Multiphysics Model Research Articles

Design and optimization of a thermoelectric generator with dimple fins to achieve higher net power

To enhance the performance of the automobile thermoelectric generator (ATEG), this study proposes a heat exchanger with dimple fins, where the number of dimples systematically increases along the direction of exhaust flow. The innovative combination of dimples with fins effectively addresses the impact of temperature reduction in the exhaust. The distribution of dimples on the fins is optimized based on a fluid-thermal-electric multiphysics model and a net power model. According to simulation results, it can be found that as the number of columns and radius of the dimples increase, the ability of the heat exchanger to transfer heat is improved while the back pressure loss of the exhaust flow is also increased. Through optimizations, the optimal dimple distribution of n = 8 and r = 1.45 mm is obtained, achieving a maximum net power output of 62.46 W. The performance of the optimized ATEG with dimple fins is greatly improved in comparison with the conventional plate-fin structure, and its conversion efficiency, output power, output voltage, and net power output are increased by 16.07 %, 28.95 %, 13.56 %, and 10.09 %, respectively. The results of this study offer valuable guidance for shaping the heat exchanger’s design.

A unified discontinuous Galerkin formulation for interfacial multiphysics modeling of thermo-chemically driven fracture

Many engineering and natural materials exhibit coupled thermo-chemo-mechanical phenomena, which can result in embrittlement and fracture. These fractures, in turn, can alter the subsequent thermal, chemical, and mechanical response. We present a theoretical formulation and computational framework for the analysis of thermo-chemically fractured solids, with emphasis on the post-fracture thermal and chemical interfacial behavior. The theoretical model is based on the thermodynamically-consistent formulation of Loeffel and Anand (IJP, 2011). The computational method extends the scalable discontinuous Galerkin/Cohesive Zone Model (DG/CZM) of Radovitzky et al. (CMAME, 2011) to thermo-chemo-mechanics, which facilitates coupled, large-scale simulations of materials and structures containing failed interfaces. In the proposed framework, all balance laws are enforced weakly via the DG formalism, resulting in a unified formulation for multiphysics problems in solids. This naturally enables the incorporation of general interface models, e.g. to account for effects such as the aeolotropic reduction in thermochemical transport due to the presence of fractures, or the acceleration of chemical reactions along crack flanks. The approach is verified against two analytical solutions of boundary value problems drawn from thermo-poro-elasticity and thermally-driven delamination. A scalable, three-dimensional simulation of thermochemically-driven concrete cracking illustrates the complete capabilities of the interfacial multiphysics modeling framework.

A multiphysics model for predicting spatiotemporal temperature profiles in microwave-heated carbon capture processes

Due to alarming rise in atmospheric CO2 ppm levels, the direct air capture process has been engineered to capture low concentrations of CO2 directly from the atmosphere using chemisorbents. However, the regeneration of chemisorbents can be energy-intensive and may not always be efficient. To potentially enhance this, microwave is employed for selective and targeted heating of the chemisorbent. Existing measurement techniques struggle to accurately capture the spatiotemporal temperature profile of solvent impregnated polymer (SIP) under microwave heating. Therefore, it becomes crucial to determine the spatiotemporal temperature distribution inside the polymer phase to expedite CO2 desorption, improve energy efficiency, and prevent material degradation. Motivated by these considerations, we propose a 3D-multiphysics model to study the spatiotemporal distribution of temperature inside a hybrid nanoscale multi-functional material. We focus on the microwave heating of a novel heterogeneous system comprising a SIP with a ferromagnetic additive (Fe3O4), further solving the heat diffusion and Maxwell’s electromagnetic equations to analyze the temperature variation inside the SIP system. By coupling the physics of electromagnetism and heat transfer, our model allows for a comprehensive analysis of the temperature distribution and heating effects inside the chemisorbent. Additionally, we conduct sensitivity analysis of spatiotemporal temperature profile on various thermal and dielectric parameters, as well as the size and location of the Fe3O4 layer. These results can help to optimize desorption rates and make the regeneration process more energy-efficient in future studies.

