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Title: On the Preconditioning of a Newton-Krylov Solver for a High-Order reconstructed Discontinuous Galerkin Discretization of All-Speed Compressible Flow with Phase Change for Application in Laser-Based Additive Manufacturing

Abstract

This dissertation focuses on the development of a fully-implicit, high-order compressible ow solver with phase change. The work is motivated by laser-induced phase change applications, particularly by the need to develop large-scale multi-physics simulations of the selective laser melting (SLM) process in metal additive manufacturing (3D printing). Simulations of the SLM process require precise tracking of multi-material solid-liquid-gas interfaces, due to laser-induced melting/ solidi cation and evaporation/condensation of metal powder in an ambient gas. These rapid density variations and phase change processes tightly couple the governing equations, requiring a fully compressible framework to robustly capture the rapid density variations of the ambient gas and the melting/evaporation of the metal powder. For non-isothermal phase change, the velocity is gradually suppressed through the mushy region by a variable viscosity and Darcy source term model. The governing equations are discretized up to 4th-order accuracy with our reconstructed Discontinuous Galerkin spatial discretization scheme and up to 5th-order accuracy with L-stable fully implicit time discretization schemes (BDF2 and ESDIRK3-5). The resulting set of non-linear equations is solved using a robust Newton-Krylov method, with the Jacobian-free version of the GMRES solver for linear iterations. Due to the sti nes associated with the acoustic waves and thermalmore » and viscous/material strength e ects, preconditioning the GMRES solver is essential. A robust and scalable approximate block factorization preconditioner was developed, which utilizes the velocity-pressure (vP) and velocity-temperature (vT) Schur complement systems. This multigrid block reduction preconditioning technique converges for high CFL/Fourier numbers and exhibits excellent parallel and algorithmic scalability on classic benchmark problems in uid dynamics (lid-driven cavity ow and natural convection heat transfer) as well as for laser-induced phase change problems in 2D and 3D.« less

Authors:
 [1]
  1. Univ. of California, Davis, CA (United States)
Publication Date:
Research Org.:
Lawrence Livermore National Lab. (LLNL), Livermore, CA (United States)
Sponsoring Org.:
USDOE
OSTI Identifier:
1361587
Report Number(s):
LLNL-TH-732004
DOE Contract Number:
AC52-07NA27344
Resource Type:
Thesis/Dissertation
Country of Publication:
United States
Language:
English
Subject:
97 MATHEMATICS, COMPUTING, AND INFORMATION SCIENCE; 42 ENGINEERING

Citation Formats

Weston, Brian T. On the Preconditioning of a Newton-Krylov Solver for a High-Order reconstructed Discontinuous Galerkin Discretization of All-Speed Compressible Flow with Phase Change for Application in Laser-Based Additive Manufacturing. United States: N. p., 2017. Web. doi:10.2172/1361587.
Weston, Brian T. On the Preconditioning of a Newton-Krylov Solver for a High-Order reconstructed Discontinuous Galerkin Discretization of All-Speed Compressible Flow with Phase Change for Application in Laser-Based Additive Manufacturing. United States. doi:10.2172/1361587.
Weston, Brian T. 2017. "On the Preconditioning of a Newton-Krylov Solver for a High-Order reconstructed Discontinuous Galerkin Discretization of All-Speed Compressible Flow with Phase Change for Application in Laser-Based Additive Manufacturing". United States. doi:10.2172/1361587. https://www.osti.gov/servlets/purl/1361587.
@article{osti_1361587,
title = {On the Preconditioning of a Newton-Krylov Solver for a High-Order reconstructed Discontinuous Galerkin Discretization of All-Speed Compressible Flow with Phase Change for Application in Laser-Based Additive Manufacturing},
author = {Weston, Brian T.},
abstractNote = {This dissertation focuses on the development of a fully-implicit, high-order compressible ow solver with phase change. The work is motivated by laser-induced phase change applications, particularly by the need to develop large-scale multi-physics simulations of the selective laser melting (SLM) process in metal additive manufacturing (3D printing). Simulations of the SLM process require precise tracking of multi-material solid-liquid-gas interfaces, due to laser-induced melting/ solidi cation and evaporation/condensation of metal powder in an ambient gas. These rapid density variations and phase change processes tightly couple the governing equations, requiring a fully compressible framework to robustly capture the rapid density variations of the ambient gas and the melting/evaporation of the metal powder. For non-isothermal phase change, the velocity is gradually suppressed through the mushy region by a variable viscosity and Darcy source term model. The governing equations are discretized up to 4th-order accuracy with our reconstructed Discontinuous Galerkin spatial discretization scheme and up to 5th-order accuracy with L-stable fully implicit time discretization schemes (BDF2 and ESDIRK3-5). The resulting set of non-linear equations is solved using a robust Newton-Krylov method, with the Jacobian-free version of the GMRES solver for linear iterations. Due to the sti nes associated with the acoustic waves and thermal and viscous/material strength e ects, preconditioning the GMRES solver is essential. A robust and scalable approximate block factorization preconditioner was developed, which utilizes the velocity-pressure (vP) and velocity-temperature (vT) Schur complement systems. This multigrid block reduction preconditioning technique converges for high CFL/Fourier numbers and exhibits excellent parallel and algorithmic scalability on classic benchmark problems in uid dynamics (lid-driven cavity ow and natural convection heat transfer) as well as for laser-induced phase change problems in 2D and 3D.},
doi = {10.2172/1361587},
journal = {},
number = ,
volume = ,
place = {United States},
year = 2017,
month = 5
}

Thesis/Dissertation:
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  • We present high-order accurate spatiotemporal discretization of all-speed flow solvers using Jacobian-free Newton Krylov framework. One of the key developments in this work is the physics-based preconditioner for the all-speed flow, which makes use of traditional semi-implicit schemes. The physics-based preconditioner is developed in the primitive variable form, which allows a straightforward separation of physical phenomena. Numerical examples demonstrate that the developed preconditioner effectively reduces the number of the Krylov iterations, and the efficiency is independent of the Mach number and mesh sizes under a fixed CFL condition.
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