Long-term stable sealing elements are a basic component in the safety concept for a possible repository for heat-emitting radioactive waste in rock salt. The sealing elements will be part of the closure concept for drifts and shafts. They will be made from a welldefinied crushed salt in employ a specific manufacturing process. The use of crushed salt as geotechnical barrier as required by the German Site Selection Act from 2017 /STA 17/ represents a paradigm change in the safety function of crushed salt, since this material was formerly only considered as stabilizing backfill for the host rock. The demonstration of the long-term stability and impermeability of crushed salt is crucial for its use as a geotechnical barrier. The KOMPASS-II project, is a follow-up of the KOMPASS-I project and continues the work with focus on improving the understanding of the thermal-hydraulic-mechanical (THM) coupled processes in crushed salt compaction with the objective to enhance the scientific competence for using crushed salt for the long-term isolation of high-level nuclear waste within rock salt repositories. The project strives for an adequate characterization of the compaction process and the essential influencing parameters, as well as a robust and reliable long-term prognosis using validated constitutive models. For this purpose, experimental studies on long-term compaction tests are combined with microstructural investigations and numerical modeling. The long-term compaction tests in this project focused on the effect of mean stress, deviatoric stress and temperature on the compaction behavior of crushed salt. A laboratory benchmark was performed identifying a variability in compaction behavior. Microstructural investigations were executed with the objective to characterize the influence of pre-compaction procedure, humidity content and grain size/grain size distribution on the overall compaction process of crushed salt with respect to the deformation mechanisms. The created database was used for benchmark calculations aiming for improvement and optimization of a large number of constitutive models available for crushed salt. The models were calibrated, and the improvement process was made visible applying the virtual demonstrator.
Accurate and efficient constitutive modeling remains a cornerstone issue for solid mechanics analysis. Over the years, the LAMÉ advanced material model library has grown to address this challenge by implementing models capable of describing material systems spanning soft polymers to stiff ceramics including both isotropic and anisotropic responses. Inelastic behaviors including (visco)plasticity, damage, and fracture have all incorporated for use in various analyses. This multitude of options and flexibility, however, comes at the cost of many capabilities, features, and responses and the ensuing complexity in the resulting implementation. Therefore, to enhance confidence and enable the utilization of the LAMÉ library in application, this effort seeks to document and verify the various models in the LAMÉ library. Specifically, the broader strategy, organization, and interface of the library itself is first presented. The physical theory, numerical implementation, and user guide for a large set of models is then discussed. Importantly, a number of verification tests are performed with each model to not only have confidence in the model itself but also highlight some important response characteristics and features that may be of interest to end-users. Finally, in looking ahead to the future, approaches to add material models to this library and further expand the capabilities are presented.
This report summarizes the international collaborations conducted by Sandia funded by the US Department of Energy Office (DOE) of Nuclear Energy (DOE-NE) Spent Fuel and Waste Science & Technology (SFWST) as part of the Sandia National Laboratories Salt R&D and Salt International work packages. This report satisfies the level-three milestone M3SF-23SN010303062. Several stand-alone sections make up this summary report, each completed by the participants. The sections discuss granular salt reconsolidation (KOMPASS), engineered barriers (RANGERS), numerical model comparison (DECOVALEX) and an NEA Salt Club working group on the development of scenarios as part of the performance assessment development process. Finally, we summarize events related to the US/German Workshop on Repository Research, Design and Operations.
Disposal rooms at the Waste Isolation Pilot Plant (WIPP) contain waste and gas, and their porosity evolves over time. This report presents several improvements to the disposal room porosity model and presents new porosity predictions for use in future WIPP Performance Assessment activities. The improvements pertain to three sub-models: the geomechanical model, the waste compaction model, and the gas pressurization model. The impacts of each major improvement were quantified and the new porosity predictions were shown to be both mesh and domain size converged. Also, sensitivity studies on the disposal room horizon, clay seam friction coefficients, and homogenized waste representation were performed to support assumptions in the disposal room porosity model. To compare the legacy and new porosity predictions, the simulation results were plotted as a response surface, where gas pressure and time are inputs and porosity is the output. The new porosity response surface is insensitive to pressures beneath lithostatic pressure and highly sensitive to pressures above lithostatic pressure. The legacy porosity response surface, on the other hand, has moderate porosity gradients over all pressures. The new porosity response surface has a stronger scientific foundation than the legacy surface and may now be used for Compliance Decision Analyses.
A credible simulation of disposal room porosity at the Waste Isolation Pilot Plant (WIPP) requires a tenable compaction model for the 55-gallon waste containers within the room. A review of the legacy waste material model, however, revealed several out-of-date and untested assumptions that could affect the model’s compaction behavior. For example, the legacy model predicted non-physical tensile out-of-plane stresses under plane strain compression. (Plane strain compression is similar to waste compaction in the middle of a long drift.) Consequently, a suite of new compaction experiments were performed on containers filled with surrogate, non-degraded, waste. The new experiments involved uniaxial, triaxial, and hydrostatic compaction tests on quarter-scale and full-scale containers. Special effort was made to measure the volume strain during uniaxial and triaxial tests, so that the lateral strain could be inferred from the axial and volume strain. These experimental measurements were then used to calibrate a pressure dependent, viscoplastic, constitutive model for the homogenized compaction behavior of the waste containers. This new waste material model’s predictions agreed far better with the experimental measurements than the legacy model’s predictions, especially under triaxial and hydrostatic conditions. Under plane strain compression, the new model predicted reasonable compressive out-of-plane stresses, instead of tensile stresses. Moreover, the new model’s plane strain behavior was substantially weaker for the same strain, yet substantially stronger for the same porosity, than the legacy model’s behavior. Although room for improvement exists, the new model appears ready for prudent engineering use.
