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While the finite element method (FEM) has now reached full maturity both in academy and industry, its use in optimization pipelines remains either computationally intensive or cumbersome. In particular, currently used optimization schemes leveraging FEM still require the choice of dedicated optimization algorithms for a specific design problem, and a “black box” approach to FEM‐based optimization remains elusive. To this end, we propose here an integrated finite element‐soft computing method, ie, the soft FEM (SoftFEM), which integrates a finite element solver within a metaheuristic search wrapper. To illustrate this general method, we focus here on solid mechanics problems. For these problems, SoftFEM is able to optimize geometry changes and mechanistic measures based on geometry constraints and material properties inputs. From the optimization perspective, the use of a fitness function based on finite element calculation imposes a series of challenges. To bypass the limitations in search capabilities of the usual optimization techniques (local search and gradient‐based methods), we propose, instead a hybrid self adaptive search technique, the multiple offspring sampling (MOS), combining two metaheuristics methods: one population‐based differential evolution method and a local search optimizer. The formulation coupling FEM to the optimization wrapper is presented in detail and its flexibility is illustrated with three representative solid mechanics problems. More particularly, we propose here the MOS as the most versatile search algorithm for SoftFEM. A new method for the identification of nonfully determined parameters is also proposed.

An elasto-viscoplastic thermodynamically consistent constitutive model for diffusion-assisted phase transformations is presented here. The model accounts for the different deformation mechanisms, their time dependence, the crystal rotations produced by microtwin propagation and the chemistry-plasticity coupling occurring at high temperature. It is applied to the study of the chemically assisted microtwinning observed in Ni-based superalloys in the temperature range of 600–800 °C. The model parameters are calibrated against multi-directional mechanical data from tensile creep tests of single crystal superalloy MD2. The constitutive model is then implemented into a crystal plasticity finite element code to study the activation of the different deformation mechanisms within single crystal and polycrystalline aggregates. Doing so, a relation between the rotations of the crystal and the creep life of the different crystal orientations is established. The results eventually reveal the critical role of the strong anisotropy of microtwin formation on the asymmetric behavior of the alloy and its relevant role on the mechanical performance.

A novel approach to accelerate greatly and simplify the determination of creep properties in metals is presented. The method combines advanced digital image correlation, thermal imaging, and conductive graded heating to produce and analyse viscoplastic deformation in a continuous range of temperatures at constant stresses. By differentiating the strain across small sections of the sample at different temperatures, one may extract the creep behaviour at many different temperatures and thus derive the activation energy. Just a single test and specimen is needed to make a first reasonable estimate. The method is suitable for all metals and alloys but is validated here for a prototype Ni-based single superalloy.

The contribution of a microtwinning mechanism to the creep deformation behaviour of single crystal superalloy MD2 is studied. Microtwinning is prevalent for uniaxial loading along 011 at 800°C for the stress range 625 to 675 MPa and 825°C for 625 MPa. Using quantitative stereology, the twin fraction and twin thickness are estimated; this allows the accumulated creep strain to be recovered, in turn supporting the role of the microtwinning mode in conferring deformation. Atom probe tomography confirms the segregation of Cr and Co at the twin/parent interface, consistent with the lowering of the stacking fault energy needed to support twin lengthening and thickening. A model for diffusion-controlled growth of twins is proposed and it is used to recover the measured creep strain rate. The work provides the basis for a thermo-mechanical constitutive model of deformation consistent with the microtwinning mechanism.

Because of their widely generalized use in many industries, composites are the subject of many research campaigns. More particularly, the development of both accurate and flexible numerical models able to capture their intrinsically multiscale modes of failure is still a challenge. The standard finite element method typically requires intensive remeshing to adequately capture the geometry of the cracks and high accuracy is thus often sacrificed in favor of scalability, and vice versa. In an effort to preserve both properties, we present here an extended finite element method (XFEM) for large scale composite fracture simulations. In this formulation, the standard FEM formulation is partially enriched by use of shifted Heaviside functions with special attention paid to the scalability of the scheme. This enrichment technique offers several benefits since the interpolation property of the standard shape function still holds at the nodes. Those benefits include (i) no extra boundary condition for the enrichment degree of freedom, and (ii) no need for transition/blending regions; both of which contribute to maintaining the scalability of the code. Two different cohesive zone models (CZM) are then adopted to capture the physics of the crack propagation mechanisms. At the intralaminar level, an extrinsic CZM embedded in the XFEM formulation is used. At the interlaminar level, an intrinsic CZM is adopted for predicting the failure. The overall framework is implemented in ALYA, a mechanics code specifically developed for large scale, massively parallel simulations of coupled multi-physics problems. The implementation of both intrinsic and extrinsic CZM models within the code is such that it conserves the extremely efficient scalability of ALYA while providing accurate physical simulations of computationally expensive phenomena. The strong scalability provided by the proposed implementation is demonstrated. The model is ultimately validated against a full experimental campaig, A.J., A.M., D.T., L.N. and L.W. acknowledge funding through the SIMUCOMP ERA-NET MATERA + project financed by the Fonds National de la Recherche (FNR) of Luxembourg, the Consejería de Educación y Empleo of the Comunidad de Madrid, the Walloon region (agreement no 1017232, CT-EUC 2010–10-12), and by the European Unions Seventh Framework Programme (FP7/2007–2013)., Peer Reviewed, Postprint (author's final draft)

While solid mechanics codes are now conventional tools both in industry and research, the increasingly more exigent requirements of both sectors are fuelling the need for more computational power and more advanced algorithms. For obvious reasons, commercial codes are lagging behind academic codes often dedicated either to the implementation of one new technique, or the upscaling of current conventional codes to tackle massively large scale computational problems. Only in a few cases, both approaches have been followed simultaneously. In this article, a solid mechanics simulation strategy for parallel supercomputers based on a hybrid approach is presented. Hybrid parallelization exploits the thread-level parallelism of multicore architectures, combining MPI tasks with OpenMP threads. This paper describes the proposed strategy, programmed in Alya, a parallel multi-physics code. Hybrid parallelization is specially well suited for the current trend of supercomputers, namely large clusters of multicores. The strategy is assessed through transient non-linear solid mechanics problems, both for explicit and implicit schemes, running on thousands of cores. In order to demonstrate the flexibility of the proposed strategy under advance algorithmic evolution of computational mechanics, a non-local parallel overset meshes method (Chimera-like) is implemented and the conservation of the scalability is demonstrated., D.D.T and A.J acknowledge funding through SIMUCOMP and ERA-NET MATERA+ project financed by the Consejería de Educación y Empleo of the Comunidad de Madrid and by the European Union’s Seventh Framework Programme (FP7/2007-2013). Thisworkwas partially supported by the grant SEV-2011-00067, Severo Ochoa Program, awarded by the Spanish Government. The authors’ would like to acknowledge PRACE infrastructure support., Peer Reviewed, Postprint (published version)

The last few years have highlighted the existence of two relevant length scales in the quest to ultrahigh-strength polycrystalline metals. Whereas the microstructural length scale – e.g. grain or twin size – has mainly be linked to the well-established Hall–Petch relationship, the sample length scale – e.g. nanopillar size – has also proven to be at least as relevant, especially in microscale structures. In this letter, a series of ballistic tests on functionally graded nanocrystalline plates are used as a basis for the justification of a “grain size gradient length scale” as an additional ballistic properties optimization parameter.