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2. Sierra/SolidMechanics 5.10 In-Development Manual

Author

Guy Bergel, Frank Beckwith, Michael Buche, Gabriel de Frias, Kevin Manktelow, Mark Merewether, Scott Miller, Krishen Parmar, Timothy Shelton, Jesse Thomas, Jeremy Trageser, Benjamin Treweek, Michael Veilleux, and Ellen Wagman

Published
2022
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3. Sierra/SolidMechanics 5.10 Example Problems Manual

Author

Steven Gomez, Jason Ivey, Kevin Manktelow, Patrick Suszko, Guy Bergel, Frank Beckwith, Michael Buche, Kenneth Belcourt, Gabriel de Frias, Mark Merewether, Scott Miller, Krishen Parmar, Timothy Shelton, Jesse Thomas, Jeremy Trageser, Benjamin Treweek, Michael Veilleux, and Ellen Wagman

Published
2022
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4. A coupled fluid-mechanical workflow to simulate the directed energy deposition additive manufacturing process

Author

Kurtis R. Ford, Daniel Moser, Michael Veilleux, Michael E. Stender, Bradley L. Trembacki, and Lauren L. Beghini

Subjects
Work (thermodynamics), Materials science, Field (physics), Applied Mathematics, Mechanical Engineering, Computational Mechanics, Mechanical engineering, Ocean Engineering, Fluid mechanics, Finite element method, Computational Mathematics, Computational Theory and Mathematics, Residual stress, Solid mechanics, Deposition (phase transition), Boundary value problem
Abstract

Simulation of additive manufacturing processes can provide essential insight into material behavior, residual stress, and ultimately, the performance of additively manufactured parts. In this work, we describe a new simulation based workflow utilizing both solid mechanics and fluid mechanics based formulations within the finite element software package SIERRA (Sierra Solid Mechanics Team in Sierra/SolidMechanics 4.52 User’s Guide SAND2019-2715. Technical report, Sandia National Laboratories, 2011) to enable integrated simulations of directed energy deposition (DED) additive manufacturing processes. In this methodology, a high-fidelity fluid mechanics based model of additive manufacturing is employed as the first step in a simulation workflow. This fluid model uses a level set field to track the location of the boundary between the solid material and background gas and precisely predicts temperatures and material deposition shapes from additive manufacturing process parameters. The resulting deposition shape and temperature field from the fluid model are then mapped into a solid mechanics formulation to provide a more accurate surface topology for radiation and convection boundary conditions and a prescribed temperature field. Solid mechanics simulations are then conducted to predict the evolution of material stresses and microstructure within a part. By combining thermal history and deposition shape from fluid mechanics with residual stress and material property evolutions from solid mechanics, additional fidelity and precision are incorporated into additive manufacturing process simulations providing new insight into complex DED builds.

Published
2021
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6. Sierra/SolidMechanics 5.4 Verification Tests Manual

Author

Guy Bergel, Frank Beckwith, Kenneth Belcourt, Gabriel de Frias, Kevin Manktelow, Mark Merewether, Scott Miller, Krishen Parmar, Julia Plews, Timothy Shelton, Jesse Thomas, Jeremy Trageser, Benjamin Treweek, Michael Veilleux, and Ellen Wagman

Published
2022
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7. Sierra/SolidMechanics 5.4 User's Guide

Author

Frank Beckwith, Guy Bergel, Gabriel de Frias, Kevin Manktelow, Mark Merewether, Scott Miller, Krishen Parmar, Timothy Shelton, Jesse Thomas, Jeremy Trageser, Benjamin Treweek, Michael Veilleux, and Ellen Wagman

Published
2022
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8. Sandia Fracture Challenge 3: detailing the Sandia Team Q failure prediction strategy

Author

Kyle N. Karlson, Michael E. Stender, Andrew J. Stershic, Jakob T. Ostien, James W. Foulk, Kevin Manktelow, Michael Veilleux, and Coleman Alleman