Criticality Control Overpack (CCO) containers are being considered for the disposal of defense-related nuclear waste at the Waste Isolation Pilot Plant (WIPP). At WIPP, these containers would be placed in underground disposal rooms, which will naturally close and compact the containers closer to one another over several centuries. This report details simulations to predict the final container configuration as an input to nuclear criticality assessments. Each container was discretely modeled, including the plywood and stainless steel pipe inside the 55-gallon drum, in order to capture its complex mechanical behavior. Although these high-fidelity simulations were computationally intensive, several different material models were considered in an attempt to reasonably bound the horizontal and vertical compaction percentages. When exceptionally strong materials were used for the containers, the horizontal and vertical closure respectively stabilized at 43:9 % and 93:7 %. At the other extreme, when the containers completely degraded and the clay seams between the salt layers were glued, the horizontal and vertical closure reached respective final values of 48:6 % and 100 %.
Accurate and efficient constitutive modeling remains a cornerstone issue for solid mechanics analysis. Over the years, the LAMÉ advanced material model library has grown to address this challenge by implementing models capable of describing material systems spanning soft polymers to stiff ceramics including both isotropic and anisotropic responses. Inelastic behaviors including (visco)plasticity, damage, and fracture have all incorporated for use in various analyses. This multitude of options and flexibility, however, comes at the cost of many capabilities, features, and responses and the ensuing complexity in the resulting implementation. Therefore, to enhance confidence and enable the utilization of the LAMÉ library in application, this effort seeks to document and verify the various models in the LAMÉ library. Specifically, the broader strategy, organization, and interface of the library itself is first presented. The physical theory, numerical implementation, and user guide for a large set of models is then discussed. Importantly, a number of verification tests are performed with each model to not only have confidence in the model itself but also highlight some important response characteristics and features that may be of interest to end-users. Finally, in looking ahead to the future, approaches to add material models to this library and further expand the capabilities are presented.
This report summarizes the international collaborations conducted by Sandia funded by the US Department of Energy Office (DOE) of Nuclear Energy Spent Fuel and Waste Science & Technology (SFWST) as part of the Sandia National Laboratories Salt R&D and Salt International work packages. This report satisfies the level-three milestone M3SF-22SN010303063. Several stand-alone sections make up this summary report, each completed by the participants. The sections discuss international collaborations on geomechanical benchmarking exercises (WEIMOS), granular salt reconsolidation (KOMPASS), engineered barriers (RANGERS), numerical model comparison (DECOVALEX) and an NEA Salt Club working group on the development of scenarios as part of the performance assessment development process. Finally, we summarize events related to the US/German Workshop on Repository Research, Design and Operations. The work summarized in this annual update has occurred during the COVID-19 pandemic, and little international or domestic travel has occurred. Most of the collaborations have been conducted via email or as virtual meetings, but a slow return to travel and in-person meetings has begun.
Accurate and efficient constitutive modeling remains a cornerstone issue for solid mechanics analysis. Over the years, the LAMÉ advanced material model library has grown to address this challenge by implementing models capable of describing material systems spanning soft polymers to stiff ceramics including both isotropic and anisotropic responses. Inelastic behaviors including (visco)plasticity, damage, and fracture have all incorporated for use in various analyses. This multitude of options and flexibility, however, comes at the cost of many capabilities, features, and responses and the ensuing complexity in the resulting implementation. Therefore, to enhance confidence and enable the utilization of the LAMÉ library in application, this effort seeks to document and verify the various models in the LAMÉ library. Specifically, the broader strategy, organization, and interface of the library itself is first presented. The physical theory, numerical implementation, and user guide for a large set of models is then discussed. Importantly, a number of verification tests are performed with each model to not only have confidence in the model itself but also highlight some important response characteristics and features that may be of interest to end-users. Finally, in looking ahead to the future, approaches to add material models to this library and further expand the capabilities are presented.
Accurate and efficient constitutive modeling remains a cornerstone issue for solid mechanics analysis. Over the years, the LAMÉ advanced material model library has grown to address this challenge by implementing models capable of describing material systems spanning soft polymers to stiff ceramics including both isotropic and anisotropic responses. Inelastic behaviors including (visco)plasticity, damage, and fracture have all incorporated for use in various analyses. This multitude of options and flexibility, however, comes at the cost of many capabilities, features, and responses and the ensuing complexity in the resulting implementation. Therefore, to enhance confidence and enable the utilization of the LAMÉ library in application, this effort seeks to document and verify the various models in the LAMÉ library. Specifically, the broader strategy, organization, and interface of the library itself is first presented. The physical theory, numerical implementation, and user guide for a large set of models is then discussed. Importantly, a number of verification tests are performed with each model to not only have confidence in the model itself but also highlight some important response characteristics and features that may be of interest to end-users. Finally, in looking ahead to the future, approaches to add material models to this library and further expand the capabilities are presented.
