Accurate prediction of ductile behavior of structural alloys up to and including failure is essential in component or system failure assessment, which is necessary for nuclear weapons alteration and life extensions programs of Sandia National Laboratories. Modeling such behavior requires computational capabilities to robustly capture strong nonlinearities (geometric and material), rate- dependent and temperature-dependent properties, and ductile failure mechanisms. This study's objective is to validate numerical simulations of a high-deformation crush of a stainless steel can. The process consists of identifying a suitable can geometry and loading conditions, conducting the laboratory testing, developing a high-quality Sierra/SM simulation, and then drawing comparisons between model and measurement to assess the fitness of the simulation in regards to material model (plasticity), finite element model construction, and failure model. Following previous material model calibration, a J2 plasticity model with a microstructural BCJ failure model is employed to model the test specimen made of 304L stainless steel. Simulated results are verified and validated through mesh and mass-scaling convergence studies, parameter sensitivity studies, and a comparison to experimental data. The converged mesh and degree of mass-scaling are the mesh discretization with 140,372 elements, and a mass scaling with a target time increment of 1.0e-6 seconds and time step scale factor of 0.5, respectively. Results from the coupled thermal-mechanical explicit dynamic analysis are comparable to the experimental data. Simulated global force vs displacement (F/D) response predicts key points such as yield, ultimate, and kinks of the experimental F/D response. Furthermore, the final deformed shape of the can and field data predicted from the analysis are similar to that of the deformed can, as measured by 3D optical CMM scans and DIC data from the experiment.
Polymers such as PTFE (polytetrafluorethylene or Teflon), EPDM (ethylene propylene diene monomer) rubber, FKM fluoroelastomer (Viton), Nylon 11, Nitrile butadiene (NBR) rubber, hydrogenated nitrile rubber (HNBR) and perfluoroelastomers (FF_202) are commonly employed in super critical CO2 (sCO2) energy conversion systems. O-rings and gaskets made from these polymers face stringent performance conditions such as elevated temperatures, high pressures, pollutants, and corrosive humid environments. In FY 2019, we conducted experiments at high temperatures (100°C and 120°C) under isobaric conditions (20 MPa). Findings showed that elevated temperatures accelerated degradation of polymers in sCO2, and that certain polymer microstructures are more susceptible to degradation over others. In FY 2020, the focus was to understand the effect of sCO2 on polymers at low (10 MPa) and high pressures (40 MPa) under isothermal conditions (100°C). It was clear that the same selectivity was observed in these experiments wherein certain polymeric functionalities showed more propensity to failure over others. Fast diffusion, supported by higher pressures and long exposure times (1000 hours) at the test temperature, caused increased damage in sCO2 environments to even the most robust polymers. We also looked at polymers under compression in sCO2 at 100°C and 20 MPa pressure to imitate actual sealing performance required of these materials in sCO2 systems. Compression worsened the physical damage that resulted from chemical attack of the polymers under these test conditions. In FY 2021, the effect of cycling temperature (from 50°C to 150°C to 50°C) for polymers under a steady sCO2 pressure of 20 MPa was studied. The aim was to understand the influence of cycling temperatures of sCO2 for typical polymers under isobaric (20 MPa) conditions. Thermoplastic polymers (Nylon, and PTFE) and elastomers (EPDM, Viton, Buna N, Neoprene, FF202, and HNBR) were subjected to 20 MPa sCO2 pressure for 50 cycles and 100 cycles in separate experiments. Samples were extracted for ex-situ characterization at 50 cycles and upon the completion of 100 cycles. Each cycle constituted of 175 minutes of cycling from 50°C to 150°C. The polymer samples were examined for physical and chemical changes by Dynamic Mechanical and Thermal Analysis (DMTA), Fourier Transform Infrared (FTIR) spectroscopy, and compression set. Density and mass changes immediately after removal from test were measured for degree of swell comparisons. Optical microscopy techniques and micro computer tomography (micro CT) images were collected on select specimens. Evaluations conducted showed that exposures to super-critical CO2 environments resulted in combinations of physical and/or chemical changes. For each polymer, the dominance of cycling temperatures under sCO2 pressures, were evaluated. Attempts were made to qualitatively link the permanent sCO2 effects to polymer micro- structure, free volume, backbone substitutions, presence of polar groups, and degree of crystallinity differences. This study has established that soft polymeric materials are conducive to failure in sCO2 through mechanisms of failure that are dependent on polymer microstructure and chemistry. Polar pendant groups, large atom substitutions on the backbone are some of the factors that are influential structural factors.
