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Abstract Additive manufacturing (AM) has emerged as a promising approach to achieve energetic materials (EMs) with intricate geometries and controlled microstructures, which are crucial for safety and performance optimization. However, current AM methods still face limitations such as limited densities and inadequate solids loading. To overcome these limitations, we have developed a pressure‐assisted binder jet (PBJ) process that has the potential to allow for the fabrication of intricate EMs while preserving their desired properties. This study aims to investigate the effects of printing parameters on the microstructures and properties of EMs, including density, solids loading, mechanical properties, and heterogeneity. Our results demonstrate that the PBJ process achieves exceptional properties in EMs, including densities up to 83.4 % and solids loading up to 95.4 %, surpassing those achieved by existing AM processes. Furthermore, the mechanical properties of the fabricated EMs are comparable to those achieved using conventional fabrication techniques, including a compressive strength of 3.32 MPa, a Young's modulus of 16.68 MPa, a Poisson's ratio of 0.45, a shear modulus of 5.73 MPa, and a bulk modulus of 21.01 GPa. Various test cases were printed to showcase the ability of the PBJ process to create EMs with complex structures and exceptional properties. Micro‐computed tomography was employed to analyze the influence of printing parameters on the internal composition and microstructures of the printed specimens. 

Abstract Predictive simulations of the shock‐to‐detonation transition (SDT) in heterogeneous energetic materials (EM) are vital to the design and control of their energy release and sensitivity. Due to the complexity of the thermo‐mechanics of EM during the SDT, both macro‐scale response and sub‐grid mesoscale energy localization must be captured accurately. This work proposes an efficient and accurate multiscale framework for SDT simulations of EM. We introduce a new approach for SDT simulation by using deep learning to model the mesoscale energy localization of shock‐initiated EM microstructures. The proposed multiscale modeling framework is divided into two stages. First, a physics‐aware recurrent convolutional neural network (PARC) is used to model the mesoscale energy localization of shock‐initiated heterogeneous EM microstructures. PARC is trained using direct numerical simulations (DNS) of hotspot ignition and growth within microstructures of pressed HMX material subjected to different input shock strengths. After training, PARC is employed to supply hotspot ignition and growth rates for macroscale SDT simulations. We show that PARC can play the role of a surrogate model in a multiscale simulation framework, while drastically reducing the computation cost and providing improved representations of the sub‐grid physics. The proposed multiscale modeling approach will provide a new tool for material scientists in designing high‐performance and safer energetic materials. 

Abstract Artificial intelligence (AI) is rapidly emerging as a enabling tool for solving complex materials design problems. This paper aims to review recent advances in AI‐driven materials‐by‐design and their applications to energetic materials (EM). Trained with data from numerical simulations and/or physical experiments, AI models can assimilate trends and patterns within the design parameter space, identify optimal material designs (micro‐morphologies, combinations of materials in composites, etc.), and point to designs with superior/targeted property and performance metrics. We review approaches focusing on such capabilities with respect to the three main stages of materials‐by‐design, namely representation learning of microstructure morphology (i. e., shape descriptors), structure‐property‐performance (S−P−P) linkage estimation, and optimization/design exploration. We leave out “process” as much work remains to be done to establish the connectivity between process and structure. We provide a perspective view of these methods in terms of their potential, practicality, and efficacy towards the realization of materials‐by‐design. Specifically, methods in the literature are evaluated in terms of their capacity to learn from a small/limited number of data, computational complexity, generalizability/scalability to other material species and operating conditions, interpretability of the model predictions, and the burden of supervision/data annotation. Finally, we suggest a few promising future research directions for EM materials‐by‐design, such as meta‐learning, active learning, Bayesian learning, and semi‐/weakly‐supervised learning, to bridge the gap between machine learning research and EM research. 

Modeling unsteady, fast transient, and advection-dominated physics problems is a pressing challenge for physics-aware deep learning (PADL). The physics of complex systems is governed by large systems of partial differential equations (PDEs) and ancillary constitutive models with nonlinear structures, as well as evolving state fields exhibiting sharp gradients and rapidly deforming material interfaces. Here, we investigate an inductive bias approach that is versatile and generalizable to model generic nonlinear field evolution problems. Our study focuses on the recent physics-aware recurrent convolutions (PARC), which incorporates a differentiator-integrator architecture that inductively models the spatiotemporal dynamics of generic physical systems. We extend the capabilities of PARC to simulate unsteady, transient, and advection-dominant systems. The extended model, referred to as PARCv2, is equipped with differential operators to model advection-reaction-diffusion equations, as well as a hybrid integral solver for stable, long-time predictions. PARCv2 is tested on both standard benchmark problems in fluid dynamics, namely Burgers and Navier-Stokes equations, and then applied to more complex shock-induced reaction problems in energetic materials. We evaluate the behavior of PARCv2 in comparison to other physics-informed and learning bias models and demonstrate its potential to model unsteady and advection-dominant dynamics regimes. 

