Publications

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Electrical conductivity is key to the performance of thermal battery cathodes. In this work we present the effects of manufacturing and processing conditions on the electrical conductivity of Li/FeS2 thermal battery cathodes. We use finite element simulations to compute the conductivity of three-dimensional microcomputed tomography cathode microstructures and compare results to experimental impedance spectroscopy measurements. A regression analysis reveals a predictive relationship between composition, processing conditions, and electrical conductivity; a trend which is largely erased after thermally-induced deformation. The trend applies to both experimental and simulation results, although is not as apparent in simulations. This research is a step toward a more fundamental understanding of the effects of processing and composition on thermal battery component microstructure, properties, and performance.

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A Galerkin/least-squares stabilization technique is applied to a discrete Elastic Viscous Stress Splitting formulation of for viscoelastic flow. From this, a possible viscoelastic stabilization method is proposed. This method is tested with the flow of an Oldroyd-B fluid past a rigid cylinder, where it is found to produce inaccurate drag coefficients. Furthermore, it fails for relatively low Weissenberg number indicating it is not suited for use as a general algorithm. In addition, a decoupled approach is used as a way separating the constitutive equation from the rest of the system. A Pressure Poisson equation is used when the velocity and pressure are sought to be decoupled, but this fails to produce a solution when inflow/outflow boundaries are considered. However, a coupled pressure-velocity equation with a decoupled constitutive equation is successful for the flow past a rigid cylinder and seems to be suitable as a general-use algorithm.

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This report summarizes progress from the Laboratory Directed Research and Development (LDRD) program during fiscal year 2014. In addition to the programmatic and financial overview, the report includes progress reports from 419 individual R&D projects in 16 categories. Information for 176 projects in their final year is presented in a more comprehensive format, while for those 243 in their pre-final years, only an abstract is presented herein.

This document describes the form and use of three supplemental capabilities added to Goma during 1998 -- augmenting conditions, automatic continuation and linear stability analysis. Augmenting conditions allow the addition of constraints and auxiliary conditions which describe the relationship between unknowns, boundary conditions, material properties and post-processing extracted quantities. Automatic continuation refers to a family of algorithms (zeroth and first order here, single and multi-parameter) that allow tracking steady-state solution paths as material parameters or boundary conditions are varied. The stability analysis capability in Goma uses the method of small disturbances and superposition of normal modes to test the stability of a steady- state flow, i.e., it determines if the disturbance grows or decays in time.

This report documents the research, developments, and mission impact of the Focal Plane Arrays (FPA) system at Sandia National Laboratory.

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Li/FeS2 thermal batteries provide a stable, robust, and reliable power source capable of long-term electrical energy storage without performance degradation. These systems rely on the electrical conductivity of FeS2 cathodes for critical performance parameters such as power and lifetime, and on permeability of the electrolyte through the solid FeS2 particles for ion transfer. The effects of component composition, manufacturing conditions, and the mechanical deformation on conductivity and permeability have not been studied. We present simulation results from a finite element computer model compared with impedance spectroscopy electrical conductivity experiments. Our methods elucidate the combined effects of slumping, particle size distribution, composition, and pellet density on properties related to electrical conduction in Li/FeS2 thermal battery cathodes.

This research project has the objective to extend the range of application, improve the efficiency and conduct simulations with the Fast Lubrication Dynamics (FLD) algorithm for concentrated particle suspensions in a Newtonian fluid solvent. The research involves a combination of mathematical development, new computational algorithms, and application to processing flows of relevance in materials processing. The mathematical developments clarify the underlying theory, facilitate verification against classic monographs in the field and provide the framework for a novel parallel implementation optimized for an OpenMP shared memory environment. The project considered application to consolidation flows of major interest in high throughput materials processing and identified hitherto unforeseen challenges in the use of FLD in these applications. Extensions to the algorithm have been developed to improve its accuracy in these applications.

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We present a review and critique of several methods for the simulation of the dynamics of colloidal suspensions at the mesoscale. We focus particularly on simulation techniques for hydrodynamic interactions, including implicit solvents (Fast Lubrication Dynamics, an approximation to Stokesian Dynamics) and explicit/particle-based solvents (Multi-Particle Collision Dynamics and Dissipative Particle Dynamics). Several variants of each method are compared quantitatively for the canonical system of monodisperse hard spheres, with a particular focus on diffusion characteristics, as well as shear rheology and microstructure. In all cases, we attempt to match the relevant properties of a well-characterized solvent, which turns out to be challenging for the explicit solvent models. Reasonable quantitative agreement is observed among all methods, but overall the Fast Lubrication Dynamics technique shows the best accuracy and performance. We also devote significant discussion to the extension of these methods to more complex situations of interest in industrial applications, including models for non-Newtonian solvent rheology, non-spherical particles, drying and curing of solvent and flows in complex geometries. This work identifies research challenges and motivates future efforts to develop techniques for quantitative, predictive simulations of industrially relevant colloidal suspension processes.

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Temperature histories on the surface of a body that has been subjected to a rapid, highenergy surface deposition process can be di cult to determine, especially if it is impossible to directly observe the surface or attach a temperature sensor to it. In this report, we explore two methods for estimating the temperature history of the surface through the use of a sensor embedded within the body very near to the surface. First, the maximum sensor temperature is directly correlated with the peak surface temperature. However, it is observed that the sensor data is both delayed in time and greatly attenuated in magnitude, making this approach unfeasible. Secondly, we propose an algorithm that involves tting the solution to a one-dimensional instantaneous energy solution problem to both the sensor data and to the results of a one-dimensional CVFEM code. This algorithm is shown to be able to estimate the surface temperature 20 C.

Ductile metals and other materials typically deform plastically under large applied loads; a behavior most often modeled using plastic deformation constitutive models. However, it is possible to capture some of the key behaviors of plastic deformation using only the framework for nonlinear elastic mechanics. In this paper, we develop a phenomenological, hysteretic, nonlinear elastic constitutive model that captures many of the features expected of a plastic deformation model. This model is based on calculating a secant modulus directly from a materials stress-strain curve. Scalar stress and strain values are obtained in three dimensions by using the von Mises invariants. Hysteresis is incorporated by tracking an additional history variable and assuming an elastic unloading response. This model is demonstrated in both single- and multi-element simulations under varying strain conditions.

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