predictions of traditional homogenization theories based on grain volumes are not sensitive to variations in local grain neighborhoods. Direct simulation of the local response with crystal plasticity finite element methods is more detailed, but the computations are expensive. To represent the stress-strain response of a polycrystalline sample given its initial grain texture and morphology we have designed a novel neural network that incorporates a convolution component to observe and reduce the information in the crystal texture field and a recursive component to represent the causal nature of the history information. This model exhibits accuracy on par with crystal plasticity simulations at minimal computational cost per prediction.
This project has developed models of variability of performance to enable robust design and certification. Material variability originating from microstructure has significant effects on component behavior and creates uncertainty in material response. The outcomes of this project are uncertainty quantification (UQ) enabled analysis of material variability effects on performance and methods to evaluate the consequences of microstructural variability on material response in general. Material variability originating from heterogeneous microstructural features, such as grain and pore morphologies, has significant effects on component behavior and creates uncertainty around performance. Current engineering material models typically do not incorporate microstructural variability explicitly, rather functional forms are chosen based on intuition and parameters are selected to reflect mean behavior. Conversely, mesoscale models that capture the microstructural physics, and inherent variability, are impractical to utilize at the engineering scale. Therefore, current efforts ignore physical characteristics of systems that may be the predominant factors for quantifying system reliability. To address this gap we have developed explicit connections between models of microstructural variability and component/system performance. Our focus on variability of mechanical response due to grain and pore distributions enabled us to fully probe these influences on performance and develop a methodology to propagate input variability to output performance. This project is at the forefront of data-science and material modeling. We adapted and innovated from progressive techniques in machine learning and uncertainty quantification to develop a new, physically-based methodology to address the core issues of the Engineering Materials Reliability (EMR) research challenge in modeling constitutive response of materials with significant inherent variability and length-scales.
The advent of fabrication techniques such as additive manufacturing has focused attention on the considerable variability of material response due to defects and other microstructural aspects. This variability motivates the development of an enhanced design methodology that incorporates inherent material variability to provide robust predictions of performance. In this work, we develop plasticity models capable of representing the distribution of mechanical responses observed in experiments using traditional plasticity models of the mean response and recently developed uncertainty quantification (UQ) techniques. To account for material response variability through variations in physical parameters, we adapt a recent Bayesian embedded modeling error calibration technique. We use Bayesian model selection to determine the most plausible of a variety of plasticity models and the optimal embedding of parameter variability. To expedite model selection, we develop an adaptive importance-sampling-based numerical integration scheme to compute the Bayesian model evidence. We demonstrate that the new framework provides predictive realizations that are superior to more traditional ones, and how these UQ techniques can be used in model selection and assessing the quality of calibrated physical parameters.
Exascale computing promises quantities of data too large to efficiently store and transfer across networks in order to be able to analyze and visualize the results. We investigate compressed sensing (CS) as an in situ method to reduce the size of the data as it is being generated during a large-scale simulation. CS works by sampling the data on the computational cluster within an alternative function space such as wavelet bases and then reconstructing back to the original space on visualization platforms. While much work has gone into exploring CS on structured datasets, such as image data, we investigate its usefulness for point clouds such as unstructured mesh datasets often found in finite element simulations. We sample using a technique that exhibits low coherence with tree wavelets found to be suitable for point clouds. We reconstruct using the stagewise orthogonal matching pursuit algorithm that we improved to facilitate automated use in batch jobs. We analyze the achievable compression ratios and the quality and accuracy of reconstructed results at each compression ratio. In the considered case studies, we are able to achieve compression ratios up to two orders of magnitude with reasonable reconstruction accuracy and minimal visual deterioration in the data. Our results suggest that, compared to other compression techniques, CS is attractive in cases where the compression overhead has to be minimized and where the reconstruction cost is not a significant concern.