Modeling for the Fabrication Process of a ϕ1185 mm C/C Composite Thermal Insulation Tube in an Isothermal Chemical Vapor Infiltration Reactor

The large-size chemical vapor infiltration (CVI) of the carbon/carbon (C/C) composite thermal insulation tube is a key component for drawing large diameter monocrystalline silicon rods. However, the CVI densification process is complex, and the cost of experiment optimization is extremely high. In this article, a multi-physics coupling simulation model was established and validated based on COMSOL Multiphysics v.5.6 software to simulate the fabrication process of an isothermal CVI process for a Φ1185 mm C/C composite thermal insulation tube. The influence of process parameters on densification was explored, and a method of optimization was proposed. Our modeling results revealed that the deposition status in areas of low densification was effectively and significantly enhanced after process optimization. At the monitoring site, the carbon density was no less than 1.08 × 103 kg·m−3, the average density of the composite-material thermal insulation tube improved by 5.7%, and the densification rate increased by 26.5%. This article effectively simulates the CVI process of large-sized C/C composite thermal insulation tubes, providing an important technical reference scheme for the preparation of large-sized C/C composite thermal insulation tubes.

Revealing the mechanism of superimposing ultrasonic vibration on microstructure evolution in friction stir welding by multi-physical multi-scale simulation

Ultrasonic vibration-enhanced friction stir welding (UVeFSW) is a promising joining method for aluminum‑lithium (Al-Li) alloy. However, directly observing the microstructural evolution in UVeFSW only by experimental methods is still a challenge. The mechanism of ultrasonic vibration (UV) on the microstructure evolution during FSW of Al-Li alloy remains unrevealed. In this study, a multi-physical multi-scale model was developed by coupling the finite element (FE) method and the Monte Carlo (MC) method to quantitatively study the impact of superimposing UV on the microstructure evolution in FSW. The preheating effect, acoustoplastic effect and residual hardening effect of UV were all considered in the model. Welding thermal processes, microstructure evolution of the material on the advancing side (AS) and in the center of the weld were quantitatively analyzed. And dislocation density and grain size in UVeFSW and FSW of Al-Li alloy were compared. Temperature field simulation results show that superimposing UV on FSW has a certain preheating effect in front of the tool. Microstructure simulation results show that the main effect of UV on microstructure evolution is the dynamic recrystallisation (DRX) process, where the maximum dislocation density in the weld nugget zone (WNZ) increases from 2.49 × 1013 m−2 to 3.49 × 1013 m−2 after superimposing UV, leading to an increase in the plastic deformation stored energy. Thereby, the driving force for nucleation and DRX increases, resulting in more nuclei in the WNZ, together with an increase in the width of the WNZ. Superimposing ultrasonic vibration in FSW can significantly refine the grain size by enhancing the activity and multiplication of dislocation in the UVeFSW of Al-Li alloy. The model is validated by the experimental results.

Transient thermal 2D FEM analysis of SiC MOSFET in short-circuit operation including high-temperature material laws and phase transition of aluminum source electrode

Understanding the electrothermal behavior of SiC MOSFET power devices under extreme operation conditions, such as short circuits, is crucial for their application certification. However, simulating short circuits in electronic components is challenging due to the necessity of a comprehensive thermal and electrical Multiphysics model that incorporates material laws and respects elevated temperatures with broad ranges. It is also needed to model the melting of the topside Al electrode. The paper presents for the first time a 2D electrothermal FEM that simulates the thermodynamic behavior of SiC MOSFET at high temperatures transistors under short-circuit conditions, including wide-range temperature-dependent material property laws. This work models the Al phase transition by considering the apparent heat capacity method and including the latent heat absorbed during the Al solid-liquid phase change (PC). The geometric accuracy of this study provides significant added values compared to existing 1D models. It was deduced that including the temperature-dependent material laws highly impacted the results. The rise in SiC junction temperature led to a delay in the onset of Al melting. It also impacted the progression manner of the Al melting process after the formation of new melting fronts.

An OpenFOAM solver for multiphysics modeling of fusion reactor design: The nemoFoam code

This paper introduces a multiphysics code, named nemoFoam, designed within the OpenFOAM environment to address the coupling of neutron and photon transport with thermal-hydraulics in nuclear reactor simulations. The code, conceived both for fusion and fission applications, employs a modular approach where the neutronic module is currently based on multi-group neutron diffusion equations, including a mono-kinetic treatment for photons. The thermal-hydraulic module is built on the standard OpenFOAM solver. The paper focuses on presenting the key features of nemoFoam and discussing the structure of the code, the nuclear and thermal-hydraulic models, and the coupling strategy between them.In order to assess the performance of the neutronic module, the code is applied to a fusion case study, indeed a benchmark against the Serpent Monte Carlo code for neutron and photon transport is performed, applying nemoFoam to the Affordable, Robust and Compact (ARC) fusion reactor design. Simulation results demonstrate good agreement with Monte Carlo benchmarks, emphasizing the potential of the code for multiphysics simulations. The modular design of nemoFoam allows users to extend the implemented model equations to study additional phenomena, focus only on selected aspects independently and, potentially, to add new solvers in each module.