Accurate predictions of room closure are important for hazardous waste repositories in rock salt formations, such as the Waste Isolation Pilot Plant (WIPP). When Munson and co-workers simulated several room closure experiments conducted at the WIPP during the 1980's and 1990's, their simulated closure curves closely agreed with the closure measurements. A careful review of their work, however, raised concerns and prompted the reinvestigation in this paper. To begin the reinvestigation, Munson's legacy Room D closure simulation was reasonably recreated in a current-day finite element code. Next, special care was taken to obtain numerically converged results, re-introduce the anhydrite strata intermittently ignored by Munson, and calibrate the Munson–Dawson (M–D) constitutive model for salt as much as possible from laboratory test measurements. When this new model was used to simulate Room D's closure, it under-predicted the horizontal and vertical closure rates by 2.34× and 3.10×, respectively, at 5.7 years after room excavation. As a result, the M–D model was extended to capture the newly established creep behavior at low equivalent stresses (<8MPa) and replace the Tresca with the Hosford equivalent stress. Simulations using the new M–D model over-predicted the horizontal closure rate by 1.15× and under-predicted the vertical closure rate by 1.08× at 5.7 years, averaged over three room closure experiments. Although further improvements could be made, the new model has a stronger scientific foundation than Munson's legacy model and appears ready for careful engineering use.
This paper presents the formulation, implementation, and demonstration of a new, largely phenomenological, model for the damage-free (micro-crack-free) thermomechanical behavior of rock salt. Unlike most salt constitutive models, the new model includes both drag stress (isotropic) and back stress (kinematic) hardening. The implementation utilizes a semi-implicit scheme and a fall-back fully-implicit scheme to numerically integrate the model's differential equations. Particular attention was paid to the initial guesses for the fully-implicit scheme. Of the four guesses investigated, an initial guess that interpolated between the previous converged state and the fully saturated hardening state had the best performance. The numerical implementation was then used in simulations that highlighted the difference between drag stress hardening versus combined drag and back stress hardening. Simulations of multi-stage constant stress tests showed that only combined hardening could qualitatively represent reverse (inverse transient) creep, as well as the large transient strains experimentally observed upon switching from axisymmetric compression to axisymmetric extension. Simulations of a gas storage cavern subjected to high and low gas pressure cycles showed that combined hardening led to substantially greater volume loss over time than drag stress hardening alone.
Based on the rationale presented, nuclear criticality is improbable after salt creep causes compaction of criticality control overpacks (CCOs) disposed at the Waste Isolation Pilot Plant, an operating repository in bedded salt for the disposal of transuranic (TRU) waste from atomic energy defense activities. For most TRU waste, the possibility of post-closure criticality is exceedingly small either because the salt neutronically isolates TRU waste canisters or because closure of a disposal room from salt creep does not sufficiently compact the low mass of fissile material. The criticality potential has been updated here because of the introduction of CCOs, which may dispose up to 380 fissile gram equivalent plutonium-239 in each container. The criticality potential is evaluated through high-fidelity geomechanical modeling of a disposal room filled with CCOs during two representative conditions: (1) large salt block fall, and (2) gradual salt compaction (without brine seepage and subsequent gas generation to permit maximum room closure). Geomechanical models of rock fall demonstrate three tiers of CCOs are not greatly disrupted. Geomechanical models of gradual room closure from salt creep predict irregular arrays of closely packed CCOs after 1000 years, when room closure has asymptotically approached maximum compaction. Criticality models of spheres and cylinders of 380 fissile gram equivalent of plutonium (as oxide) at the predicted irregular spacing demonstrate that an array of CCOs is not critical when surrounded by salt and magnesium oxide, provided the amount of hydrogenous material shipped in the CCO (usually water and plastics) is controlled or boron carbide (a neutron poison) is mixed with the fissile contents.
Accurate and efficient constitutive modeling remains a cornerstone issue for solid mechanics analysis. Over the years, the LAMÉ advanced material model library has grown to address this challenge by implementing models capable of describing material systems spanning soft polymers to stiff ceramics including both isotropic and anisotropic responses. Inelastic behaviors including (visco)plasticity, damage, and fracture have all incorporated for use in various analyses. This multitude of options and flexibility, however, comes at the cost of many capabilities, features, and responses and the ensuing complexity in the resulting implementation. Therefore, to enhance confidence and enable the utilization of the LAMÉ library in application, this effort seeks to document and verify the various models in the LAMÉ library. Specifically, the broader strategy, organization, and interface of the library itself is first presented. The physical theory, numerical implementation, and user guide for a large set of models is then discussed. Importantly, a number of verification tests are performed with each model to not only have confidence in the model itself but also highlight some important response characteristics and features that may be of interest to end-users. Finally, in looking ahead to the future, approaches to add material models to this library and further expand the capabilities are presented.
This report summarizes the international collaboration work conducted by Sandia and funded by the US Department of Energy Office (DOE) of Nuclear Energy Spent Fuel and Waste Science & Technology (SFWST) as part of the Sandia National Laboratories Salt R&D and Salt International work packages. This report satisfies the level-three milestone M3SF-20SN010303062. Several stand-alone sections make up this summary report, each completed by the participants. The sections discuss international collaborations on geomechanical benchmarking exercises (WEIMOS), granular salt reconsolidation (KOMPASS), engineered barriers (RANGERS), and model comparison (DECOVALEX). Lastly, the report summarizes a newly developed working group on the development of scenarios as part of the performance assessment development process, and the activities related to the Nuclear Energy Agency (NEA) Salt club and the US/German Workshop on Repository Research, Design and Operations.