Subjects
education.field_of_study, business.industry, Computer science, Population, Computational Mechanics, Structural engineering, Plasticity, Mechanics of Materials, Modeling and Simulation, Test statistic, Calibration, Material Deformation, business, education, Failure mode and effects analysis
Abstract

The third Sandia Fracture Challenge highlighted the geometric and material uncertainties introduced by modern additive manufacturing techniques. Tasked with the challenge of predicting failure of a complex additively-manufactured geometry made of 316L stainless steel, we combined a rigorous material calibration scheme with a number of statistical assessments of problem uncertainties. Specifically, we used optimization techniques to calibrate a rate-dependent and anisotropic Hill plasticity model to represent material deformation coupled with a damage model driven by void growth and nucleation. Through targeted simulation studies we assessed the influence of internal voids and surface flaws on the specimens of interest in the challenge which guided our material modeling choices. Employing the Kolmogorov–Smirnov test statistic, we developed a representative suite of simulations to account for the geometric variability of test specimens and the variability introduced by material parameter uncertainty. This approach allowed the team to successfully predict the failure mode of the experimental test population as well as the global response with a high degree of accuracy.

Published
2019
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9. Sierra/SolidMechanics 5.2 User's Guide

Author

Frank Beckwith, Guy Bergel, Gabriel de Frias, Kevin Manktelow, Mark Merewether, Scott Miller, Matthew Mosby, Krishen Parmar, Julia Plews, Timothy Shelton, Jesse Thomas, Benjamin Treweek, Michael Tupek, Michael Veilleux, Ellen Wagman, and Kenneth Belcourt

Published
2021
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10. Sierra/SolidMechanics 5.2 Verification Tests Manual

Author

Frank Beckwith, Gabriel de Frias, Michael Veilleux, Ellen Wagman, Kevin Manktelow, Mark Merewether, Benjamin Treweek, Michael R. Tupek, Scott Gampert, Jesse Thomas, Timothy Shelton, Julia Plews, Matthew Mosby, Scott T. Miller, and Guy Bergel

Published
2021
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11. Sierra/SolidMechanics 5.2 Theory Manual

Author

Michael Veilleux, Gabriel de Frias, Donald Guy, Michael Tupek, Timothy Shelton, Matthew Mosby, Benjamin Treweek, Ellen Wagman, Frank Beckwith, Jesse Thomas, Krishen Parmar, Scott T. Miller, Kevin Manktelow, Julia Plews, and Mark Merewether

Published
2021
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13. Sierra/SolidMechanics 5.0 Example Problems Manual

Author

Frank Beckwith, Guy Bergel, Gabriel de Frias, Kevin Manktelow, Mark Merewether, Scott Miller, Matthew Mosby, Julia Plews, Vicki Porter, Timothy Shelton, Jesse Thomas, Benjamin Treweek, Michael Tupek, Michael Veilleux, and Ellen Wagman

Published
2021
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14. Sierra/SolidMechanics 5.0 Verification Tests Manual

Author

Frank Beckwith, Guy Bergel, Gabriel de Frias, Kevin Manktelow, Mark Merewether, Scott Miller, Matthew Mosby, Julia Plews, Vicki Porter, Timothy Shelton, Jesse Thomas, Benjamin Treweek, Michael Tupek, Michael Veilleux, and Ellen Wagman

Published
2021
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15. Sierra/SolidMechanics 5.0 User's Guide

Author

Michael Tupek, Vicki Porter, Julia Plews, Ellen Wagman, Scott T. Miller, Kevin Manktelow, Michael Veilleux, Timothy Shelton, Mark Merewether, Guy Bergel, Frank Beckwith, Jesse Thomas, Benjamin Treweek, Gabriel de Frias, and Matthew Mosby

Published
2021
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16. Sierra/SolidMechanics 4.58 User's Guide Addendum for Shock Capabilities

