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  1. Establishing model credibility for process-microstructure-property relationships in additive manufacturing using exascale computing

    Rolchigo, Matt ; Coleman, John ; Carson, Robert ; ... - International Journal of High Performance Computing Applications
    Additive Manufacturing (AM) of alloys holds significant promise as a disruptive technology in various industries, yet its adoption is often hindered by challenges in achieving consistent part quality. These issues are primarily due to the complex process-microstructure-property (PSP) relationships inherent to AM. Computational models can greatly aid in understanding these relationships, but their widespread impact and adoption has been limited by a lack of validated, open-source, and computationally efficient PSP modeling frameworks and hardware limitations. This study leverages the ExaAM software suite and data from the AMBench-2018 series of laser powder bed fusion (LPBF) benchmark experiments to perform a comprehensivemore » model assessment, including verification, validation, sensitivity analysis, and uncertainty quantification. The RADICAL-EnTK workflow manager was used to perform an ensemble of heat transport, solidification, and mechanical response simulations on the exascale computer Frontier, considering uncertainties in critical model inputs such as laser spot size and nucleation parameters, and consisting of 125 explicit grain structure simulations and 7875 crystal plasticity simulations. For a selected location within the Inconel 625 AMBench-2018 test artifact, sensitivity analysis and uncertainty quantification were performed using the predicted distributions of grain structure and mechanical properties. Qualitative agreement was found between the predicted grain size and texture and the observed AMBench-2018 microstructure, the mean predicted yield stress was within 5% of the experimental measurement mean, and the mean predicted engineering stress at 5% strain was within 10% of the experimental measurement mean. In conclusion, the insights gained from development and validation of the ExaAM PSP modeling framework will help guide future directions for enhancing the credibility and reliability of PSP models in AM, thereby accelerating the adoption of AM technologies in various industries.« less

  2. Ab initio studies on structural and thermodynamic properties of magnetic Fe

    Yang, Songge ; Wang, Yi ; Liu, Zi-Kui ; ... - Computational Materials Science
    The present work systematically investigates the total energy, phonon spectra, and thermodynamic properties of different polymorphs of pure Fe, i.e., FCC, BCC, and HCP, with the ab initio approach, considering various magnetic configurations. In general, the calculated energy vs. volume curves and phonon spectra agree well with previous calculations and the experimental data. In addition, their thermodynamic properties are estimated by the quasiharmonic approximation (QHA). Specifically, a superposition approach based on the latest Zentropy theory was utilized to predict magnetic transition temperatures and thermodynamic properties of pure Fe. With the ensemble of the partition function considering the multiplicity of eachmore » magnetic microstate, the current work successfully reproduced the Curie/Néel temperature and the Schottky anomaly of heat capacity in FCC, BCC, and HCP Fe purely based on the ab initio input, which exhibits good agreement with the experimental data and CALPHAD modeling.« less

  3. Lattice instability and magnetic phase transitions in strongly correlated MnAs

    Petkov, Valeri ; Zafar, Adeel ; Tadisetti, Durga R. ; ... - Journal of Physics. Condensed Matter
    Using variable temperature x-ray total scattering in magnetic field, we study the interaction between lattice and magnetic degrees of freedom in MnAs, which loses its ferromagnetic order and hexagonal ('H') lattice symmetry at 318 K to recover the latter and become a true paramagnet when the temperature is increased to 400 K. Our results show that the 318 K transition is accompanied by highly anisotropic displacements of Mn atoms that appear as a lattice degree of freedom bridging the 'H' and orthorhombic phases of MnAs. This is a rare example of a lowering of an average crystal symmetry due tomore » an increased displacive disorder emerging on heating. Furthermore, our results also show that magnetic and lattice degrees of freedom appear coupled but not necessarily equivalent control variables for triggering phase transitions in strongly correlated systems in general and in particular in MnAs.« less

