Abstract
Interface-resolved direct numerical simulations (DNSs) of chemical vapor infiltration (CVI) have been performed over a range of furnace-operating conditions (Thiele moduli) and for practical woven preform geometries. A level-set method is used to resolve the geometry of the initial preform at tow scale. The interface between the vapor and solid phase is then evolved in time through the entire CVI densification cycle, fully resolving the time-varying topology between the two phases. In contrast to previous level-set methods for CVI simulation, the physical reaction and diffusion processes govern the level-set movement in the current approach. The surface deposition kinetics is described by the usual one-step model. In this paper, the DNS data are used to study the evolving porosity, surface-to-volume ratio, and flow infiltration properties (permeability and effective diffusivities). Comparisons are made to popularly-assumed structure functions and the standard, Kozeny–Carmen porous media model commonly employed in modeled CFD simulations of CVI. The virtual DNS experiments reveal a Thiele modulus and preform geometry (fabric layup) dependence which the existing microstructural and infiltration models are not able to describe throughout the entire densification process. The DNS-based, woven geometry-specific correlations can be applied directly to mean-field, furnace-scale CFD simulations.
| Original language | English |
|---|---|
| Pages (from-to) | 4595-4607 |
| Number of pages | 13 |
| Journal | Journal of the American Ceramic Society |
| Volume | 105 |
| Issue number | 7 |
| DOIs | |
| State | Published - Jul 2022 |
Funding
This research was supported by the High-Performance Computing for Manufacturing Project Program (HPC4Mfg), managed by the U.S. Department of Energy Advanced Manufacturing Office (AMO) within the Energy Efficiency and Renewable Energy Office (EERE). The work was performed using resources of the Oak Ridge Leadership Computing Facility (OLCF) and Oak Ridge National Laboratory, which are supported by the Office of Science of the U.S. Department of Energy under Contract No.?DE-AC0500OR22725. Notice: This manuscript has been authored by UT‐Battelle, LLC, under contract DE‐AC05‐00OR22725 with the US Department of Energy (DOE). The U.S. government retains and the publisher, by accepting the article for publication, acknowledges that the U.S. government retains a nonexclusive, paid‐up, irrevocable, worldwide license to publish or reproduce the published form of this manuscript, or allow others to do so, for U.S. government purposes. DOE will provide public access to these results of federally sponsored research in accordance with the DOE Public Access Plan ( http://energy.gov/downloads/doe‐public‐access‐plan ). This research was supported by the High‐Performance Computing for Manufacturing Project Program (HPC4Mfg), managed by the U.S. Department of Energy Advanced Manufacturing Office (AMO) within the Energy Efficiency and Renewable Energy Office (EERE). The work was performed using resources of the Oak Ridge Leadership Computing Facility (OLCF) and Oak Ridge National Laboratory, which are supported by the Office of Science of the U.S. Department of Energy under Contract No. DE‐AC0500OR22725.
| Funders | Funder number |
|---|---|
| High-Performance Computing for Manufacturing Project Program | |
| U.S. Department of Energy Advanced Manufacturing Office | |
| U.S. Department of Energy | DE‐AC0500OR22725 |
| Advanced Manufacturing Office | |
| Office of Science | |
| Office of Energy Efficiency and Renewable Energy | |
| Oak Ridge National Laboratory |
Keywords
- Manufacturing
- ceramic matrix composites
- chemical vapor infiltration
- direct numerical simulations
- high performance computing
- level-set methods
- modeling/model
- silicon carbide