Experimental measurements of room closure in salt repositories are valuable for understanding the evolution of the underground and for validating geomechanical models. Room closure was measured during a number of experiments at the Waste Isolation Pilot Plant (WIPP) during the 1980's and 1990's. Most rooms were excavated using a multi-pass mining sequence, where each pass necessarily destroyed some of the mining sequence closure measurement points. These destroyed points were promptly reinstalled to capture the closure after the mining pass. After the room was complete, the mining sequence closure measurement stations were supplemented with remotely read closure measurement stations. Although many aspects of these experiments were thoroughly documented, the digital copies of the closure data were inadvertently destroyed, the non-trivial process of zeroing and shifting the raw closure measurements after each mining pass was not precisely described, the various closure measurements within a given room were not directly compared on the same plot, and the measurements were collected for several years longer than previously reported. Consequently, the hand-written mining sequence closure measurements for Rooms D, B, G, and Q were located in the WIPP archives, digitized, and reanalyzed for this report. The process of reconstructing the mining sequence closure histories was documented in detail and the raw data can be found in the appendices. Within the mid-section of a given room, the reconstructed closure histories were largely consistent with other mining sequence and remotely read closure histories, which builds confidence in the experiments and suggests that plane strain is an appropriate modeling assumption. The reconstructed closure histories were also reasonably consistent with previously published results, except in one notable case: the reconstructed Room Q closure histories 30 days after excavation were about 45 % less than the corresponding closures reported in Munson's 1997 capstone paper.
Accurate and efficient constitutive modeling remains a cornerstone issue for solid mechanics analysis. Over the years, the LAMÉ advanced material model library has grown to address this challenge by implementing models capable of describing material systems spanning soft polymers to stiff ceramics including both isotropic and anisotropic responses. Inelastic behaviors including (visco)plasticity, damage, and fracture have all incorporated for use in various analyses. This multitude of options and flexibility, however, comes at the cost of many capabilities, features, and responses and the ensuing complexity in the resulting implementation. Therefore, to enhance confidence and enable the utilization of the LAMÉ library in application, this effort seeks to document and verify the various models in the LAMÉ library. Specifically, the broader strategy, organization, and interface of the library itself is first presented. The physical theory, numerical implementation, and user guide for a large set of models is then discussed. Importantly, a number of verification tests are performed with each model to not only have confidence in the model itself but also highlight some important response characteristics and features that may be of interest to end-users. Finally, in looking ahead to the future, approaches to add material models to this library and further expand the capabilities are presented
In Germany, rock salt formations are a possible host rock taken into account for the safe disposal of heat-emitting radioactive waste. With respect to crushed salt will be used in the repository for backfilling of open cavitied (using dry material). With time, the crushed salt will be compacted by the convergence of the host rock and reaches porosities comparable with the rock salts. The compaction behaviour of crushed salt has been investigated within the last 40 years, however, its behaviour at low porosities and the resulting low permeabilities becomes relevant with the introduction of the approach of the containment providing rock zone. In the current state, the database and process understanding have some important gaps in knowledge referring the material behaviour, existing laboratory and numerical models, especially for the porosity range. The objective of this project was the development of methods and strategies for the reduction of deficits in the prediction of crushed salt compaction leading to an improvement of the prognosis quality. It includes the development of experimental methods for determining crushed salt properties in the range of low porosities, the enhancement of process understanding and the investigation and development of existing numerical models.
Accurate and efficient constitutive modeling remains a cornerstone issue for solid mechanics analysis. Over the years, the LAMÉ advanced material model library has grown to address this challenge by implementing models capable of describing material systems spanning soft polymers to stiff ceramics including both isotropic and anisotropic responses. Inelastic behaviors including (visco)plasticity, damage, and fracture have all incorporated for use in various analyses. This multitude of options and flexibility, however, comes at the cost of many capabilities, features, and responses and the ensuing complexity in the resulting implementation. Therefore, to enhance confidence and enable the utilization of the LAMÉ library in application, this effort seeks to document and verify the various models in the LAMÉ library. Specifically, the broader strategy, organization, and interface of the library itself is first presented. The physical theory, numerical implementation, and user guide for a large set of models is then discussed. Importantly, a number of verification tests are performed with each model to not only have confidence in the model itself but also highlight some important response characteristics and features that may be of interest to end-users. Finally, in looking ahead to the future, approaches to add material models to this library and further expand the capabilities are presented.
Reedlunn, Benjamin; Lepage, William S.; Daly, Samantha H.; Shaw, John A.
The tensile response of superelastic shape memory alloys (SMAs) has been widely studied, but detailed experimental studies under multi-axial loading are relatively rare. In Part I, we present the isothermal responses of commercially-available superelastic NiTi tubes for a series of proportional stretch-twist controlled histories, spanning pure tension to simple torsion to pure compression. These axial-shear responses are used to quantify the onset and saturation during forward (loading) and reverse (unloading) stress-induced transformations for the first time. Each of the four transformation surfaces is well-captured by a smooth (three-parameter) ellipse in both strain and stress space. A simple Gibbs free energy model is presented to show how the driving force for phase transformation is approximately constant across all proportional strain paths and how the stress and strain transformation surfaces are conjugate to one another. In addition, transformation kinetics and surface strain morphologies are characterized by stereo digital image correlation (DIC). Under extension at low amounts of twist, stress-induced transformation involves strain localization in helical bands that evolve into axial propagation of ring-like transformation fronts with fine criss-crossing fingers (similar to those seen by Q. P. Sun and co-workers in pure extension). However, at large amounts of twist, including simple torsion and pure torsion, we report a new transformation morphology, involving strain localization along nearly longitudinal bands in the tube. The sequel (Part II) will address the response to non-proportional stretch-twist paths. Together, these detailed multi-axial results advance the scientific understanding of superelasticity and inform efforts to develop high-fidelity SMA constitutive models and simulation tools.