  4. Physical Properties of Moist, Fermented Corn Kernels

    Blazer, Keagan J. ; Shinners, Kevin J. ; Kluge, Zachary A. ; ... - Processes
    A novel approach to producing corn stover biomass feedstock has been investigated. In this approach, corn grain and stover are co-harvested at moisture contents much less than typical corn silage. The grain and stover are conserved together by anaerobic storage and fermentation and then separated before end use. When separated from the stover, the moist, fermented grain had physical characteristics that differ from typical low-moisture, unfermented grain. A comprehensive study was conducted to quantify the physical properties of this moist, fermented grain. Six corn kernel treatments, either fermented or unfermented, having different moisture contents, were used. Moist, fermented kernels (26more » and 36% w.b. moisture content) increased in size during storage. The fermented kernels’ widths and thicknesses were 10% and 15% greater, respectively, and their volume was 28% greater than the dry kernels (15% w.b.). Dry basis particle density was 9% less for moist, fermented kernels. Additionally, the dry basis bulk density was 29% less, and the dry basis hopper-discharged mass flow rate was 36% less. Moist, fermented grain had significantly greater kernel-to-kernel coefficients of friction and angles of repose compared to relatively dry grain. The friction coefficient on four different surfaces was also significantly greater for fermented kernels. Fermented corn kernels had lower individual kernel rupture strengths than unfermented kernels. These physical differences must be considered when designing material handling and processing systems for moist, fermented corn grain.« less

  5. Lignin-based jet fuel and its blending effect with conventional jet fuel

    Yang, Zhibin ; Xu, Zhangyang ; Feng, Maoqi ; ... - Fuel
    Sustainable aviation fuels (SAFs) must demonstrate specific physical and chemical properties as well as material compatibility (i.e., seal swell) to be used as an aviation turbine fuel. Several alternative jet fuels incorporated in ASTM D7566 are comprised mainly of n/iso-alkanes and can only be blended up to 50 vol% due to material compatibility and density issues. Prior work illustrated the ability of cycloalkanes to replace aromatics’s role in material compatibility. Here, we report the first archival documentation of a feedstock and chemical process to yield a product composition able to complement existing SAF ASTM D7566 annexes. A lignin-based jet fuelmore » (LJF) blend components is generated and composed of mostly C7-C18 mono, di, and tri-cycloalkanes. The neat LJF was blended with conventional jet fuel at 10 vol% (LJF blend) to simulate an ASTM “Fast Track” evaluation process. Fuel properties that are critical to engine operability (ATSM D4054 Tier 3 & 4) were either predicted or experimental tested based on the volume availability. All LJF blend’s critical properties fall within the experience range of conventional jet fuel, with o-ring swelling exceeding the typical range of conventional fuels. Here, these results in total support the potential use of this LJF pathway to complement other SAF pathways and achieve 100% drop-in SAF.« less

  6. Synthesis and behavior of bulk iron nitride soft magnets via high-pressure spark plasma sintering

    Monson, Todd C. ; Zheng, Baolong ; Delaney, Robert E. ; ... - Journal of Materials Research
    Abstract In this study, dense bulk iron nitrides (Fe x N) were synthesized for the first time ever using spark plasma sintering (SPS) of Fe x N powders. The Fe 4 N phase of iron nitride in particular has significant potential to serve as a new soft magnetic material in both transformer and inductor cores and electrical machines. The density of SPSed Fe x N increased with SPS temperature and pressure. The microstructure of the consolidated bulk Fe x N was characterized with X-ray diffraction (XRD), scanning electron microscopy (SEM), transmission electronmore » microscopy (TEM), and superconducting quantum interference device (SQUID) magnetometry. XRD revealed a primary phase of Fe 4 N with secondary phases of Fe 3 N and metallic iron. Finite element analysis (FEA) was also applied to investigate and explain localized heating and temperature distribution during SPS. The effects of processing on interface bonding formation and phase evolution were investigated and discussed in detail to provide insight into fundamental phenomena and microstructural evolution in SPSed Fe x N. Graphic abstract« less

  7. High-Spin Superatom Stabilized by Dual Subshell Filling

    Bista, Dinesh ; Aydt, Alexander P. ; Anderton, Kevin J. ; ... - Journal of the American Chemical Society
    Quantum confinement in small symmetric clusters leads to the bunching of electronic states into closely packed shells, enabling the classification of clusters with well-defined valences as superatoms. Like atoms, superatomic clusters with filled shells exhibit enhanced electronic stability. Here, we show that octahedral transition-metal chalcogenide clusters can achieve filled shell electronic configurations when they have 100 valence electrons in 50 orbitals or 114 valence electrons in 57 orbitals. While these stable clusters are intrinsically diamagnetic, we use our understanding of their electronic structures to theoretically predict that a cluster with 107 valence electrons would uniquely combine high stability and high-spinmore » magnetic moment, attained by filling a majority subshell of 57 electrons and a minority subshell of 50 electrons. Further, we experimentally demonstrate this predicted stability, high-spin magnetic moment (S = 7/2), and fully delocalized electronic structure in a new cluster, [NEt4]5[Fe6S8(CN)6]. This work presents the first computational and experimental demonstration of the importance of dual subshell filling in transition-metal chalcogenide clusters.« less

