Add Rosenthal temperature source model idaholab#63

doc/content/source/materials/RosenthalTemperatureSource.md

@@ -0,0 +1,31 @@
+# Rosenthal temperature source material
+
+!syntax description /Materials/RosenthalTemperatureSource
+
+## Description
+
+This material implements the Rosenthal equation for meltpool geometry [!cite](Rosenthal1946). The temperature profile is defined as:
+\begin{equation}
+T(x,r)=T_0 + \frac{\lambda P}{2 \pi k_T r} \exp\left[{- \frac{V(r+x)}{2 \alpha}}\right],
+\end{equation}
+where $T_0$ is the ambient temperature, $P$ is the laser power, $\lambda$ is the power absorption coefficient, $k_T$ is the thermal conductivity, $\alpha$ is the thermal diffusivity, and $V$ is the scanning velocity. Here, $r$ is the radial distance from the heat source defined as $r = \sqrt{x^2+y^2+z^2}$, where x, y, z, are the positional coordinates within the moving reference frame. The laser heat source is assumed to move in x direction such that the position x is updated with $(x-x_0-Vt)$, where $x_0$ is the initial position coordinate at $t=0$.
+
+The meltpool depth and width is calculated as follows:
+
+\begin{equation}
+D \approx \sqrt{\frac{2 \lambda P}{ \pi e \rho C_p V (T_m-T_0)}}\, ,
+\end{equation}
+\begin{equation}
+W = 2 D,
+\end{equation}
+where $T_m$ is the melting temperature, $\rho$ is the density, and $C_p$ is the specific heat.
+
+## Example Input Syntax
+
+!listing test/tests/melt_pool_geometry/rosenthal_temp_source.i block=Materials/meltpool
+
+!syntax parameters /Materials/RosenthalTemperatureSource
+
+!syntax inputs /Materials/RosenthalTemperatureSource
+
+!syntax children /Materials/RosenthalTemperatureSource

include/materials/RosenthalTemperatureSource.h

@@ -0,0 +1,51 @@
+/****************************************************************************/
+/*                        DO NOT MODIFY THIS HEADER                         */
+/*                                                                          */
+/* MALAMUTE: MOOSE Application Library for Advanced Manufacturing UTilitiEs */
+/*                                                                          */
+/*           Copyright 2021 - 2023, Battelle Energy Alliance, LLC           */
+/*                           ALL RIGHTS RESERVED                            */
+/****************************************************************************/
+
+#pragma once
+
+#include "Material.h"
+
+/**
+ * Rosenthal temperature distribution.
+ */
+template <bool is_ad>
+class RosenthalTemperatureSourceTempl : public Material
+{
+public:
+  static InputParameters validParams();
+
+  RosenthalTemperatureSourceTempl(const InputParameters & parameters);
+
+protected:
+  virtual void computeQpProperties() override;
+
+  /// Laser power
+  const Real _P;
+  /// Scanning velocity
+  const Real _V;
+  /// Ambient temperature away from the surface
+  const Real _T0;
+  /// Melting temperature
+  const Real _Tm;
+  /// Initial heat source location
+  const Real _x0;
+
+  const GenericMaterialProperty<Real, is_ad> & _thermal_conductivity;
+  const GenericMaterialProperty<Real, is_ad> & _specific_heat;
+  const GenericMaterialProperty<Real, is_ad> & _density;
+  const GenericMaterialProperty<Real, is_ad> & _absorptivity;
+
+  GenericMaterialProperty<Real, is_ad> & _thermal_diffusivity;
+  GenericMaterialProperty<Real, is_ad> & _temp_source;
+  GenericMaterialProperty<Real, is_ad> & _meltpool_depth;
+  GenericMaterialProperty<Real, is_ad> & _meltpool_width;
+};
+
+typedef RosenthalTemperatureSourceTempl<false> RosenthalTemperatureSource;
+typedef RosenthalTemperatureSourceTempl<true> ADRosenthalTemperatureSource;

