Publications

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Additive Manufacturing (AM) presents unprecedented opportunities to enable design freedom in parts that are unachievable via conventional manufacturing. However, AM-processed components generally lack the necessary performance metrics for widespread commercial adoption. We present a novel AM processing and design approach using removable heat sink artifacts to tailor the mechanical properties of traditionally low strength and low ductility alloys. The design approach is demonstrated with the Fe-50 at.% Co alloy, as a model material of interest for electromagnetic applications. AM-processed components exhibited unprecedented performance, with a 300 % increase in strength and an order-of-magnitude improvement in ductility relative to conventional wrought material. These results are discussed in the context of product performance, production yield, and manufacturing implications toward enabling the design and processing of high-performance, next-generation components, and alloys.

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This work proposes a finite element (FE) analysis workflow to simulate directed energy deposition (DED) additive manufacturing at a macroscopic length scale (i.e. part length scale) and to predict thermal conditions during manufacturing, as well as distortions, strength and residual stresses at the completion of manufacturing. The proposed analysis method incorporates a multi-step FE workflow to elucidate the thermal and mechanical responses in laser engineered net shaping (LENS) manufacturing. For each time step, a thermal element activation scheme captures the material deposition process. Then, activated elements and their associated geometry are analyzed first thermally for heat flow due to radiation, convection, and conduction, and then mechanically for the resulting stresses, displacements, and material property evolution. Simulations agree with experimentally measured in situ thermal measurements for simple cylindrical build geometries, as well as general trends of local hardness distribution and plastic strain accumulation (represented by relative distribution of geometrically necessary dislocations).

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Laser engineered net shaping (LENS) is an additive manufacturing process that presents a promising method of creating or repairing metal parts not previously feasible with traditional manufacturing methods. The LENS process involves the directed deposition of metal via a laser power source and a spray of metal powder co-located to create and feed a molten pool (also referred to generically as Directed Energy Deposition, DED). DED technologies are being developed for use in prototyping, repair, and manufacturing across a wide variety of materials including stainless steel, titanium, tungsten carbidecobalt, aluminum, and nickel based superalloys. However, barriers to the successful production and qualification of LENS produced or repaired parts remain. This work proposes a finite element (FE) analysis methodology capable of simulating the LENS process at the continuum length scale (i.e. part length scale). This method incorporates an element activation scheme wherein only elements that exceed the material melt temperature during laser heating are activated and carried through to subsequent analysis steps. Following the initial element activation calculation, newly deposited, or activated elements and the associated geometry, are carried through to thermal and mechanical analyses to calculate heat flow due to radiation, convection, and conduction as well as stresses and displacements. The final aim of this work is to develop a validated LENS process simulation capability that can accurately predict temperature history, final part shape, distribution of strength, microstructural properties, and residual stresses based on LENS process parameters.

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Finite element method (FEM) numerical simulations of heat transfer for high-temperature regimes often require modeling of grey-body enclosure radiation where enclosure geometry definitions are obtained as part of the model grid generation process. Owing to the expense of solving the radiation problem, typical FEM approaches loosely couple the radiative transfer solution as boundary conditions to a standard conduction formulation. When the problem at hand is thermal-mechanical and relative motion occurs between enclosure surfaces, the simulation code is tasked with providing a means of updating the original enclosure surface geometry to reflect the deformed configuration. While this scenario is manageable for contiguously meshed discretizations, the difficulty of updating enclosure geometry is greatly increased when the model admits sliding. Here the analysis code must employ both mechanical and thermal contact, relying heavily on geometric search and contact constraints to enforce closure for the conduction formulation. General purpose large-deformation FEM structural codes employ surface contact utilities to provide geometric search and contact constraint definitions. This paper describes an ongoing effort to leverage contact utilities for solving the enclosure radiation problem in deforming and sliding mesh scenarios while having minimal impact to a traditional modeling approach. The current effort is divided into two areas, enclosure definitions and thermal contact, but the primary focus here is on enabling use of contact to provide definition of the enclosure. The proposed methodology is demonstrated on simple enclosure radiation models using SNL Sierra Mechanics Dash contact utilities and the Chaparral enclosure radiation library with Sierra Mechanics Structural and Thermal application codes. Sandia National Laboratories is a multi-program laboratory managed and operated by Sandia Corporation, a wholly owned subsidiary of Lockheed Martin Corporation, for the U.S. Department of Energys National Nuclear Security Administration under contract DE-AC04-94AL85000. Copyright © 2012 by ASME.