This report is a summary of the international collaboration work conducted by Sandia and funded by the US Department of Energy Office (DOE) of Nuclear Energy Spent Fuel and Waste Science & Technology (SFWST) as part of the Sandia National Laboratories Salt R&D and Salt International work packages. This report satisfies milestone level-three milestone M3SF-205N010303062. Several stand-alone sections make up this summary report, each completed by the participants. The first two sections discuss international collaborations on geomechanical benchmarking exercises (WEIMOS), granular salt reconsolidation (KOMPASS), engineered barriers (RANGERS), and documentation of Features, Events, and Processes (FEPs).
Room ceilings and walls at the Waste Isolation Pilot Plant tend to collapse over time, causing rubble piles on floors of empty rooms. The surrounding rock formation will gradually compact these rubble piles until they eventually become solid salt, but the length of time for a rubble pile to reach a certain porosity and permeability is unknown. This paper details the initial model development to predict the porosity and fluid flow network of a closing empty room. Conventional geomechanical numerical methods would struggle to model empty room collapse and rubble pile consolidation, so three different meshless methods, the Immersed Isogeometric Analysis (IGA) Meshfree Method, Reproducing Kernel Particle Method (RKPM), and Conformal Reproducing Kernel (CRK) method, were assessed. First, each meshless method simulated gradual room closure, without ceiling or wall collapse. All methods produced equivalent predictions to a finite element method reference solution, with comparable computational speed. Second, the Immersed IGA Meshfree method and RKPM simulated two-dimensional empty room collapse and rubble pile consolidation. Both methods successfully simulated large viscoplastic deformations, fracture, and rubble pile rearrangement to produce qualitatively realistic results. Finally, the meshless simulation results helped identify a mechanism for empty room closure that had been previously overlooked.
The Waste Isolation Pilot Plant (WIPP) is a geologic repository for defense-related nuclear waste. If left undisturbed, the virtually impermeable rock salt surrounding the repository will isolate the nuclear waste from the biosphere. If humans accidentally intrude into the repository in the future, then the likelihood of a radionuclide release to the biosphere will depend significantly on the porosity and permeability of the repository itself. Room ceilings and walls at the WIPP tend to collapse over time, causing rubble piles to form on floors of empty rooms. The surrounding rock formation will gradually compact these rubble piles until they eventually become solid salt, but the length of time for a rubble pile to reach a certain porosity and permeability is unknown. This report details the first efforts to build models to predict the porosity and permeability evolution of an empty room as it closes. Conventional geomechanical numerical methods would struggle to model empty room collapse and rubble pile consolidation, so three different meshless methods, the Immersed Isogeometric Analysis Meshfree, Reproducing Kernel Particle Method (RKPM), and the Conformal Reproducing Kernel method, were assessed. First, the meshless methods and the finite element method each simulated gradual room closure, without ceiling or wall collapse. All three methods produced equivalent room closure predictions with comparable computational speed. Second, the Immersed Isogeometric Analysis Meshfree method and RKPM simulated two-dimensional empty room collapse and rubble pile consolidation. Both methods successfully simulated large viscoplastic deformations, fracture, and rubble pile rearrangement to produce qualitatively realistic results. In addition to geomechanical simulations, the flow channels in damaged salt and crushed salt were measured using micro-computed tomography, and input into a computational fluid dynamics simulation to predict the salt's permeability. Although room for improvement exists, the current simulation approaches appear promising.
Bedded salt contains interfaces between the host salt and other in situ materials such as clay seams, or different impurities such as anhydrite or polyhalite in contact with the salt. These inhomogeneities are thought to have first-order effects on the closure of nearby drifts and potential roof collapses. Despite their importance, characterizations of the peak shear strength and residual shear strength of interfaces in salt are extremely rare in the published literature. This paper presents results from laboratory experiments designed to measure the mechanical behavior of a bedding interface or clay seam as it is sheared. The series of laboratory direct shear tests reported in this paper were performed on several samples of materials from the Permian Basin in New Mexico. These tests were conducted at numerous normal and shear loads up to the expected in situ pre-mining stress conditions. Tests were performed on samples with a halite/clay contact, a halite/anhydrite contact, a halite/polyhalite contact, and on plain salt samples without an interface for comparison. Intact shear strength values were determined for all of the test samples along with residual values for the majority of the tests. The results indicated only a minor variation in shear strength, at a given normal stress, across all samples. This result was surprising because sliding along clay seams is regularly observed in the underground, suggesting the clay seam interfaces should be weaker than plain salt. Post-test inspections of these samples noted that salt crystals were intrinsic to the structure of the seam, which probably increased the shear strength as compared to a typical clay seam.
The Waste Isolation Pilot Plant (WIPP) is an operating geologic repository in southeastern New Mexico for transuranic (TRU) waste from nuclear defense activities. Past nuclear criticality concerns have generally been low at the WIPP due to the low initial concentration of fissile material and the natural tendency of fissile solute to disperse during fluid transport in porous media (Rechard et al. 2000). On the other hand, the list of acceptable WIPP waste types has expanded over the years to include Criticality Control Overpack (CCO) containers and Pipe Overpack (POP) containers. Containers bound for WIPP are bundled together in hexagon shaped 7-packs (six containers surround one container in the center). Two 7-packs are often combined into a TRUPACT-II package for a total of 14 containers. Most TRUPACT-II packages are restricted to a maximum fissile mass equivalent to plutonium (FMEP) between 0.1 and 0.38 kg, but a CCO TRUPACT-II package and a POP TRUPACT-II package are respectively permitted to have 5.32 kg and 2.80 kg FMEP (see Section 3 of US DOE (2013)). Consequently, CCO container criticality after emplacement at the WIPP was evaluated in Saylor and Scaglione (2018), and Oak Ridge National Laboratories is currently at work on POP container criticality analyses.