  8. Understanding Uncertainty in Microstructure Evolution and Constitutive Properties in Additive Process Modeling

    Rolchigo, Matt ; Carson, Robert ; Belak, James - Metals
    Coupled process–microstructure–property modeling, and understanding the sources of uncertainty and their propagation toward error in part property prediction, are key steps toward full utilization of additive manufacturing (AM) for predictable quality part development. The OpenFOAM model for process conditions, the ExaCA model for as-solidified grain structure, and the ExaConstit model for constitutive mechanical properties are used as part of the ExaAM modeling framework to examine a few of the various sources of uncertainty in the modeling workflow. In addition to “random” uncertainty (due to random number generation in the orientations and locations of grains present), the heterogeneous nucleation density N0more » and the mean substrate grain spacing S0 are varied to examine their impact of grain area development as a function of build height in the simulated microstructure. While mean grain area after 1 mm of build is found to be sensitive to N0 and S0, particularly at small N0 and large S0 (despite some convergence toward similar values), the resulting grain shapes and overall textures develop in a reasonably similar manner. As a result of these similar textures, ExaConstit simulation using ExaCA representative volume elements (RVEs) from various permutations of N0, S0, and location within the build resulted in similar yield stress, stress–strain curve shape, and stress triaxiality distributions. It is concluded that for this particular material and scan pattern, 15 layers is sufficient for ExaCA texture and ExaConstit predicted properties to become relatively independent of additional layer simulation, provided that reasonable estimates for N0 and S0 are used. However, additional layers of ExaCA will need to be run to obtain mean grain areas independent of build height and baseplate structure.« less

  9. High surface area magnetic double perovskite La2AlFeO6 as an efficient and stable photo-Fenton catalyst under a wide pH range

    Jin, Zehua ; Xu, Chang ; Zhou, Tingting ; ... - Applied Surface Science
    Photo-Fenton process is an efficient way to treat the organic pollutants in wastewater. However, the efficiency is limited by serious leaching of iron ion, separation of spent catalyst from reaction system for facile recycling, low (pH<4) reaction environment. Herein, we report a preparation of a novel magnetic double perovskite photocatalyst La2AlFeO6, and refractory organic pollutants like phenol, etc. were used as probes to test the efficiency of catalyst. The results showed that the catalytic material retained high surface area and high ratio of Fe3+ on its surface, and the generated ·OH, ·O2- and 1O2 lead to a highly photocatalytic efficiencymore » even at neutral pH condition. In addition, the as prepared double perovskite photocatalyst La2AlFeO6 also exhibits excellent stable and magnetic properties. There is no iron ion leaching detected during the courses of the reaction. Furthermore, the spent catalyst can be separated by magnetic field easily, and thus can be reused after simple air drying without any further treatment or calcination.« less

  10. A mesoscopic digital twin that bridges length and time scales for control of additively manufactured metal microstructures

    Heo, Tae Wook ; Khairallah, Saad ; Shi, Rongpei ; ... - JPhys Materials
    We present our recent development of an integrated mesoscale digital twin (DT) framework for relating processing conditions, microstructures, and mechanical responses of additively manufactured (AM) metals. In particular, focusing on the laser powder bed fusion technique, we describe how individual modeling and simulation capabilities are coupled to investigate and control AM microstructural features at multiple length and time scales. We review our prior case studies that demonstrate the integrated modeling schemes, in which high-fidelity melt pool dynamics simulations provide accurate local thermal profiles and histories to subsequent AM microstructure simulations. We also report our new mechanical response modeling results formore » predicted AM microstructures. In addition, we illustrate how our DT framework has been validated through modeling–experiment integration, as well as how it has been practically utilized to guide and analyze AM experiments. Finally, we share our perspectives on future directions of further development of the DT framework for more efficient, accurate predictions and wider ranges of applications.« less
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