b'Coupling of Spark PlasmaDeveloping process-informed design through multiphysics, multi-scale Sintering with Advancedmodeling and simulation enables researchers to determine process-structure-Modeling to Enableproperty-performance correlations.Process Scale-up T he goal of this research project was to develop a high-fidelity, multi-scale, multiphysics modeling and simulation code application for spark plasma sintering (SPS), which is valued for using less energy compared to conventional sintering, fabricating near net shape parts, and producing parts with nano-sized microstructures. Accurate modeling and simulation tools specific to SPS are needed to predict the influence of the coupled electrical, thermal, and mechanical physical processes used to create parts from metallic and ceramic micron and nano-TOTAL APPROVED AMOUNT:sized powders. Voltage, temperature, and pressure are transmitted to the powder $1,250,000 over 3 years through steel rams and graphite tooling, causing the powder to undergo rapid evolution PROJECT NUMBER:and densification. In this project, the full manufacturing apparatus was also modeled 19P45-031 to investigate the role of the rams and tooling on the powder microstructure evolution. These two different length scales separate to an engineering-scale simulation that PRINCIPAL INVESTIGATOR:encompasses the full geometry of the apparatus and a set of microstructure evolution Stephanie Pitts models of the sintering powder. The key outcomes of this project include two significant CO-INVESTIGATORS: phase-field model developments, enhanced electro-thermal contact models, an initial Al Casagranda, INL multi-scale electro-thermal coupled model prototype, and the collection of a suite Casey Icenhour, INL of experimental data to inform model development. These multiphysics simulation Dennis Tucker, INL advances and code developments advance the ability to simulate and study other Jorgen Rufner, INL advanced manufacturing techniques, such as including laser welding and additive Larry Aagesen, INL manufacturing applications.Troy Holland, INL TALENT PIPELINE:R. Edwin Garca, Purdue University Casey Icenhour, student at North Carolina State UniversityLucas Robinson, Purdue University Lucas Robinson, student at Purdue UniversitySpencer Doran, student degree at Oregon State UniversityINTELLECTUAL PROPERTY:Contributions to MOOSE Electromagnetic Module for enhancement of interface models and multiphysics verification and validation available on https://github.com.Contributions to the MOOSE Application Library for Advanced Manufacturing Utilities (MALAMUTE) modeling and simulation tool available on https://hpcgitlab.hpc.inl.gov.Microstructural evolution in a compact of yttrium oxide particles simulated using electro-thermal phase-field model. Top row: microstructure, with solid in red, void in blue, and interfaces between particles in yellow. Middle row: local electrical conductivity showing highest conductivity at the interfaces. Bottom row: heat generated99during the evolution showing highest temperatures along connected interfaces.'