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This document summarizes research performed under the SNL LDRD entitled - Computational Mechanics for Geosystems Management to Support the Energy and Natural Resources Mission. The main accomplishment was development of a foundational SNL capability for computational thermal, chemical, fluid, and solid mechanics analysis of geosystems. The code was developed within the SNL Sierra software system. This report summarizes the capabilities of the simulation code and the supporting research and development conducted under this LDRD. The main goal of this project was the development of a foundational capability for coupled thermal, hydrological, mechanical, chemical (THMC) simulation of heterogeneous geosystems utilizing massively parallel processing. To solve these complex issues, this project integrated research in numerical mathematics and algorithms for chemically reactive multiphase systems with computer science research in adaptive coupled solution control and framework architecture. This report summarizes and demonstrates the capabilities that were developed together with the supporting research underlying the models. Key accomplishments are: (1) General capability for modeling nonisothermal, multiphase, multicomponent flow in heterogeneous porous geologic materials; (2) General capability to model multiphase reactive transport of species in heterogeneous porous media; (3) Constitutive models for describing real, general geomaterials under multiphase conditions utilizing laboratory data; (4) General capability to couple nonisothermal reactive flow with geomechanics (THMC); (5) Phase behavior thermodynamics for the CO2-H2O-NaCl system. General implementation enables modeling of other fluid mixtures. Adaptive look-up tables enable thermodynamic capability to other simulators; (6) Capability for statistical modeling of heterogeneity in geologic materials; and (7) Simulator utilizes unstructured grids on parallel processing computers.

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Aria is a Galerkin finite element based program for solving coupled-physics problems described by systems of PDEs and is capable of solving nonlinear, implicit, transient and direct-to-steady state problems in two and three dimensions on parallel architectures. The suite of physics currently supported by Aria includes the incompressible Navier-Stokes equations, energy transport equation, species transport equations, nonlinear elastic solid mechanics, and electrostatics as well as generalized scalar, vector and tensor transport equations. Additionally, Aria includes support for arbitrary Lagrangian-Eulerian (ALE) and level set based free and moving boundary tracking. Coupled physics problems are solved in several ways including fully-coupled Newton's method with analytic or numerical sensitivities, fully-coupled Newton-Krylov methods, fully-coupled Picard's method, and a loosely-coupled nonlinear iteration about subsets of the system that are solved using combinations of the aforementioned methods. Error estimation, uniform and dynamic h-adaptivity and dynamic load balancing are some of Aria's more advanced capabilities. Aria is based on the Sierra Framework.

This report documents the results for an FY06 ASC Algorithms Level 2 milestone combining error estimation and adaptivity, uncertainty quantification, and probabilistic design capabilities applied to the analysis and design of bistable MEMS. Through the use of error estimation and adaptive mesh refinement, solution verification can be performed in an automated and parameter-adaptive manner. The resulting uncertainty analysis and probabilistic design studies are shown to be more accurate, efficient, reliable, and convenient.

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We describe parallel simulations of viscous, incompressible, free surface, Newtonian fluid flow problems that include dynamic contact lines. The Galerlin finite element method was used to discretize the fully-coupled governing conservation equations and a ''pseudo-solid'' mesh mapping approach was used to determine the shape of the free surface. In this approach, the finite element mesh is allowed to deform to satisfy quasi-static solid mechanics equations subject to geometric or kinematic constraints on the boundaries. As a result, nodal displacements must be included in the set of problem unknowns. Issues concerning the proper constraints along the solid-fluid dynamic contact line in three dimensions are discussed. Parallel computations are carried out for an example taken from the coating flow industry, flow in the vicinity of a slot coater edge. This is a three-dimensional free-surface problem possessing a contact line that advances at the web speed in one region but transitions to static behavior in another part of the flow domain. Discussion focuses on parallel speedups for fixed problem size, a class of problems of immediate practical importance.