This report is a summary of the international collaboration and laboratory work funded by the US Department of Energy Office (DOE) of Nuclear Energy Spent Fuel and Waste Science & Technology (SFWST) as part of the Sandia National Laboratories Salt R&D work package. This report satisfies milestone level-four milestone M4SF-19SNO10303064. Several stand-alone sections make up this summary report, each completed by the participants. The first two sections discuss international collaborations on geomechanical benchmarking exercises (WEIMOS), granular salt reconsolidation (KOMPASS), engineered barriers (RANGERS), and documentation of Features, Events, and Processes (FEPs).
The mechanical response of additively manufactured (AM) stainless steel 304L has been investigated across a broad range of loading conditions, covering 11 decades of strain rate, and compared with the behaviors of traditional ingot-derived (wrought) material. In general, the AM material exhibits a greater strength and reduced ductility compared with the baseline wrought form. These differences are consistently found from quasi-static and high strain rate tests. A detailed investigation of the microstructure, the defect structure, the phase, and the composition of both forms reveals differences that may contribute to the differing mechanical behaviors. Compared with the baseline wrought material, dense AM stainless steel 304L has a more complex grain structure with substantial sub-structure, a fine dispersion of ferrite, increased dislocation density, oxide dispersions and larger amounts of nitrogen. In-situ neutron diffraction studies conducted during quasi-static loading suggest that the increased strength of AM material is due to its initially greater dislocation density. The flow strength of both forms is correlated with dislocation density through a square root dependence akin to a Taylor-like relationship. Neutron diffraction measurements of lattice strains also correlate with a crystal plasticity finite element simulations of the tensile test. Other simulations predict a significant degree of elastic and plastic anisotropy due to crystallographic texture. Hopkinson tests at higher strain rates $\dot{ε}$ = 500 and 2500 s-1 ) also show a greater strength for AM stainless steel 304L; although, the differences compared with wrought are reduced at higher strain rates. Gas gun impact tests, including reverse ballistic, forward ballistic and spall tests, consistently reveal a larger dynamic strength in the AM material. The Hugoniot Elastic Limit (HEL) of AM SS 304L exceeds that of wrought material although considerable variability is observed with the AM material. Forward ballistic testing demonstrates spall strengths of AM material (3.27 -- 3.91 GPa) that exceed that of the wrought material (2.63 -- 2.88 GPa). The Hugoniot equation-of-state for AM samples matches archived data for this metal alloy.
Bedded salt contains interfaces between the host salt and other in situ materials such as clay seams, or different materials such as anhydrite or polyhalite in contact with the salt. These inhomogeneities are thought to have first-order effects on the closure of nearby drifts and potential roof collapses. Despite their importance, characterizations of the peak shear strength and residual shear strength of interfaces in salt are extremely rare in the published literature. This paper presents results from laboratory experiments designed to measure the mechanical behavior of a bedding interface or clay seam as it is sheared. The series of laboratory direct shear tests reported in this paper were performed on several samples of materials from the Permian Basin in New Mexico. These tests were conducted at several normal and shear loads up to the expected in situ pre-mining stress conditions. Tests were performed on samples with a halite/clay contact, a halite/anhydrite contact, a halite/polyhalite contact, and on plain salt samples without an interface for comparison. Intact shear strength values were determined for all of the test samples along with residual values for the majority of the tests. The test results indicated only a minor variation in shear strength, at a given normal stress, across all samples. This result was surprising because sliding along clay seams is regularly observed in the underground, suggesting the clay seam interfaces should be weaker than plain salt. Post-test inspections of these samples noted that salt crystals were intrinsic to the structure of the seam, which probably increased the shear strength as compared to a more typical clay seam.
The Munson-Dawson (MD) constitutive model was originally developed in the 1980's to predict the thermomechanical behavior of rock salt. Since then, it has been used to simulate the evolution of the underground in nuclear waste repositories, mines, and storage caverns for gases and liquids. This report covers three enhancements to the MD model. (1) New transient and steady-state rate terms were added to capture salt's creep behavior at low equivalent stresses (below about 8 MPa). These new terms were calibrated against a series of triaxial compression creep experiments on salt from the Waste Isolation Pilot Plant. (2) The equivalent stress measure was changed from the Tresca stress to the Hosford stress. By varying a single exponent, the Hosford stress can reduce to the Tresca stress, the von Mises stress, or a range of behaviors in-between. This exponent was calibrated against true triaxial compression experiments on salt hollow cylinders. (3) The MD model's numerical implementation was overhauled, adding a line search algorithm to the implicit solution scheme. The new implementation was verified against analytical solutions, and benchmarked against a pre-existing implementation on a room closure simulation. The new implementation pre- dicted virtually identical room closure, yet sped up the simulation by 16x . (The source code of the new implementation is included in an appendix of this report.)