We use machine learning (ML) to infer stress and plastic flow rules using data from representative polycrystalline simulations. In particular, we use so-called deep (multilayer) neural networks (NN) to represent the two response functions. The ML process does not choose appropriate inputs or outputs, rather it is trained on selected inputs and output. Likewise, its discrimination of features is crucially connected to the chosen input-output map. Hence, we draw upon classical constitutive modeling to select inputs and enforce well-accepted symmetries and other properties. In the context of the results of numerous simulations, we discuss the design, stability and accuracy of constitutive NNs trained on typical experimental data. With these developments, we enable rapid model building in real-time with experiments, and guide data collection and feature discovery.
There exists significant demand for improved Reynolds-Averaged Navier-Stokes (RANS) turbulence models that are informed by and can represent a richer set of turbulence physics. This paper presents a method of using deep neural networks to learn a model for the Reynolds stress anisotropy tensor from high-fidelity simulation data. A novel neural network architecture is proposed which uses a multiplicative layer with an invariant tensor basis to embed Galilean invariance into the predicted anisotropy tensor. It is demonstrated that this neural network architecture provides improved prediction accuracy compared with a generic neural network architecture that does not embed this invariance property. The Reynolds stress anisotropy predictions of this invariant neural network are propagated through to the velocity field for two test cases. For both test cases, significant improvement versus baseline RANS linear eddy viscosity and nonlinear eddy viscosity models is demonstrated.
Particle methods in computational physics are useful for modeling the motion of fluids and solids subject to large deformations. Under these conditions, mesh-based approaches often fail due to decreasing element quality leading to inaccuracy and instability. The developed software package called Moab investigates and prototypes next-generation particle methods, focusing on rigorous error analysis and active error minimization strategies during the computation. The present work discusses examples calculations representative of real engineering problems with quantified and maximized accuracy while demonstrating the potential for meeting engineering performance re- quirements.
In many scientific fields, empirical models are employed to facilitate computational simulations of engineering systems. For example, in fluid mechanics, empirical Reynolds stress closures enable computationally-efficient Reynolds Averaged Navier Stokes simulations. Likewise, in solid mechanics, constitutive relations between the stress and strain in a material are required in deformation analysis. Traditional methods for developing and tuning empirical models usually combine physical intuition with simple regression techniques on limited data sets. The rise of high performance computing has led to a growing availability of high fidelity simulation data. These data open up the possibility of using machine learning algorithms, such as random forests or neural networks, to develop more accurate and general empirical models. A key question when using data-driven algorithms to develop these empirical models is how domain knowledge should be incorporated into the machine learning process. This paper will specifically address physical systems that possess symmetry or invariance properties. Two different methods for teaching a machine learning model an invariance property are compared. In the first method, a basis of invariant inputs is constructed, and the machine learning model is trained upon this basis, thereby embedding the invariance into the model. In the second method, the algorithm is trained on multiple transformations of the raw input data until the model learns invariance to that transformation. Results are discussed for two case studies: one in turbulence modeling and one in crystal elasticity. It is shown that in both cases embedding the invariance property into the input features yields higher performance at significantly reduced computational training costs.
The objective of this work is to investigate the efficacy of using calibration strategies from Uncertainty Quantification (UQ) to determine model coefficients for LES. As the target methods are for engineering LES, uncertainty from numerical aspects of the model must also be quantified. 15 The ultimate goal of this research thread is to generate a cost versus accuracy curve for LES such that the cost could be minimized given an accuracy prescribed by an engineering need. Realization of this goal would enable LES to serve as a predictive simulation tool within the engineering design process.