High-resolution and reduced-order multi-physics simulation on thermal–hydraulic and thermoelectric characteristics of the thermionic space reactor core

The simulation of a thermionic space reactor core necessitates a comprehensive consideration of the intricate interplay between fluid flow, heat transfer, and thermionic energy conversion, constituting a multi-physics coupling challenge. Given the absence of a thermionic conversion model in contemporary CFD (Computational Fluid Dynamics) codes, accurately simulating the thermal–hydraulic and thermo-electric behavior of thermionic reactors in existing CFD software is particularly challenging. To analyze the multi-physics coupling phenomena in thermionic reactors, this paper revises the conjugate heat transfer solver in the proprietary 3D (three-dimensional) finite-volume CFD code, mFVM (modular Finite-Volume Method Code), to enable bidirectional coupling with the thermionic conversion model. This enhancement aims to predict the high-resolution three-dimensional temperature field and thermoelectric characteristics of the thermionic reactor core. Furthermore, a reduced-order multi-physics model of the thermionic reactor core is established using RESYS (Reactor System Simulation Code). The numerical simulation outcomes for both the high-resolution and reduced-order multi-physics models, pertaining to electrically heated and fission-heated TFEs (Thermionic Fuel Elements), are validated against experimental data. The results indicate that the emitter electron cooling effects caused by thermionic emission reduced the maximum temperature of emitter by about 200 K for both electrically heated and fission-heated TFE. Therefore, a bidirectional coupling between the thermal–hydraulic model and the thermionic conversion model is essential for precisely calculating the temperature field within the TFE and the thermionic reactor core. Thereafter, both the high-resolution model and the reduced-order model are utilized to investigate the thermal–hydraulic and thermoelectric characteristics of the TOPAZ-II reactor core. The calculated electrical power of the TOPAZ-II reactor is 5.39 kWe using the mFVM model and 5.47 kWe using the RESYS model. Finally, an analysis of the thermoelectric conversion characteristics based on the simulation results of the reduced-order model reveals that the TOPAZ-II reactor system is capable of load-following only when the load resistance exceeds 0.06 Ω under nominal full power operation conditions.

Quantitative failure analysis of lithium-ion batteries based on direct current internal resistance decomposition model

Accurate failure analysis plays a pivotal role in the optimization design and lifetime prediction of 4.45 V high-voltage LiCoO2/Graphite (LCO/Gr) batteries. Multiphysics coupling model brings great opportunities to conduct battery failure analysis quantitatively, although it is quite challenging because many model parameters need to be handled properly. Herein, we systematically elaborate the differences of ion and electron transport properties before and after cycling ageing of LCO/Gr batteries by constructing direct current internal resistance (DCR) decomposition model. The key parameters acquisition method is established, and the mechanism of DCR growth is elucidated. Furthermore, the aforementioned model parameters are refined by using a hybrid power pulse characteristics (HPPC) curve optimization algorithm based on DCR decomposition results obtained from the three-electrode battery system. Through analyzing the influence of single-factor parameter ageing on battery voltage output capacity and discharge temperature rise, the main factors affecting battery failure process are identified. For instance, the account of the positive electrochemical reaction resistance related to the kpos increased from the initial 22.9% of total DCR to 37.3% after ageing. This work provides a reliable quantitative analysis basis for the global optimization design of advanced LIBs.

Numerical and experimental studies on dissimilar joining of Hastelloy C-276 and SS-316L using microwave hybrid heating at 2.45 GHz

Dissimilar joints of SS-316L and C-276 (Hastelloy) were developed using C-276 powder with microwave exposure 600 s in microwave applicator (2.45 GHz, 900 W). A multi-physics model was validated with experimental studies and simulation were carried out to analyse the microwave-joint interaction characteristics. The simulation results showed that a concentrated electric field (5.86 × 104 V/m) and higher resistive losses (3.07 × 107 W/m3) at the joint region facilitated rapid heat generation locally. Microstructural characterization of the joint revealed the formation of cellular grains such as Fe-Ni intermetallic phases with Mo, Cr and W-carbides along the grain boundaries. Joints exhibited average microhardness of 290 HV, and tensile strength of 425 ± 10 MPa and 14% elongation with failure due to both ductile and brittle fracture modes.

