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Born Qualified Grand Challenge LDRD Final Report

Roach, R.A.; Argibay, Nicolas A.; Allen, Kyle M.; Balch, Dorian K.; Beghini, Lauren L.; Bishop, Joseph E.; Boyce, Brad B.; Brown, Judith A.; Burchard, Ross L.; Chandross, M.; Cook, Adam W.; DiAntonio, Christopher D.; Dressler, Amber D.; Forrest, Eric C.; Ford, Kurtis R.; Ivanoff, Thomas I.; Jared, Bradley H.; Johnson, Kyle J.; Kammler, Daniel K.; Koepke, Joshua R.; Kustas, Andrew K.; Lavin, Judith M.; Leathe, Nicholas L.; Lester, Brian T.; Madison, Jonathan D.; Mani, Seethambal S.; Martinez, Mario J.; Moser, Daniel M.; Rodgers, Theron R.; Seidl, Daniel T.; Brown-Shaklee, Harlan J.; Stanford, Joshua S.; Stender, Michael S.; Sugar, Joshua D.; Swiler, Laura P.; Taylor, Samantha T.; Trembacki, Bradley T.

This SAND report fulfills the final report requirement for the Born Qualified Grand Challenge LDRD. Born Qualified was funded from FY16-FY18 with a total budget of ~$13M over the 3 years of funding. Overall 70+ staff, Post Docs, and students supported this project over its lifetime. The driver for Born Qualified was using Additive Manufacturing (AM) to change the qualification paradigm for low volume, high value, high consequence, complex parts that are common in high-risk industries such as ND, defense, energy, aerospace, and medical. AM offers the opportunity to transform design, manufacturing, and qualification with its unique capabilities. AM is a disruptive technology, allowing the capability to simultaneously create part and material while tightly controlling and monitoring the manufacturing process at the voxel level, with the inherent flexibility and agility in printing layer-by-layer. AM enables the possibility of measuring critical material and part parameters during manufacturing, thus changing the way we collect data, assess performance, and accept or qualify parts. It provides an opportunity to shift from the current iterative design-build-test qualification paradigm using traditional manufacturing processes to design-by-predictivity where requirements are addressed concurrently and rapidly. The new qualification paradigm driven by AM provides the opportunity to predict performance probabilistically, to optimally control the manufacturing process, and to implement accelerated cycles of learning. Exploiting these capabilities to realize a new uncertainty quantification-driven qualification that is rapid, flexible, and practical is the focus of this effort.

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Comprehensive Material Characterization and Simultaneous Model Calibration for Improved Computational Simulation Credibility

Seidl, Daniel T.; Jones, Elizabeth M.; Lester, Brian T.

Computational simulation is increasingly relied upon for high-consequence engineering decisions, and a foundational element to solid mechanics simulations is a credible material model. Our ultimate vision is to interlace material characterization and model calibration in a real-time feedback loop, where the current model calibration results will drive the experiment to load regimes that add the most useful information to reduce parameter uncertainty. The current work investigated one key step to this Interlaced Characterization and Calibration (ICC) paradigm, using a finite load-path tree to incorporate history/path dependency of nonlinear material models into a network of surrogate models that replace computationally-expensive finite-element analyses. Our reference simulation was an elastoplastic material point subject to biaxial deformation with a Hill anisotropic yield criterion. Training data was generated using either a space-filling or adaptive sampling method, and surrogates were built using either Gaussian process or polynomial chaos expansion methods. Surrogate error was evaluated to be on the order of 10⁻5 and 10⁻3 percent for the space-filling and adaptive sampling training data, respectively. Direct Bayesian inference was performed with the surrogate network and with the reference material point simulator, and results agreed to within 3 significant figures for the mean parameter values, with a reduction in computational cost over 5 orders of magnitude. These results bought down risk regarding the surrogate network and facilitated a successful FY22-24 full LDRD proposal to research and develop the complete ICC paradigm.

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GDSA Framework Development and Process Model Integration FY2021

Mariner, Paul M.; Berg, Timothy M.; Debusschere, Bert D.; Eckert, Aubrey C.; Harvey, Jacob H.; LaForce, Tara; Leone, Rosemary C.; Mills, Melissa M.; Nole, Michael A.; Park, Heeho D.; Perry, F.V.; Seidl, Daniel T.; Swiler, Laura P.; Chang, Kyung W.