This report describes an experimental study to determine the mechanical behavior of the polyurethane rubber material that was used in the W80-4 MCC Shock/Breach Phase 1 test series. Compression experiments were conducted on cylindrical specimens over a wide range of loading rates to characterize the material over the range of strain rates that were experienced in the shock/breach testing. Additionally, specimen diameter was varied to determine the effect of confinement on the material response and was found to be significant. This data is used to populate a material model to enable accurate analyses and finite element simulations of the shock/breach test series.
To develop a fundamental understanding of dynamic strain aging, discovery experiments were designed and completed to inform the development of a dislocation based micromechanical constitutive model that will ultimately tie to continuum level plasticity and failure models. Dynamic strain aging occurs when dislocation motion is hindered by the repetitive interaction of solute atoms, most frequently interstitials, with dislocation cores. Initially, the solute atmospheres pin the dislocation core until the virtual force on the dislocation is high enough to allow glissile motion. At temperatures where the interstitials are mobile enough, the atmospheres can repeatedly reform, lock, and release dislocations producing a characteristic serrated flow curve. This phenomenon can produce unusual mechanical behavior of materials and changes in the strain rate and temperature responses. Detrimental effects such as loss of ductility often accompany these altered responses.
The supercritical carbon dioxide (sCO2) Brayton cycle is a promising candidate for future nuclear reactors due to its ability to improve power cycle energy conversion efficiency. The sCO2 Brayton cycle can operate with an efficiency of 45-50% at operating temperatures of 550-700 C. One of the greatest hurdles currently faced by sCO2 Brayton cycles is the corrosivity of sCO2 and the lack of long-term alloy corrosion and mechanical performance data, as these will be key to enhancing the longevity of the system, and thus the levelized cost of electricity. Past studies have shown that sCO2 corrosion occurs through the formation of metal carbonates, oxide layers, and carburization, and alloys with Cr, Mo and Ni generally exhibit less corrosion. While stainless steels may offer sufficient corrosion resistance at the lower range of temperatures seen by the sCO2 Brayton cycles, more expensive nickel-based alloys are typically needed for the higher temperature regions. This study investigates the effects of corrosion on the Haynes 230 alloy, with a preliminary view on changes in the mechanical properties. High temperature CO2 is used for this study as the corrosion products are similar to that of supercritical CO2, allowing for an estimation of the susceptibility towards corrosion without the need for high pressure experimentation.
The supercritical carbon dioxide (sCO2) Brayton cycle is a promising candidate for future nuclear reactors due to its ability to improve power cycle energy conversion efficiency. The sCO2 Brayton cycle can operate with an efficiency of 45-50% at operating temperatures of 550-700 C. One of the greatest hurdles currently faced by sCO2 Brayton cycles is the extreme corrosivity of sCO2. This affects the longevity of the power cycle and thus the levelized cost of electricity. Past studies have shown that sCO2 corrosion occurs through the formation of metal carbonates, oxide layers, and carburization, and alloys with Cr, Mo and Ni generally exhibit less corrosion. While stainless steels may offer sufficient corrosion resistance at the lower range of temperatures seen by the sCO2 Brayton cycles, more expensive alloys such as Inconel and Haynes are typically needed for the higher temperature regions. This study investigates the effects of corrosion on the Haynes 230 alloy, focusing on changes in the mechanical properties.