Multi-scale predictive models for the shock sensitivity of energetic materials connect energy localization (“hotspots”) in the microstructure to macro-scale detonation phenomena. Calculations of hotspot ignition and growth rely on models for chemical reaction rates expressed in Arrhenius forms; these chemical kinetic models, therefore, are foundational to the construction of physics-based, simulation-derived meso-informed closure (reactive burn) models. However, even for commonly used energetic materials (e.g., HMX in this paper) there are a wide variety of reaction rate models available. These available reaction rate models produce reaction time scales that vary by several orders of magnitude. From a multi-scale modeling standpoint, it is important to determine which model best represents the reactive response of the material. In this paper, we examine three global Arrhenius-form rate models that span the range of reaction time scales, namely, the Tarver 3-equation, the Henson 1-equation, and the Menikoff 1-equation models. They are employed in a meso-informed ignition and growth model which allows for connecting meso-scale hotspot dynamics to macro-scale shock-to-detonation transition. The ability of the three reaction models to reproduce experimentally observed sensitivity is assessed by comparing the predicted criticality envelope (Walker–Wasley curve) with experimental data for pressed HMX Class V microstructures. The results provide a guideline for model developers on the plausible range of time-to-ignition that are produced by physically correct Arrhenius rate models for HMX. 

Abstract Many mechanical engineering applications call for multiscale computational modeling and simulation. However, solving for complex multiscale systems remains computationally onerous due to the high dimensionality of the solution space. Recently, machine learning (ML) has emerged as a promising solution that can either serve as a surrogate for, accelerate or augment traditional numerical methods. Pioneering work has demonstrated that ML provides solutions to governing systems of equations with comparable accuracy to those obtained using direct numerical methods, but with significantly faster computational speed. These high-speed, high-fidelity estimations can facilitate the solving of complex multiscale systems by providing a better initial solution to traditional solvers. This paper provides a perspective on the opportunities and challenges of using ML for complex multiscale modeling and simulation. We first outline the current state-of-the-art ML approaches for simulating multiscale systems and highlight some of the landmark developments. Next, we discuss current challenges for ML in multiscale computational modeling, such as the data and discretization dependence, interpretability, and data sharing and collaborative platform development. Finally, we suggest several potential research directions for the future. 

Sensitivity in polymer-bonded explosives (PBXs) relies on the presence of defects, such as cracks and voids, which create localized thermal energy, commonly known as hotspots, and initiate reactions through various localization phenomena. Our prior research has explored the use of internal gas pressure induced by thermite ignition to generate localized defects for PBX sensitization. However, further research is required to gain a more comprehensive understanding of the defect generation process resulting from internal gas pressure. This study investigates the process of defect generation in PBXs in response to internally induced gas pressure by applying controlled compressed gas to a fabricated cavity within the materials, simulating the gas pressure emitting from thermite. X-ray micro-computed tomography was employed to visualize the microstructure of the sample before and after gas injection. The experiments reveal the significance of gas pressure, cavity shape, temperature, and specimen compaction pressure in the defect generation. Numerical simulations using Abaqus/Standard were conducted to assess the defect generation in mock PBXs under varying gas pressures, cohesive properties, and binder thicknesses. The simulation results demonstrate the substantial influence of these properties on the ability to generate defects in mock PBXs. This study contributes to a better understanding of the factors influencing defect generation in mock PBXs. This knowledge is crucial for achieving precise control over defect generation, leading to improved ignition and detonation characteristics in PBXs. 

Complex spin textures in itinerant electron magnets hold promises for next-generation memory and information technology. The long-ranged and often frustrated electron-mediated spin interactions in these materials give rise to intriguing localized spin structures such as skyrmions. Yet, simulations of magnetization dynamics for such itinerant magnets are computationally difficult due to the need for repeated solutions to the electronic structure problems. We present a convolutional neural network (CNN) model to accurately and efficiently predict the electron-induced magnetic torques acting on local spins. Importantly, as the convolutional operations with a fixed kernel (receptive field) size naturally take advantage of the locality principle for many-electron systems, CNNs offer a scalable machine learning approach to spin dynamics. We apply our approach to enable large-scale dynamical simulations of skyrmion phases in itinerant spin systems. By incorporating the CNN model into Landau-Lifshitz-Gilbert dynamics, our simulations successfully reproduce the relaxation process of the skyrmion phase and stabilize a skyrmion lattice in larger systems. The CNN model also allows us to compute the effective receptive fields, thus providing a systematic and unbiased method for determining the locality of the original electron models.