The Spent Fuel and Waste Science and Technology (SFWST) Campaign of the U.S. Department of Energy (DOE) Office of Nuclear Energy (NE), Office of Spent Fuel & Waste Disposition (SFWD) is conducting research and development (R&D) on geologic disposal of spent nuclear fuel (SNF) and highlevel nuclear waste (HLW). A high priority for SFWST disposal R&D is disposal system modeling (DOE 2012, Table 6; Sevougian et al. 2019). The SFWST Geologic Disposal Safety Assessment (GDSA) work package is charged with developing a disposal system modeling and analysis capability for evaluating generic disposal system performance for nuclear waste in geologic media.

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High fidelity surrogate modeling of fuel dissolution for probabilistic assessment of repository performance

International High-Level Radioactive Waste Management 2019, IHLRWM 2019

Mariner, Paul M.; Swiler, Laura P.; Seidl, Daniel T.; Debusschere, Bert J.; Vo, Jonathan; Frederick, Jennifer M.; Jerden, James L.

Two surrogate models are under development to rapidly emulate the effects of the Fuel Matrix Degradation (FMD) model in GDSA Framework. One is a polynomial regression surrogate with linear and quadratic fits, and the other is a k-Nearest Neighbors regressor (kNNr) method that operates on a lookup table. Direct coupling of the FMD model to GDSA Framework is too computationally expensive. Preliminary results indicate these surrogate models will enable GDSA Framework to rapidly simulate spent fuel dissolution for each individual breached spent fuel waste package in a probabilistic repository simulation. This capability will allow uncertainties in spent fuel dissolution to be propagated and sensitivities in FMD inputs to be quantified and ranked against other inputs.

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High-throughput Material Characterization using the Virtual Fields Method

Jones, Elizabeth M.; Carroll, Jay D.; Karlson, Kyle N.; Kramer, Sharlotte L.; Lehoucq, Richard B.; Reu, Phillip L.; Seidl, Daniel T.; Turner, Daniel Z.

Modeling material and component behavior using finite element analysis (FEA) is critical for modern engineering. One key to a credible model is having an accurate material model, with calibrated model parameters, which describes the constitutive relationship between the deformation and the resulting stress in the material. As such, identifying material model parameters is critical to accurate and predictive FEA. Traditional calibration approaches use only global data (e.g. extensometers and resultant force) and simplified geometries to find the parameters. However, the utilization of rapidly maturing full-field characterization tech- niques (e.g. Digital Image Correlation (DIC)) with inverse techniques (e.g. the Virtual Feilds Method (VFM)) provide a new, novel and improved method for parameter identification. This LDRD tested that idea: in particular, whether more parameters could be identified per test when using full-field data. The research described in this report successfully proves this hypothesis by comparing the VFM results with traditional calibration methods. Important products of the research include: verified VFM codes for identifying model parameters, a new look at parameter covariance in material model parameter estimation, new validation tech- niques to better utilize full-field measurements, and an exploration of optimized specimen design for improved data richness.

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Multi-fidelity information fusion and resource allocation

Jakeman, John D.; Eldred, Michael S.; Geraci, Gianluca G.; Seidl, Daniel T.; Smith, Thomas M.; Gorodetsky, Alex A.; Pham, Trung P.; Narayan, Akil N.; Zeng, Xiaoshu Z.; Ghanem, Roger G.

This project created and demonstrated a framework for the efficient and accurate prediction of complex systems with only a limited amount of highly trusted data. These next generation computational multi-fidelity tools fuse multiple information sources of varying cost and accuracy to reduce the computational and experimental resources needed for designing and assessing complex multi-physics/scale/component systems. These tools have already been used to substantially improve the computational efficiency of simulation aided modeling activities from assessing thermal battery performance to predicting material deformation. This report summarizes the work carried out during a two year LDRD project. Specifically we present our technical accomplishments; project outputs such as publications, presentations and professional leadership activities; and the project’s legacy.

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Results 1–25 of 45
Results 1–25 of 45