This project targeted a full-field understanding of the conversion of plastic work into heat using advanced diagnostics (digital image correlation, DIC, combined with infrared, IR, imaging). This understanding will act as a catalyst for reformulating the prevalent simplistic model, which will ultimately transform Sandia's ability to design for and predict thermomechanical behavior, impacting national security applications including nuclear weapon assessments of accident scenarios. Tensile 304L stainless steel dogbones are pulled in tension at quasi-static rates until failure and full-field deformation and temperature data are captured, while accounting for thermal losses. The IR temperature fields are mapped onto the DIC coordinate system (Lagrangian formulation). The resultant fields are used to calculate the Taylor-Quinney coefficient, β, at two strain rates rates (0.002 s-1 and 0.08 s-1) and two temperatures (room temperature, RT, and 250°C).
Many existing shape memory alloy (SMA) devices consist of slender beams and frames. To better understand SMA beam behavior, we experimentally examined the isothermal, room temperature response of superelastic NiTi rods and tubes, of similar outer diameters, subjected to four different modes of loading. Pure tension, pure compression, and pure bending experiments were first performed to establish and compare the baseline uniaxial and bending behaviors of rods and tubes. Column buckling experiments were then performed on rod and tube columns of several slenderness ratios to investigate their mechanical responses, phase transformation kinetics under combined uniaxial and bending deformation, and the interaction between material and structural instabilities. In all experiments, stereo digital image correlation measured local displacement fields in order to capture phenomena such as strain localization and propagating phase boundaries. Superelastic mechanical behavior and the nature of stress-induced phase transformation were found to be strongly affected by specimen geometry and the deformation mode. Under uniaxial tension, both the rod and tube had well-defined loading and unloading plateaus in their superelastic responses, during which stress-induced phase transformation propagated along the length of the specimen in the form of a high/low strain front. Due to the dependence of strain localization on kinematic compatibility, the high/low strain front morphologies differed between the rod and tube: for the rod, the high/low strain front consisted of a diffuse “neck”, while the high/low strain front in the tube consisted of distinct, criss-crossing “fingers.” During uniaxial compression, both cross-sectional forms exhibited higher transformation stresses and smaller transformation strains than uniaxial tension, highlighting the now well-known tension-compression asymmetry of SMAs. Additionally, phase transformation localization and propagation were absent under compressive loading. During pure bending, the moment-curvature response of both forms exhibited plateaus and strain localization during forward and reverse transformations. Rod specimens developed localized, high-curvature regions that propagated along the specimen axis and caused shear strain near the high/low curvature interface; whereas, the tube specimens exhibited finger/wedge-like high strain regions over the tensile side of the tube which caused nonlinear strain profiles through the thickness of the specimen that did not propagate. It was therefore found that classical beam theory assumptions did not hold in the presence of phase transformation localization (although, the assumptions did hold on average for the tube). During column buckling, the structures were loaded into the post-buckling regime yet recovered nearly-straight forms upon unloading. Strain localization was observed only for high aspect ratio (slender) tubes, but the mechanical responses were similar to that of rods of the same slenderness ratio. Also, an interesting “unbuckling” phenomenon was discovered in certain low aspect ratio (stout) columns, where late post-buckling straightening was observed despite continuous monotonic loading. Thus, these behaviors are some of the challenging phenomena which must be captured when developing SMA constitutive models and executing structural simulations.
In situ neutron diffraction measurements were completed for this study during tensile and compressive deformation of stainless steel 304L additively manufactured (AM) using a high power directed energy deposition process. Traditionally produced wrought 304L material was also studied for comparison. The AM material exhibited roughly 200 MPa higher flow stress relative to the wrought material. Crystallite size, crystallographic texture, dislocation density, and lattice strains were all characterized to understand the differences in the macroscopic mechanical behavior. The AM material’s initial dislocation density was about 10 times that of the wrought material, and the flow strength of both materials obeyed the Taylor equation, indicating that the AM material’s increased yield strength was primarily due to greater dislocation density. Finally, a ~50 MPa flow strength tension/compression asymmetry was observed in the AM material, and several potential causes were examined.
This report is a summary of the international collaboration and laboratory work funded by the US Department of Energy Office of Nuclear Energy Spent Fuel and Waste Science & Technology (SFWST) as part of the Sandia National Laboratories Salt R&D work package. This report satisfies milestone levelfour milestone M4SF-17SN010303014. Several stand-alone sections make up this summary report, each completed by the participants. The first two sections discuss international collaborations on geomechanical benchmarking exercises (WEIMOS) and bedded salt investigations (KOSINA), while the last three sections discuss laboratory work conducted on brucite solubility in brine, dissolution of borosilicate glass into brine, and partitioning of fission products into salt phases.
Room D was an in-situ, isothermal, underground experiment conducted at theWaste Isolation Pilot Plant between 1984 and 1991. The room was carefully instrumented to measure the horizontal and vertical closure immediately upon excavation and for several years thereafter. Early finite element simulations of salt creep around Room D under predicted the vertical closure by 4.5×, causing investigators to explore a series of changes to the way Room D was modeled. Discrepancies between simulations and measurements were resolved through a series of adjustments to model parameters, which were openly acknowledged in published reports. Interest in Room D has been rekindled recently by the U.S./German Joint Project III and Project WEIMOS, which seek to improve the predictions of rock salt constitutive models. Joint Project participants calibrate their models solely against laboratory tests, and benchmark the models against underground experiments, such as room D. This report describes updating legacy Room D simulations to today’s computational standards by rectifying several numerical issues. Subsequently, the constitutive model used in previous modeling is recalibrated two different ways against a suite of new laboratory creep experiments on salt extracted from the repository horizon of the Waste Isolation Pilot Plant. Simulations with the new, laboratory-based, calibrations under predict Room D vertical closure by 3.1×. A list of potential improvements is discussed.