Numerical simulation and experimental investigation of the molten pool evolution and defects formation mechanism of Selective laser melted CuSn20/Diamond composites

Some defects such as small pores, thermal damage of diamond particle and micro-cracks between diamond and metal matrix existed in SLM-fabricated metal-bonded diamond tools. For further application, it is vital to understand the formation mechanism of such defects by SLM-fabricated parameters. In this work, a multiphysics field numerical simulation model based on computational fluid dynamics (CFD) was developed to investigate molten pool evolution and defects formation mechanism for SLM-fabricated CuSn20-bonded diamond composites. From simulation results, the metal particles melt and flow forward under the action of the laser. Also, the presence of diamond particles can obstruct the normal flow of melted CuSn20 fluid. Increasing the laser power can widen and stabilize the molten pool, however, exacerbate the thermal damage of diamond particles. Specially, the migration and marginalisation of the diamond particles during the formation of molten pool were found by simulation and experimental results. Unavoidably, there are obvious gaps in the interfacial bonding region of diamond and CuSn20 due to the comprehensive reasons of thermal gradient, differences in thermophysical properties of two materials and undergo continuous migration and rotational behavior of diamond particles. These findings have potential value for understanding and optimizing the process of SLM-fabricated metal-bonded diamond tools.

Dynamic modeling of a synchronous reluctance machine for transient simulation of vibrations under variable rotor magnetization

This work introduces a new approach for the dynamic simulation of a permanent magnet-assisted synchronous reluctance machine with the ability to consider dynamic changes in the rotor magnetization. The aim is to comprehensively analyze the dynamics of a machine through transient simulations of the occurring magnetic and mechanical forces that influence the noise and vibration characteristics. A simplified magnetic model considering the effects of magnetic reluctances, leakage flux, and magnetic saturation is utilized to efficiently calculate the dynamically changing magnetic forces in the air gap. Unlike conventional designs employing rare earth magnets in the rotor, the design at hand utilizes non-rare earth magnets that enable adjustments of the magnets’ flux output. The novelty of the presented approach lies in its ability to consider these dynamic changes when calculating the air gap flux. The magnetic forces are then applied to an elastic multibody model of the motor, which includes the rotor, stator, bearings, and the housing, for the computation of the bearing forces and housing deformations. The presented multi-physical model allows for transient simulations of the forces acting on the bearings and the housing, capturing the dynamic response of the motor under varying rotor magnetization, air gaps, and loads. With the proposed approach, this study offers predictions regarding critical vibration characteristics that occur during dynamic operation, providing valuable insights for noise reduction efforts.

Assessing elevated pressure impact on photoelectrochemical water splitting via multiphysics modeling

Photoelectrochemical (PEC) water splitting is a promising approach for sustainable hydrogen production. Previous studies have focused on devices operated at atmospheric pressure, although most applications require hydrogen delivered at elevated pressure. Here, we address this critical gap by investigating the implications of operating PEC water splitting directly at elevated pressure. We evaluate the benefits and penalties associated with elevated pressure operation by developing a multiphysics model that incorporates empirical data and direct experimental observations. Our analysis reveals that the operating pressure influences bubble characteristics, product gas crossover, bubble-induced optical losses, and concentration overpotential, which are crucial for the overall device performance. We identify an optimum pressure range of 6–8 bar for minimizing losses and achieving efficient PEC water splitting. This finding provides valuable insights for the design and practical implementation of PEC water splitting devices, and the approach can be extended to other gas-producing (photo)electrochemical systems. Overall, our study demonstrates the importance of elevated pressure in PEC water splitting, enhancing the efficiency and applicability of green hydrogen generation.

Simulation and experimental studies on surface quality of vibration-assisted ECM

ABSTRACT Electrochemical machining (ECM) offers a superior technology for manufacturing hard-cutting metals such as modified Inconel 718 (IN718). However, in many cases, poor surface quality arises because of the specific dissolution characteristics of the material, hindering further application of the process. Vibration-assisted ECM (VA-ECM) has been proposed in the hope of solving the problem by oscillating the cathode. A multiphysics model was developed for pulsed ECM (PECM) and VA-ECM. Systematic experiments were performed to clarify the mechanism of cathode oscillation on surface quality and verify the computational results. With 20 Hz vibration frequency and 25% duty cycle, the surface roughness reaches 0.39 µm, show that higher oscillation frequency and lower duty cycle are effective in improving surface quality. Finally, dissolution models of modified IN718 under PECM and VA-ECM are proposed. By oscillating the cathode, electrolyte fluctuation is enhanced, electrolytic products are removed effectively, the surface quality is improved significantly.