Author

Frank Beckwith, Gabriel de Frias, Julia Plews, Vicki Porter, Matthew Mosby, Michael R. Tupek, Scott T. Miller, Jacob Koester, Mark Merewether, Scott Gampert, Jesse Thomas, Ellen Wagman, Timothy Shelton, Kevin Manktelow, Benjamin Treweek, Kenneth Belcourt, and Michael Veilleux

Subjects
Physics, Shock (circulatory), medicine, Addendum, Mechanics, medicine.symptom
Published
2020
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17. Sierra/SolidMechanics 4.58 User's Guide

Author

Michael R. Tupek, Ellen Wagman, Frank Beckwith, Mark Merewether, Scott T. Miller, Julia Plews, Scott Gampert, Matthew Mosby, Jacob Koester, Jesse Thomas, Benjamin Treweek, Kevin Manktelow, Gabriel de Frias, Kenneth Belcourt, Michael Veilleux, Timothy Shelton, and Vicki Porter

Published
2020
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18. Sierra/SolidMechanics 4.58 Verification Tests Manual

Author

Frank Beckwith, Kenneth Belcourt, Gabriel de Frias, Jacob Koester, Kevin Manktelow, Mark Merewether, Scott Miller, Matthew Mosby, Julia Plews, Vicki Porter, Timothy Shelton, Jesse Thomas, Benjamin Treweek, Michael Tupek, Michael Veilleux, and Ellen Wagman

Published
2020
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19. Sierra/SolidMechanics 4.58 Example Problems Manual

Author

Frank Beckwith, Kenneth Belcourt, Gabriel de Frias, Jacob Koester, Kevin Manktelow, Mark Merewether, Scott Miller, Matthew Mosby, Julia Plews, Vicki Porter, Timothy Shelton, Jesse Thomas, Benjamin Treweek, Michael Tupek, Michael Veilleux, and Ellen Wagman

Published
2020
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20. Sierra/SolidMechanics 4.58 Theory Manual

Author

Vicki Porter, Ellen Wagman, Kenneth Belcourt, Jacob Koester, Benjamin Treweek, Scott T. Miller, Jesse Thomas, Michael R. Tupek, Michael Veilleux, Frank Beckwith, Kevin Manktelow, Mark Merewether, Gabriel de Frias, Timothy Shelton, Julia Plews, and Matthew Mosby

Published
2020
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21. Sierra/SolidMechanics 4.56.2 User's Guide

Author

Gabriel de Frias, Jacob Koester, Michael Veilleux, Benjamin Treweek, Kevin Manktelow, Vicki Porter, Michael R. Tupek, Mark Merewether, Frank Beckwith, Timothy Shelton, Julia Plews, Matthew Mosby, Jesse Thomas, Kenneth Belcourt, and Scott T. Miller

Published
2020
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22. A thermal-mechanical finite element workflow for directed energy deposition additive manufacturing process modeling

Author

Thale R. Smith, Joshua D. Sugar, Michael E. Stender, Daryl J. Dagel, Michael Veilleux, Samuel R. Subia, Lauren L. Beghini, Arthur A. Brown, and Christopher W. San Marchi

Subjects
010302 applied physics, Length scale, Work (thermodynamics), Materials science, Biomedical Engineering, 02 engineering and technology, Mechanics, 021001 nanoscience & nanotechnology, Thermal conduction, 01 natural sciences, Industrial and Manufacturing Engineering, Finite element method, Residual stress, 0103 physical sciences, Thermal, Deposition (phase transition), General Materials Science, Laser engineered net shaping, 0210 nano-technology, Engineering (miscellaneous)
Abstract

This work proposes a finite element (FE) analysis workflow to simulate directed energy deposition (DED) additive manufacturing at a macroscopic length scale (i.e. part length scale) and to predict thermal conditions during manufacturing, as well as distortions, strength and residual stresses at the completion of manufacturing. The proposed analysis method incorporates a multi-step FE workflow to elucidate the thermal and mechanical responses in laser engineered net shaping (LENS) manufacturing. For each time step, a thermal element activation scheme captures the material deposition process. Then, activated elements and their associated geometry are analyzed first thermally for heat flow due to radiation, convection, and conduction, and then mechanically for the resulting stresses, displacements, and material property evolution. Simulations agree with experimentally measured in situ thermal measurements for simple cylindrical build geometries, as well as general trends of local hardness distribution and plastic strain accumulation (represented by relative distribution of geometrically necessary dislocations).