src/materials/RosenthalTemperatureSource.C

@@ -0,0 +1,84 @@
+/****************************************************************************/
+/*                        DO NOT MODIFY THIS HEADER                         */
+/*                                                                          */
+/* MALAMUTE: MOOSE Application Library for Advanced Manufacturing UTilitiEs */
+/*                                                                          */
+/*           Copyright 2021 - 2023, Battelle Energy Alliance, LLC           */
+/*                           ALL RIGHTS RESERVED                            */
+/****************************************************************************/
+
+#include "RosenthalTemperatureSource.h"
+
+registerMooseObject("HeatConductionApp", RosenthalTemperatureSource);
+registerMooseObject("HeatConductionApp", ADRosenthalTemperatureSource);
+
+template <bool is_ad>
+InputParameters
+RosenthalTemperatureSourceTempl<is_ad>::validParams()
+{
+  InputParameters params = Material::validParams();
+  params.addClassDescription("Computes the thermal profile following the Rosenthal equation");
+  params.addParam<MaterialPropertyName>(
+      "thermal_conductivity", "thermal_conductivity", "Property name of the thermal conductivity");
+  params.addParam<MaterialPropertyName>(
+      "specific_heat", "specific_heat", "Property name of the specific heat");
+  params.addParam<MaterialPropertyName>("density", "density", "Property name of the density");
+  params.addParam<MaterialPropertyName>(
+      "absorptivity", "absorptivity", "Property name of the power absorption coefficient");
+  params.addRequiredParam<Real>("power", "Laser power");
+  params.addRequiredParam<Real>("velocity", "Scanning velocity");
+  params.addParam<Real>(
+      "ambient_temperature", 300, "Ambient temparature far away from the surface");
+  params.addRequiredParam<Real>("melting_temperature", "Melting temparature of the material");
+  params.addParam<Real>("initial_position", 0.0, "Initial coordiate of the heat source");
+  return params;
+}
+template <bool is_ad>
+RosenthalTemperatureSourceTempl<is_ad>::RosenthalTemperatureSourceTempl(
+    const InputParameters & parameters)
+  : Material(parameters),
+    _P(getParam<Real>("power")),
+    _V(getParam<Real>("velocity")),
+    _T0(getParam<Real>("ambient_temperature")),
+    _Tm(getParam<Real>("melting_temperature")),
+    _x0(getParam<Real>("initial_position")),
+    _thermal_conductivity(getGenericMaterialProperty<Real, is_ad>("thermal_conductivity")),
+    _specific_heat(getGenericMaterialProperty<Real, is_ad>("specific_heat")),
+    _density(getGenericMaterialProperty<Real, is_ad>("density")),
+    _absorptivity(getGenericMaterialProperty<Real, is_ad>("absorptivity")),
+    _thermal_diffusivity(declareGenericProperty<Real, is_ad>("thermal_diffusivity")),
+    _temp_source(declareGenericProperty<Real, is_ad>("temp_source")),
+    _meltpool_depth(declareGenericProperty<Real, is_ad>("meltpool_depth")),
+    _meltpool_width(declareGenericProperty<Real, is_ad>("meltpool_width"))
+{
+}
+
+template <bool is_ad>
+void
+RosenthalTemperatureSourceTempl<is_ad>::computeQpProperties()
+{
+  const Real & x = _q_point[_qp](0);
+  const Real & y = _q_point[_qp](1);
+  const Real & z = _q_point[_qp](2);
+
+  // Moving heat source and distance
+  Real x_t = x - _x0 - _V * _t;
+  Real r = std::sqrt(x_t * x_t + y * y + z * z);
+
+  _thermal_diffusivity[_qp] = _thermal_conductivity[_qp] / (_specific_heat[_qp] * _density[_qp]);
+
+  _temp_source[_qp] = _T0 + (_absorptivity[_qp] * _P) /
+                                (2.0 * libMesh::pi * _thermal_conductivity[_qp] * r) *
+                                std::exp(-_V / (2.0 * _thermal_diffusivity[_qp]) * (r + x_t));
+  if (_temp_source[_qp] > _Tm)
+    _temp_source[_qp] = _Tm;
+
+  _meltpool_depth[_qp] =
+      std::sqrt((2.0 * _absorptivity[_qp] * _P) / (std::exp(1.0) * libMesh::pi * _density[_qp] *
+                                                   _specific_heat[_qp] * (_Tm - _T0) * _V));
+
+  _meltpool_width[_qp] = 2.0 * _meltpool_depth[_qp];
+}
+
+template class RosenthalTemperatureSourceTempl<false>;
+template class RosenthalTemperatureSourceTempl<true>;