Interaction of ultrasonic guided waves with interfacial debonding in a stiffened composite plate under variable temperature and operational conditions

Stiffeners play a vital role in strengthening thin panels in a wide range of engineering constructions by reducing additional structural weight. However, these structures are vulnerable to issues such as interlayer delamination or skin-stiffener interfacial debonding due to high stress levels developed from external environmental conditions and operational loadings. In contrast, ultrasonic-guided wave (UGW) techniques exhibit an efficient and precise approach for monitoring discontinuities or damages in composite structures. There is a lack of research on understanding the characteristics of the interaction between UGW and interfacial debonding when in-plane edge loading and environmental factors are simultaneously taken into account. Therefore, this study is motivated by the need to develop a multiphysics numerical model which employs a commercially available finite element software, COMSOL Multiphysics®, to simulate UGW propagation in a stiffened composite plate with debonding at the plate-stiffener interface through a piezoelectric transducer under the combined influence of in-plane edge load and hygrothermal environment. The stiffened plate and piezoelectric patches are modelled with the tetrahedral element, and the bottom surface of the attached stiffener has a through-width 0.1 mm deep groove simulated for debonding. The developed FE model is validated against the results of the conducted experiments and those found in the available literature through the correlation coefficient. Further, the study conducts a comprehensive parametric investigation on stiffened cross-ply (0/90/0) laminated plates, considering variations in debonding size, in-plane load, and hygrothermal load intensity through the excitation of A0 mode. The acquired response is processed to compare the peak amplitude of various modes and energy of the waveform. Additionally, statistical indices such as normalised correlation moment (NCM) and variance of the continuous wavelet transform (CWT) peak are estimated to understand the impact of various parameters on waveform. The results show that the presence of a 90° lamina in the cross-ply laminate generates a low amplitude S0 mode in the scattered response. Moreover, a mode conversion from A0 to S0 mode is observed due to perfect bonding between the plate and the stiffener, providing insights into the bonding state in the panel. Furthermore, it is found that the magnitude of the in-plane loading marginally affects the peak amplitude of various modes in the scattered response. Additionally, when temperature intensity rises, the energy and amplitude of the UGW signals acquired through piezoelectric patches positioned in a direct line with the actuator gradually increase. The NCM value enhances with debonding regardless of exposed hygrothermal condition and reduces with increasing temperature intensity. In addition, the variance of the CWT peak reduces with debonding. The findings of this research are expected to be helpful for the development of efficient algorithms for detecting damages for structural health monitoring of stiffened composite panels.

Design and multiphysical modeling of SMA-driven bi-stable structures with efficient energy consumption

The present study investigates a bi-stable shape-morphing mechanism with 3D-printed polymer components and shape memory alloy (SMA) actuators. The system is designed to optimize energy efficiency by employing two sets of SMA wires, enabling it to achieve shape transformation and return to its original form without the necessity of continuous power input. This enhances control, accelerates shape transformation, and significantly reduces energy consumption. The bi-stable shape-morphing process and the requisite electrical, geometric, and mechanical parameters is modelled through multiphysics simulations in COMSOL software, followed by a finite element analysis in ABAQUS. Due to its contribution to energy conservation and functionality enhancement, bi-stability is of significant value in a variety of structural applications, including adaptive building façades. The potential applications of the suggested structure are further discussed.

Free Vibration of Thermally Loaded FG-GPLRC Nanoplates Integrated with Magneto-Electro-Elastic Layers in Contact with Fluid

This work investigates the free vibrations of innovative thermally loaded nanoplates constructed by integrating magneto-electro-elastic (MEE) layers with functionally-graded graphene platelet-reinforced composite cores (FG-GPLRC) and accounting for viscous fluid interactions. An advanced multiphysics model is developed using the Navier–Stokes equations to capture fluid structure coupling effects, Halpin–Tsai, and the rule of mixtures micromechanics to predict the non-uniform effective properties, third-order shear deformation plates theory (TSDPT) to incorporate thickness stretching, and the nonlocal strain gradient theory (NSGT) to characterize size dependencies. The Galerkin technique is used to solve the governing equations, which are derived from the Hamilton’s principle. Parametric analyses quantify the influences of fluid depth, temperature fluctuations, temperature profiles, nonlocal and strain gradient parameters, electric and magnetic potentials, graphene distribution patterns, graphene weight fractions, and boundary conditions on the vibration response. The outcomes of this study provide design guidelines and predictive tools enabling active vibration control systems for next-generation thermally-loaded nanocomposite structures with widespread applications from aerospace vehicles to nanoelectronics.