We seek to develop a fundamental understanding of dynamic strain aging through discovery experiments to inform the development of a dislocation based micromechanical constitutive model that can tie to existing continuum level plasticity and failure analysis tools. Dynamic strain aging (DSA) occurs when dislocation motion is hindered by the repetitive interaction of solute atoms, most frequently interstitials, with dislocation cores. At temperatures where the interstitials are mobile enough, the atmospheres can repeatedly reform, lock, and release dislocations producing a characteristic serrated flow curve. This phenomenon can produce reversals in the expected mechanical behavior of materials with varying strain rate or temperature. Loss of ductility can also occur. Experiments were conducted on various forms of 304L stainless steel over a range of temperatures and strain rates, along with temporally extreme measurements to capture information from the data signals during serrated flow. The experimental approach and observations for some of the test conditions are described herein.
This paper examines the variability of predicted responses when multiple stress-strain curves (reflecting variability from replicate material tests) are propagated through a finite element model of a ductile steel can being slowly crushed. Over 140 response quantities of interest (including displacements, stresses, strains, and calculated measures of material damage) are tracked in the simulations. Each response quantity’s behavior varies according to the particular stress-strain curves used for the materials in the model. We desire to estimate response variability when only a few stress-strain curve samples are available from material testing. Propagation of just a few samples will usually result in significantly underestimated response uncertainty relative to propagation of a much larger population that adequately samples the presiding random-function source. A simple classical statistical method, Tolerance Intervals, is tested for effectively treating sparse stress-strain curve data. The method is found to perform well on the highly nonlinear input-to-output response mappings and non-standard response distributions in the can-crush problem. The results and discussion in this paper support a proposition that the method will apply similarly well for other sparsely sampled random variable or function data, whether from experiments or models. Finally, the simple Tolerance Interval method is also demonstrated to be very economical.
A unique experimental capability was developed so combined mechanical and thermal loads could be imposed on specimens that are representative of laser welded structures. The apparatus, instrumentation and specimens were designed concurrently to yield the ability to apply a wide range of loading conditions that accurately replicate the multiaxial stress states produced in laser welded, sealed structures during pressurization at high temperatures up to 800 °C. Axial, radial and torsional loads can be applied individually or in combination, by direct or variable loading paths, to eventual failure of laser weld specimens. Several advantages exist for applying equivalent stress states by mechanical means rather than pressurization with gas, including: repeatability, controlled failure, safe experiments, assessment of loading path dependence, experimental efficiency and overall facility. The experimental design and development are described along with resulting measurements and findings from sample experiments.
Glass-to-metal seals are used extensively to protect and isolate electronic components. Small strains of just a few percent are typical in the metal during processing of seals, but generate substantial tensile stresses in the glass during the solidification portion of the process. These tensile stresses can lead to glass cracking either immediately or over time, which results in a loss of hermiticity of the seal. Measurement of the metal in the small strain region needs to be very accurate as small differences in the evolving state of the metal have significant influence on the stress state in the glass and glass-metal interfaces. Small strain tensile experiments were conducted over the temperatures range of 25-800 °C. Experiments were designed to quantify stress relaxation and reloading combined with mid-test thermal changes. The effect of strain rate was measured by directly varying the applied strain rate during initial loading and reloading and by monitoring the material response during stress relaxation experiments. Coupled thermal mechanical experiments were developed to capture key features of glass-to-metal seal processing details such as synchronized thermal and mechanical loading, thermal excursions at various strain levels, and thermal cycling during stress relaxation or creep loadings. Small changes in the processing cycle parameters were found to have non-insignificant effect on the metal behavior. The resulting data and findings will be presented.
We are developing the capability to track material changes through numerous possible steps of the manufacturing process, such as forging, machining, and welding. In this work, experimental and modeling results are presented for a multiple-step process in which an ingot of stainless steel 304L is forged at high temperature, then machined into a thin slice, and finally subjected to an autogenous GTA weld. The predictions of temperature, yield stress, and recrystallized volume fraction are compared to experimental results.