test/tests/melt_pool_geometry/gold/rosenthal_temp_source_out.csv

@@ -0,0 +1,4 @@
+time,meltpool_depth,meltpool_width
+0,0,0
+0.1,0.0001520055760675,0.00030401115213499
+0.2,0.0001520055760675,0.00030401115213499

test/tests/melt_pool_geometry/rosenthal_temp_source.i

@@ -0,0 +1,104 @@
+[Mesh]
+  type = GeneratedMesh
+  dim = 2
+  xmax = 2.0
+  ymin = -1
+  ymax = 1
+  nx = 2
+  ny = 2
+[]
+
+[Variables]
+  [temp]
+    initial_condition = 393
+  []
+[]
+
+[AuxVariables]
+  [temp_src]
+    order = FIRST
+    family = MONOMIAL
+  []
+[]
+
+[AuxKernels]
+  [temp_src]
+    type = ADMaterialRealAux
+    variable = temp_src
+    property = temp_source
+  []
+[]
+
+[Kernels]
+  [time]
+    type = ADHeatConductionTimeDerivative
+    variable = temp
+  []
+  [heat_conduct]
+    type = ADHeatConduction
+    variable = temp
+    thermal_conductivity = thermal_conductivity
+  []
+[]
+
+[Materials]
+  [heat]
+    type = ADHeatConductionMaterial
+    specific_heat = 500
+    thermal_conductivity = 20
+  []
+  [density]
+    type = ADGenericConstantMaterial
+    prop_names = 'density'
+    prop_values = '8000'
+  []
+  [meltpool]
+    type = ADRosenthalTemperatureSource
+    power = 1000
+    velocity = 2.0
+    absorptivity = 1.0
+    melting_temperature = 1660
+    ambient_temperature = 393
+  []
+[]
+
+[Postprocessors]
+  [meltpool_depth]
+    type = ADElementAverageMaterialProperty
+    mat_prop = meltpool_depth
+  []
+  [meltpool_width]
+    type = ADElementAverageMaterialProperty
+    mat_prop = meltpool_width
+  []
+[]
+
+[Preconditioning]
+  [full]
+    type = SMP
+    full = true
+  []
+[]
+
+[Executioner]
+  type = Transient
+  solve_type = NEWTON
+
+  nl_rel_tol = 1e-6
+  nl_abs_tol = 1e-6
+
+  petsc_options_iname = '-ksp_type -pc_type -pc_factor_mat_solver_package'
+  petsc_options_value = 'preonly lu       superlu_dist'
+
+  l_max_its = 100
+
+  # end_time = 20
+  num_steps = 2
+  dt = 0.1
+  dtmin = 1e-4
+[]
+
+[Outputs]
+  exodus = true
+  csv = true
+[]

test/tests/melt_pool_geometry/tests

@@ -0,0 +1,19 @@
+[Tests]
+  issues = '#63'
+  [rosenthal_temp]
+    type = 'Exodiff'
+    input = 'rosenthal_temp_source.i'
+    exodiff = 'rosenthal_temp_source_out.e'
+    abs_zero = 1e-8
+    design = 'RosenthalTemperatureSource.md'
+    requirement = 'MALAMUTE shall provide analytical expression for meltpool geometry and corresponding temperature profile'
+  []
+  [rosenthal_depth]
+    type = 'CSVDiff'
+    input = 'rosenthal_temp_source.i'
+    csvdiff = 'rosenthal_temp_source_out.csv'
+    abs_zero = 1e-8
+    design = 'RosenthalTemperatureSource.md'
+    requirement = 'MALAMUTE shall provide analytical expression for meltpool depth and width'
+  []
+[]