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A Monte Carlo model for 3D grain evolution during welding

Modelling and Simulation in Materials Science and Engineering

Rodgers, Theron R.; Mitchell, John A.; Tikare, Veena T.

Welding is one of the most wide-spread processes used in metal joining. However, there are currently no open-source software implementations for the simulation of microstructural evolution during a weld pass. Here we describe a Potts Monte Carlo based model implemented in the SPPARKS kinetic Monte Carlo computational framework. The model simulates melting, solidification and solid-state microstructural evolution of material in the fusion and heat-affected zones of a weld. The model does not simulate thermal behavior, but rather utilizes user input parameters to specify weld pool and heat-affect zone properties. Weld pool shapes are specified by Bézier curves, which allow for the specification of a wide range of pool shapes. Pool shapes can range from narrow and deep to wide and shallow representing different fluid flow conditions within the pool. Surrounding temperature gradients are calculated with the aide of a closest point projection algorithm. The model also allows simulation of pulsed power welding through time-dependent variation of the weld pool size. Example simulation results and comparisons with laboratory weld observations demonstrate microstructural variation with weld speed, pool shape, and pulsed-power.

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TYPE Journal Article YEAR 2017
ScopusOSTIDOI

An active learning high-throughput microstructure calibration framework for solving inverse structure–process problems in materials informatics

Acta Materialia

Tran, Anh; Mitchell, John A.; Swiler, Laura P.; Wildey, Tim

Determining a process–structure–property relationship is the holy grail of materials science, where both computational prediction in the forward direction and materials design in the inverse direction are essential. Problems in materials design are often considered in the context of process–property linkage by bypassing the materials structure, or in the context of structure–property linkage as in microstructure-sensitive design problems. However, there is a lack of research effort in studying materials design problems in the context of process–structure linkage, which has a great implication in reverse engineering. In this work, given a target microstructure, we propose an active learning high-throughput microstructure calibration framework to derive a set of processing parameters, which can produce an optimal microstructure that is statistically equivalent to the target microstructure. The proposed framework is formulated as a noisy multi-objective optimization problem, where each objective function measures a deterministic or statistical difference of the same microstructure descriptor between a candidate microstructure and a target microstructure. Furthermore, to significantly reduce the physical waiting wall-time, we enable the high-throughput feature of the microstructure calibration framework by adopting an asynchronously parallel Bayesian optimization by exploiting high-performance computing resources. Case studies in additive manufacturing and grain growth are used to demonstrate the applicability of the proposed framework, where kinetic Monte Carlo (kMC) simulation is used as a forward predictive model, such that for a given target microstructure, the target processing parameters that produced this microstructure are successfully recovered.

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TYPE Journal Article YEAR 2020
ScopusOSTIDOI

An Approach to Upscaling SPPARKS Generated Synthetic Microstructures of Additively Manufactured Metals

Mitchell, John A.

Additive manufacturing (AM) of metal parts can save time, energy, and produce parts that cannot otherwise be made with traditional machining methods. Near final part geometry is the goal for AM, but material microstructures are inherently different from those of wrought materials as they arise from a complex temperature history associated with the additive process. It is well known that strength and other properties of interest in engineering design follow from microstructure and temperature history. Because of complex microstructure morphologies and spatial heterogeneities, properties are heterogeneous and reflect underlying microstructure. This report describes a method for distributing properties across a finite element mesh so that effects of complex heterogeneous microstructures arising from additive manufacturing can be systematically incorporated into engineering scale calculations without the need for conducting a nearly impossible and time consuming effort of meshing material details. Furthermore, the method reflects the inherent variability in AM materials by making use of kinetic Monte Carlo calculations to model the AM process associated with a build.

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TYPE SAND Report YEAR 2019
OSTIDOI

Fast three-dimensional rules-based simulation of thermal-sprayed microstructures

Computational Materials Science

Rodgers, Theron R.; Mitchell, John A.; Olson, Aaron J.; Bolintineanu, Dan S.; Vackel, Andrew V.; Moore, Nathan W.

Thermal spray processes involve the repeated impact of millions of discrete particles, whose melting, deformation, and coating-formation dynamics occur at microsecond timescales. The accumulated coating that evolves over minutes is comprised of complex, multiphase microstructures, and the timescale difference between the individual particle solidification and the overall coating formation represents a significant challenge for analysts attempting to simulate microstructure evolution. In order to overcome the computational burden, researchers have created rule-based models (similar to cellular automata methods) that do not directly simulate the physics of the process. Instead, the simulation is governed by a set of predefined rules, which do not capture the fine-details of the evolution, but do provide a useful approximation for the simulation of coating microstructures. Here, we introduce a new rules-based process model for microstructure formation during thermal spray processes. The model is 3D, allows for an arbitrary number of material types, and includes multiple porosity-generation mechanisms. Example results of the model for tantalum coatings are presented along with sensitivity analyses of model parameters and validation against 3D experimental data. The model's computational efficiency allows for investigations into the stochastic variation of coating microstructures, in addition to the typical process-to-structure relationships.

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TYPE Journal Article YEAR 2021
ScopusOSTIDOI

High Fidelity Simulations of Large-scale Wireless Networks (Part II - FY2017)

Onunkwo, Uzoma O.; Ganti, Anand G.; Mitchell, John A.; Scoggin, Michael P.; Schroeppel, Richard C.; Van Leeuwen, Brian P.; Wolf, Michael W.

The ability to simulate wireless networks at large-scale for meaningful amount of time is considerably lacking in today's network simulators. For this reason, many published work in this area often limit their simulation studies to less than a 1,000 nodes and either over-simplify channel characteristics or perform studies over time scales much less than a day. In this report, we show that one can overcome these limitations and study problems of high practical consequence. This work presents two key contributions to high fidelity simulation of large-scale wireless networks: (a) wireless simulations can be sped up by more than 100X in runtime using ideas from spatial indexing algorithms and clipping of negligible signals and (b) clustering and task-oriented programming paradigm can be used to reduce inter- process communication in a parallel discrete event simulation resulting in a better scaling efficiency.

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TYPE SAND Report YEAR 2017
OSTIDOI
Results 1–25 of 62
Results 1–25 of 62