Reynolds Averaged Navier Stokes (RANS) models are widely used in industry to predict fluid flows, despite their acknowledged deficiencies. Not only do RANS models often produce inaccurate flow predictions, but there are very limited diagnostics available to assess RANS accuracy for a given flow configuration. If experimental or higher fidelity simulation results are not available for RANS validation, there is no reliable method to evaluate RANS accuracy. This paper explores the potential of utilizing machine learning algorithms to identify regions of high RANS uncertainty. Three different machine learning algorithms were evaluated: support vector machines, Adaboost decision trees, and random forests. The algorithms were trained on a database of canonical flow configurations for which validated direct numerical simulation or large eddy simulation results were available, and were used to classify RANS results on a point-by-point basis as having either high or low uncertainty, based on the breakdown of specific RANS modeling assumptions. Classifiers were developed for three different basic RANS eddy viscosity model assumptions: the isotropy of the eddy viscosity, the linearity of the Boussinesq hypothesis, and the non-negativity of the eddy viscosity. It is shown that these classifiers are able to generalize to flows substantially different from those on which they were trained. Feature selection techniques, model evaluation, and extrapolation detection are discussed in the context of turbulence modeling applications.
The Poisson-Boltzmann theory for electrolytes near a charged surface is known to be invalid due to unaccounted physics associated with high ion concentration regimes. To investigate this regime, fluids density functional theory (f-DFT) and molecular dynamics (MD) simulations were used to determine electric surface potential as a function of surface charge. Based on these detailed computations, for electrolytes with nonpolar solvent, the surface potential is shown to depend quadratically on the surface charge in the high charge limit. We demonstrate that modified Poisson-Boltzmann theories can model this limit if they are augmented with atomic packing densities provided by MD. However, when the solvent is a highly polar molecule, water in this case, an intermediate regime is identified in which a constant capacitance is realized. Simulation results demonstrate the mechanism underlying this regime, and for the salt water system studied here, it persists throughout the range of physically realistic surface charge densities so the potential's quadratic surface charge dependence is not obtained.
We present a Green-Kubo method to spatially resolve transport coefficients in compositionally heterogeneous mixtures. We develop the underlying theory based on well-known results from mixture theory, Irving-Kirkwood field estimation, and linear response theory. Then, using standard molecular dynamics techniques, we apply the methodology to representative systems. With a homogeneous salt water system, where the expectation of the distribution of conductivity is clear, we demonstrate the sensitivities of the method to system size, and other physical and algorithmic parameters. Then we present a simple model of an electrochemical double layer where we explore the resolution limit of the method. In this system, we observe significant anisotropy in the wall-normal vs. transverse ionic conductances, as well as near wall effects. Finally, we discuss extensions and applications to more realistic systems such as batteries where detailed understanding of the transport properties in the vicinity of the electrodes is of technological importance.
This study details a methodology for quantification of errors and uncertainties of a finite element heat transfer model applied to a Ruggedized Instrumentation Package (RIP). The proposed verification and validation (V&V) process includes solution verification to examine errors associated with the code's solution techniques, and model validation to assess the model's predictive capability for quantities of interest. The model was subjected to mesh resolution and numerical parameters sensitivity studies to determine reasonable parameter values and to understand how they change the overall model response and performance criteria. To facilitate quantification of the uncertainty associated with the mesh, automatic meshing and mesh refining/coarsening algorithms were created and implemented on the complex geometry of the RIP. Automated software to vary model inputs was also developed to determine the solution’s sensitivity to numerical and physical parameters. The model was compared with an experiment to demonstrate its accuracy and determine the importance of both modelled and unmodelled physics in quantifying the results' uncertainty. An emphasis is placed on automating the V&V process to enable uncertainty quantification within tight development schedules.
Advances in technology for electrochemical energy storage require increased understanding of electrolyte/electrode interfaces, including the electric double layer structure, and processes involved in charging of the interface, and the incorporation of this understanding into quantitative models. Simplified models such as Helmholtz's electric double-layer (EDL) concept don't account for the molecular nature of ion distributions, solvents, and electrode surfaces and therefore cannot be used in predictive, high-fidelity simulations for device design. This report presents theoretical results from models that explicitly include the molecular nature of the electrical double layer and predict critical electrochemical quantities such as interfacial capacitance. It also describes development of experimental tools for probing molecular properties of electrochemical interfaces through optical spectroscopy. These optical experimental methods are designed to test our new theoretical models that provide descriptions of the electric double layer in unprecedented detail.