Numerical Modeling of Electron Beam Cold Hearth Melting for the Cold Hearth

The electron beam cold hearth melting (EBCHM) process is one of the key processes for titanium alloy production. The unique characteristic of this pyrometallurgy process is the application of the cold hearth, which is responsible for controlling the Low-Density Inclusions (LDIs) and High-Density Inclusions (HDIs) in the melt. As a key process of inclusion removal, the information such as melt residence time in the cold hearth is directly related to the control of metallurgical defects in the ingot, and may also affect the composition distribution of the ingot. In this paper, the details for the physical phenomena, namely the evolution of the pool, the evolution of the flow, and the evolution of the component in the cold hearth during EBCHM are investigated using a modified multi-physical numerical model. The effects of melting temperature and melting speed on these phenomena were investigated. The purpose is to provide more fundamental knowledge and to further enhance the applications of EBCHM for more titanium alloys.

The role of ionic concentration polarization on the behavior of nanofluidic membranes

Water, the elixir of life, faces a pressing challenge—salinity. As humanity's demand for freshwater intensifies, the significance of efficient desalination processes becomes paramount. The promising prospects of nanofluidic membranes and unique electrokinetic phenomena like ion concentration polarization (ICP) signal optimistic strides in enhancing salt removal processes. This study is dedicated to elucidating the transport mechanism of buffer ions at interfaces between micro and nanochannels. To achieve this, we introduce a multiphysics coupling model that incorporates a boundary condition for the fixed surface voltage, offering a comprehensive description of the impact of nanochannel arrays. In this context, it is important to note that the nanochannel array is characterized by a positive charge density, akin to a cation exchange membrane (CEM), seamlessly integrated into the microchannel wall to serve as a cationic half-cell. The analysis involved solving governing equations, including the Poisson-Nernst-Planck, continuity, and Navier-Stokes equations, numerically using the finite element method in an unsteady state. Employing cylindrical nanochannel array configurations—single, dual, and triple—we scrutinized their impact on salt species concentration and removal efficiency under specified conditions (c0=1mM, ρv=2C/m3, LN=10μm, VT=26mV, Vsurr=4VT, VL/VR=8,t≥0.5 and ζ=−60mV). The single nanochannel array configuration demonstrated a relatively uniform salt distribution, achieving a removal efficiency of approximately 58%. The introduction of two nanochannel arrays at distinct locations resulted in a notable increase in removal efficiency, reaching 72%, particularly in the "down first" configuration, emphasizing a synergistic effect. The presence of three nanochannel arrays, each with varying lengths, produced intricate patterns, with the highest removal efficiency observed at 91% in the "different length" condition. This study emphasizes the superior desalination capabilities achievable through multiple nanochannel arrays, advancing our understanding of nanofluidic membrane applications for efficient water desalination. In conclusion, emulating electrodialysis membrane procedures, particularly by integrating an anionic half-cell, holds promise for further advancing desalination processes, offering a potential avenue to enhance efficiency.

Electrical current-assisted reactive crucible melting technique: Case study of the Fe-Sn system

Modern materials science relies heavily on the advancement of combinatorial high-throughput experimental and computational methods to discover new advanced materials. Among these methods, the reactive crucible melting (RCM) technique stands out as particularly promising. However, a significant challenge in RCM combinatorial analysis is the occurrence of "missing" phases. In this study, we successfully addressed this limitation through the application of electrical current stressing. Furthermore, we investigate the influence of electric current stressing on diffusion rates and the phase formation processes within the reactive crucible. We employed Comsol Multiphysics modeling to analyze the experimental results in the framework of electromigration theory, focusing on the distribution of electrical field lines, temperature gradients, and current density values. Additionally, through the integration of finite element calculations with analysis of Electron Backscatter Diffraction (EBSD) and Magneto-Optical Kerr Effect (MOKE) data, we estimated the gradient of internal stresses along the boundaries of the crucible's reaction volume induced by the diffusion of electrically-induced vacancies and adatoms. Due to modest values of the current density in our experiment and the disparity between the rates of crucible body dissolution and vacancy diffusion, no compressive or tensile stresses were observed. Nonetheless, we propose that the developed electrical current-assisted reactive crucible melting technique holds promise for synthesizing metastable phases existing under high positive or negative pressures.