Published
2018
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24. Sierra/SolidMechanics 4.56 Capabilities In Development

Author

Mark Merewether, Julia Plews, Gabriel de Frias, Matthew Mosby, Vicki Porter, Timothy Shelton, Jesse Thomas, Michael Tupek, Michael Veilleux, Kevin Manktelow, Frank Beckwith, Kenneth Belcourt, Scott Miller, Benjamin Treweek, Ellen Wagman, and Jacob Koester

Published
2020
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25. Sierra/SolidMechanics 4.56 Theory Manual

Author

Timothy Shelton, Mark Merewether, Kevin Manktelow, Kenneth Belcourt, Frank Beckwith, Scott T. Miller, Ellen Wagman, Jacob Koester, Michael Veilleux, Julia Plews, Jesse Thomas, Michael R. Tupek, Matthew Mosby, Vicki Porter, Gabriel de Frias, and Benjamin Treweek

Published
2020
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26. Sierra/SolidMechanics 4.56 Goodyear User's Guide

Author

Mark Merewether, Julia Plews, Gabriel de Frias, Matthew Mosby, Vicki Porter, Timothy Shelton, Jesse Thomas, Michael Tupek, Michael Veilleux, Kevin Manktelow, Frank Beckwith, Kenneth Belcourt, Scott Miller, Benjamin Treweek, Ellen Wagman, and Jacob Koester

Published
2020
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27. Sierra/SolidMechanics 4.56 User's Guide

Author

Timothy Shelton, Jacob Koester, Frank Beckwith, Michael R. Tupek, Vicki Porter, Michael Veilleux, Ellen Wagman, Gabriel de Frias, Jesse Thomas, Benjamin Treweek, Mark Merewether, Kevin Manktelow, Julia Plews, Matthew Mosby, Scott T. Miller, and Kenneth Belcourt

Subjects
Geology
Published
2020
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28. Sierra/SolidMechanics 4.56 Example Problems Manual

Author

Frank Beckwith, Kenneth Belcourt, Gabriel de Frias, Jacob Koester, Kevin Manktelow, Mark Merewether, Scott Miller, Matthew Mosby, Julia Plews, Vicki Porter, Timothy Shelton, Jesse Thomas, Benjamin Treweek, Michael Tupek, Michael Veilleux, and Ellen Wagman

Published
2020
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29. Sierra/SolidMechanics 4.56 Verification Tests Manual

Author

Michael Veilleux, Frank Beckwith, Kenneth Belcourt, Gabriel de Frias, Jacob Koester, Kevin Manktelow, Mark Merewether, Scott Miller, Matthew Mosby, Julia Plews, Vicki Porter, Timothy Shelton, Jesse Thomas, Benjamin Treweek, Michael Tupek, and Ellen Wagman

Published
2020
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30. Sierra/SolidMechanics 4.54 Goodyear Specific

Author

Vicki Porter, Kevin Manktelow, Frank Beckwith, Michael Veilleux, Timothy Shelton, Jesse Thomas, Michael R. Tupek, Mark Merewether, Julia Plews, Matthew Mosby, Gabriel de Frias, Scott T. Miller, and Kenneth Belcourt

Published
2019
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31. Sierra/SolidMechanics 4.54 Verification Tests Manual

Author

Michael Veilleux, Frank Beckwith, Kenneth Noel Belcourt, Gabriel Jose de Frias, Kevin Manktelow, Mark Thomas Merewether, Scott T Miller, Matthew David Mosby, Julia A. Plews, Vicki L. Porter, Timothy Shelton, Jesse David Thomas, and Michael R. Tupek

Published
2019
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32. Sierra/SolidMechanics 4.54 Example Problems Manual