Room D was an in-situ, isothermal, underground experiment conducted at the Waste Isolation Pilot Plant between 1984 and 1991. The room was carefully instrumented to measure the horizontal and vertical closure immediately upon excavation and for several years thereafter. Early finite element simulations of salt creep around Room D under-predicted the vertical closure by 4.5×, causing investigators to explore a series of changes to the way Room D was modeled. Discrepancies between simulations and measurements were resolved through a series of adjustments to model parameters, which were openly acknowledged in published reports. Interest in Room D has been rekindled recently by the U.S./German Joint Project III and Project WEIMOS, which seek to improve the predictions of rock salt constitutive models. Joint Project participants calibrate their models solely against laboratory tests, and benchmark the models against underground experiments, such as room D. This report describes updating legacy Room D simulations to today’s computational standards by rectifying several numerical issues. Subsequently, the constitutive model used in previous modeling is recalibrated two different ways against a suite of new laboratory creep experiments on salt extracted from the repository horizon of the Waste Isolation Pilot Plant. Simulations with the new, laboratory-based, calibrations under-predict Room D vertical closure by 3.1×. A list of potential improvements is discussed.
This report presents an experimental study motivated by results obtained during the 2013 Sandia Fracture Challenge. The challenge involved A286 steel, shear-dominated compression specimens whose load-deflection response contained a load maximum fol- lowed by significant displacement under decreasing load, ending with a catastrophic fracture. Blind numerical simulations deviated from the experiments well before the maximum load and did not predict the failure displacement. A series of new tests were conducted on specimens machined from the original A286 steel stock to learn more about the deformation and failure processes in the specimen and potentially improve future numerical simulations. The study consisted of several uniaxial tension tests to explore anisotropy in the material, and a set of new tests on the compression speci- men. In some compression specimen tests, stereo digital image correlation (DIC) was used to measure the surface strain fields local to the region of interest. In others, the compression specimen was loaded to a given displacement prior to failure, unloaded, sectioned, and imaged under the microscope to determine when material damage first appeared and how it spread. The experiments brought the following observations to light. The tensile tests revealed that the plastic response of the material is anisotropic. DIC during the shear- dominated compression tests showed that all three in-plane surface strain components had maxima in the order of 50% at the maximum load. Sectioning of the specimens revealed no signs of material damage at the point where simulations deviated from the experiments. Cracks and other damage did start to form approximately when the max- imum load was reached, and they grew as the load decreased, eventually culminating in catastrophic failure of the specimens. In addition to the steel specimens, a similar study was carried out for aluminum 7075-T651 specimens. These specimens achieved much lower loads and displacements, and failure occurred very close to the maximum in the load-deflection response. No material damage was observed in these specimens, even when failure was imminent. In the future, we plan to use these experimental results to improve numerical simu- lations of the A286 steel experiments, and to improve plasticity and failure models for the Al 7075 stock. The ultimate goal of our efforts is to increase our confidence in the results of numerical simulations of elastic-plastic structural behavior and failure.
This report details a work in progress. We have attempted to calibrate and validate a Von Mises plasticity model with the Johnson-Cook failure criterion ( Johnson & Cook , 1985 ) against a set of experiments on various specimens of Al 6061-T651. As will be shown, the effort was not successful, despite considerable attention to detail. When the model was com- pared against axial-torsion experiments on tubes, it over predicted failure by 3 x in tension, and never predicted failure in torsion, even when the tube was twisted by 4 x further than the experiment. While this result is unfortunate, it is not surprising. Ductile failure is not well understood. In future work, we will explore whether more sophisticated material mod- els of plasticity and failure will improve the predictions. Selecting the appropriate advanced material model and interpreting the results of said model are not trivial exercises, so it is worthwhile to fully investigate the behavior of a simple plasticity model before moving on to an anisotropic yield surface or a similarly complicated model.
Future remote sensing applications will require higher resolution and therefore higher data rates (up to perhaps 100 gigabits per second) while achieving lower mass and cost. A current limitation to the design space is high speed high bandwidth data does not cross movable gimbals because of cabling issues. This requires the detectors to be off gimbal. The ability to get data across the gimbal would open up efficiencies in designs where the detectors and the electronics can be placed anywhere on the system. Fiber optic cables provide light weight high speed high bandwidth connections. Current options are limited to 20,000 cycles as opposed to the 1,000,000 cycles needed for future space based applications. To extend this to the million+ regime, requires a thorough understanding of the failure mechanisms and the materials, proper selection of materials (e.g., glass and jacket material) allowable geometry changes to the cable, radiation hardness, etc.
The objective of this work was to describe several of the ductile failure criteria com- monly used to solve practical problems. The following failure models were considered: equivalent plastic strain, equivalent plastic strain in tension, maximum shear, Mohr- Coulomb, Wellman's tearing parameter, Johnson-Cook and BCJ MEM. The document presents the main characteristics of each failure model as well as sample failure predic- tions for simple proportional loading stress histories in three dimensions and in plane stress. Plasticity calculations prior to failure were conducted with a simple, linear hardening, J2 plasticity model. The resulting failure envelopes were plotted in prin- cipal stress space and plastic strain space, where the dependence on stress triaxiality and Lode angle are clearly visible. This information may help analysts select a ductile fracture model for a practical problem and help interpret analysis results.
