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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. Wed . "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 = {Wed May 17 00:00:00 EDT 2017},
month = {Wed May 17 00:00:00 EDT 2017}
}

Thesis/Dissertation:
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