This work examines the variability of predicted responses when multiple stress-strain curves (reflecting variability from replicate material tests) are propagated through a transient dynamics finite element model of a ductile steel can being slowly crushed. An elastic-plastic constitutive model is employed in the large-deformation simulations. The present work assigns the same material to all the can parts: lids, walls, and weld. Time histories of 18 response quantities of interest (including displacements, stresses, strains, and calculated measures of material damage) at several locations on the can and various points in time are monitored in the simulations. Each response quantity's behavior varies according to the particular stressstrain curves used for the materials in the model. We estimate response variability due to variability of the input material curves. When only a few stress-strain curves are available from material testing, response variance will usually be significantly underestimated. This is undesirable for many engineering purposes. This paper describes the can-crush model and simulations used to evaluate a simple classical statistical method, Tolerance Intervals (TIs), for effectively compensating for sparse stress-strain curve data in the can-crush problem. Using the simulation results presented here, the accuracy and reliability of the TI method are being evaluated on the highly nonlinear inputto- output response mappings and non-standard response distributions in the can-crush UQ problem.
The material characterization tests conducted on 304L VAR stainless steel and Schott 8061 glass have provided higher fidelity data for calibration of material models used in Glass - T o - Metal (GTM) seal analyses. Specifically, a Thermo - Multi - Linear Elastic Plastic ( thermo - MLEP) material model has be en defined for S S304L and the Simplified Potential Energy Clock nonlinear visc oelastic model has been calibrated for the S8061 glass. To assess the accuracy of finite element stress analyses of GTM seals, a suite of tests are proposed to provide data for comparison to mo del predictions.
This report demonstrates versatile and practical model validation and uncertainty quantification techniques applied to the accuracy assessment of a computational model of heated steel pipes pressurized to failure. The Real Space validation methodology segregates aleatory and epistemic uncertainties to form straightforward model validation metrics especially suited for assessing models to be used in the analysis of performance and safety margins. The methodology handles difficulties associated with representing and propagating interval and/or probabilistic uncertainties from multiple correlated and uncorrelated sources in the experiments and simulations including: material variability characterized by non-parametric random functions (discrete temperature dependent stress-strain curves); very limited (sparse) experimental data at the coupon testing level for material characterization and at the pipe-test validation level; boundary condition reconstruction uncertainties from spatially sparse sensor data; normalization of pipe experimental responses for measured input-condition differences among tests and for random and systematic uncertainties in measurement/processing/inference of experimental inputs and outputs; numerical solution uncertainty from model discretization and solver effects.
To support higher fidelity modeling of residual stresses in glass-to-metal (GTM) seals and to demonstrate the accuracy of finite element analysis predictions, characterization and validation data have been collected for Sandia’s commonly used compression seal materials. The temperature dependence of the storage moduli, the shear relaxation modulus master curve and structural relaxation of the Schott 8061 glass were measured and stress-strain curves were generated for SS304L VAR in small strain regimes typical of GTM seal applications spanning temperatures from 20 to 500 C. Material models were calibrated and finite element predictions are being compared to measured data to assess the accuracy of predictions.
The distinction between electricity and fuel use in analyses of global power consumption statistics highlights the critical importance of establishing efficient synthesis techniques for solar fuelsthose chemicals whose bond energies are obtained through conversion processes driven by solar energy. Photoelectrochemical (PEC) processes show potential for the production of solar fuels because of their demonstrated versatility in facilitating optoelectronic and chemical conversion processes. Tandem PEC-photovoltaic modular configurations for the generation of hydrogen from water and sunlight (solar water splitting) provide an opportunity to develop a low-cost and efficient energy conversion scheme. The critical component in devices of this type is the PEC photoelectrode, which must be optically absorptive, chemically stable, and possess the required electronic band alignment with the electrochemical scale for its charge carriers to have sufficient potential to drive the hydrogen and oxygen evolution reactions. After many decades of investigation, the primary technological obstacle remains the development of photoelectrode structures capable of efficient conversion of light with visible frequencies, which is abundant in the solar spectrum. Metal oxides represent one of the few material classes that can be made photoactive and remain stable to perform the required functions.