Author

Michael Veilleux, Frank Beckwith, Kenneth Noel Belcourt, Gabriel Jose de Frias, Kevin Manktelow, Mark Thomas Merewether, Scott T Miller, Matthew David Mosby, Julia A. Plews, Vicki L. Porter, Timothy Shelton, Jesse David Thomas, and Michael R. Tupek

Published
2019
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33. Sierra/SolidMechanics 4.54 User's Guide

Author

Timothy Shelton, Kevin Manktelow, Frank Beckwith, Vicki Porter, Michael Veilleux, Gabriel de Frias, Scott T. Miller, Michael R. Tupek, Jesse Thomas, Kenneth Belcourt, Julia Plews, Matthew Mosby, and Mark Merewether

Published
2019
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34. Sierra/SolidMechanics 4.54 Theory Manual

Author

Michael Tupek, Gabriel de Frias, Scott T. Miller, Jesse Thomas, Michael Veilleux, Kenneth Belcourt, Frank Beckwith, Timothy Shelton, Kevin Manktelow, Mark Merewether, Julia Plews, Matthew Mosby, and Vicki Porter

Published
2019
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36. Sierra/SolidMechanics 4.52 Goodyear Specific

Author

Vicki Porter, Kenneth Belcourt, Gabriel de Frias, Michael Tupek, Mark Merewether, Michael Veilleux, Frank Beckwith, San Le, Timothy Shelton, Patrick G. Xavier, Matthew Mosby, Kevin Manktelow, Jesse Thomas, and Julia Plews

Published
2019
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37. Sierra/SolidMechanics 4.52 Theory Manual

Author

Frank Beckwith, Jesse Thomas, Michael Veilleux, Gabriel de Frias, San Le, Matthew Mosby, Vicki Porter, Kevin Manktelow, Mark Merewether, Patrick G. Xavier, Kenneth Belcourt, Michael Tupek, Julia Plews, and Timothy Shelton

Published
2019
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38. Sierra/SolidMechanics 4.52 User's Guide

Author

Gabriel de Frias, Jesse Thomas, Vicki Porter, Frank Beckwith, Michael Veilleux, Mark Merewether, San Le, Timothy Shelton, Michael R. Tupek, Kevin Manktelow, Patrick G. Xavier, Julia Plews, Matthew Mosby, and Kenneth Belcourt

Subjects
Computer science
Published
2019
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39. Library of Advanced Materials for Engineering (LAME) 4.50

Author

Mark Thomas Merewether, Nathan K Crane, Julia A. Plews, Gabriel Jose de Frias, San Le, David John Littlewood, Matthew David Mosby, Kendall H. Pierson, Vicki L. Porter, Timothy Shelton, Jesse David Thomas, Michael R. Tupek, Michael Veilleux, Patrick G. Xavier, William M. Scherzinger, and Brian T. Lester

Published
2018
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40. Sierra/SolidMechanics 4.50 User's Guide

Author

San Le, Julia Plews, Michael Veilleux, Gabriel de Frias, Timothy Shelton, Mark Merewether, Kevin Manktelow, David John Littlewood, Michael Tupek, Matthew Mosby, Nathan K Crane, Jesse Thomas, Patrick G. Xavier, Christopher J.R. Clutz, Vicki Porter, and Kendall H. Pierson

Published
2018
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41. Sierra/SolidMechanics 4.50 Theory Manual

Author

San Le, Kevin Manktelow, Vicki Porter, Michael Veilleux, Gabriel de Frias, Patrick G. Xavier, Timothy Shelton, Kendall H. Pierson, David John Littlewood, Nathan K Crane, Jesse Thomas, Mark Merewether, Christopher J.R. Clutz, Julia Plews, Matthew Mosby, and Michael R. Tupek

Subjects
Materials science
Published
2018
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42. Sierra/SolidMechanics 4.50 Verification Tests Manual

Author

Mark Thomas Merewether, Julia A. Plews, Nathan K Crane, Gabriel Jose de Frias, San Le, David John Littlewood, Matthew David Mosby, Kendall H. Pierson, Vicki L. Porter, Timothy Shelton, Jesse David Thomas, Michael R. Tupek, Michael Veilleux, Patrick G. Xavier, Christopher J.R. Clutz, and Kevin Manktelow

Published
2018
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43. Sandia fracture challenge 2: Sandia California’s modeling approach

Author

Arthur A. Brown, Kyle N. Karlson, James W. Foulk, and Michael Veilleux

Subjects
Materials science, Viscoplasticity, Numerical analysis, Isotropy, Computational Mechanics, 02 engineering and technology, Mechanics, 01 natural sciences, Physics::Geophysics, 010101 applied mathematics, Quantum nonlocality, 020303 mechanical engineering & transports, 0203 mechanical engineering, Thermomechanical coupling, Mechanics of Materials, Modeling and Simulation, Regularization (physics), Crack initiation, Forensic engineering, 0101 mathematics, Anisotropy
Abstract

The second Sandia Fracture Challenge illustrates that predicting the ductile fracture of Ti-6Al-4V subjected to moderate and elevated rates of loading requires thermomechanical coupling, elasto-thermo-poro-viscoplastic constitutive models with the physics of anisotropy and regularized numerical methods for crack initiation and propagation. We detail our initial approach with an emphasis on iterative calibration and systematically increasing complexity to accommodate anisotropy in the context of an isotropic material model. Blind predictions illustrate strengths and weaknesses of our initial approach. We then revisit our findings to illustrate the importance of including anisotropy in the failure process. Mesh-independent solutions of continuum damage models having both isotropic and anisotropic yields surfaces are obtained through nonlocality and localization elements.

Published
2016
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44. A 10-node composite tetrahedral finite element for solid mechanics

Author

J. W. Foulk, Jakob T. Ostien, Alejandro Mota, and Michael Veilleux

Subjects
Numerical Analysis, Applied Mathematics, Composite number, General Engineering, Geometry, 010103 numerical & computational mathematics, Mixed finite element method, Plasticity, 01 natural sciences, Finite element method, 010101 applied mathematics, Solid mechanics, Tetrahedron, Node (circuits), 0101 mathematics, Mathematics
Published
2016
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45. Sierra/SolidMechanics 4.48 Theory Manual

Author

Gabriel de Frias, San Le, Michael Veilleux, Patrick G. Xavier, Kendall H. Pierson, Vicki Porter, Julia Plews, Michael R. Tupek, Matthew Mosby, David John Littlewood, Mark Merewether, Nathan K Crane, Timothy Shelton, and Jesse Thomas

Published
2018
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46. Sierra/SolidMechanics 4.48 Goodyear Specific

Author

Timothy Shelton, Michael R. Tupek, Vicki Porter, Michael Veilleux, Nathan B. Crane, Gabriel de Frias, Jesse Thomas, Patrick G. Xavier, Mark Merewether, Kendall H. Pierson, Julia Plews, Matthew Mosby, San Le, and David John Littlewood

Published
2018
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49. Sierra/SolidMechanics 4.46 Example Problems Manual

Author

Scott T. Miller, Jacob Koester, Timothy Shelton, Julia Plews, Matthew Mosby, Benjamin Treweek, Ellen Wagman, Michael R. Tupek, Gabriel de Frias, Vicki Porter, Jesse Thomas, Michael Veilleux, Kenneth Belcourt, Mark Merewether, Kevin Manktelow, and Frank Beckwith

Published
2018
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50. Sierra/SolidMechanics 4.48 Capabilities in Development

Author

Gabriel de Frias, Mark Merewether, Vicki Porter, Nathan K Crane, Patrick G. Xavier, David John Littlewood, Michael Veilleux, San Le, Michael R. Tupek, Kendall H. Pierson, Jesse Thomas, Julia Plews, Matthew Mosby, and Timothy Shelton

Subjects
Engineering, business.industry, Environmental resource management, business
Published
2018
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