Non-destructive detection methods can reliably certify that gas transfer system (GTS) reservoirs do not have cracks larger than 5%-10% of the wall thickness. To determine the acceptability of a reservoir design, analysis must show that short cracks will not adversely affect the reservoir behavior. This is commonly done via calculation of the J-Integral, which represents the energetic driving force acting to propagate an existing crack in a continuous medium. J is then compared against a material's fracture toughness (J{sub c}) to determine whether crack propagation will occur. While the quantification of the J-Integral is well established for long cracks, its validity for short cracks is uncertain. This report presents the results from a Sandia National Laboratories project to evaluate a methodology for performing J-Integral evaluations in conjunction with its finite element analysis capabilities. Simulations were performed to verify the operation of a post-processing code (J3D) and to assess the accuracy of this code and our analysis tools against companion fracture experiments for 2- and 3-dimensional geometry specimens. Evaluation is done for specimens composed of 21-6-9 stainless steel, some of which were exposed to a hydrogen environment, for both long and short cracks.
Sandia currently lacks a high fidelity method for predicting loads on and subsequent structural response of earth penetrating weapons. This project seeks to test, debug, improve and validate methodologies for modeling earth penetration. Results of this project will allow us to optimize and certify designs for the B61-11, Robust Nuclear Earth Penetrator (RNEP), PEN-X and future nuclear and conventional penetrator systems. Since this is an ASC Advanced Deployment project the primary goal of the work is to test, debug, verify and validate new Sierra (and Nevada) tools. Also, since this project is part of the V&V program within ASC, uncertainty quantification (UQ), optimization using DAKOTA [1] and sensitivity analysis are an integral part of the work. This project evaluates, verifies and validates new constitutive models, penetration methodologies and Sierra/Nevada codes. In FY05 the project focused mostly on PRESTO [2] using the Spherical Cavity Expansion (SCE) [3,4] and PRESTO Lagrangian analysis with a preformed hole (Pen-X) methodologies. Modeling penetration tests using PRESTO with a pilot hole was also attempted to evaluate constitutive models. Future years work would include the Alegra/SHISM [5] and AlegrdEP (Earth Penetration) methodologies when they are ready for validation testing. Constitutive models such as Soil-and-Foam, the Sandia Geomodel [6], and the K&C Concrete model [7] were also tested and evaluated. This report is submitted to satisfy annual documentation requirements for the ASC Advanced Deployment program. This report summarizes FY05 work performed in the Penetration Mechanical Response (ASC-APPS) and Penetration Mechanics (ASC-V&V) projects. A single report is written to document the two projects because of the significant amount of technical overlap.
The effect of temperature on the tensile properties of annealed 304L stainless steel and HERF 304L stainless steel forgings was determined by completing experiments over the moderate range of -40 F to 160 F. Temperature effects were more significant in the annealed material than the HERF material. The tensile yield strength of the annealed material at -40 F averaged twenty two percent above the room temperature value and at 160 F averaged thirteen percent below. The tensile yield strength for the three different geometry HERF forgings at -40 F and 160 F changed less than ten percent from room temperature. The ultimate tensile strength was more temperature dependent than the yield strength. The annealed material averaged thirty six percent above and fourteen percent below the room temperature ultimate strength at -40 F and 160 F, respectively. The HERF forgings exhibited similar, slightly lower changes in ultimate strength with temperature. For completeness and illustrative purposes, the stress-strain curves are included for each of the tensile experiments conducted. The results of this study prompted a continuation study to determine tensile property changes of welded 304L stainless steel material with temperature, documented separately.
This paper describes the analyses and the experimental mechanics program to support the National Aeronautics and Space Administration (NASA) investigation of the Shuttle Columbia accident. A synergism of the analysis and experimental effort is required to insure that the final analysis is valid - the experimental program provides both the material behavior and a basis for validation, while the analysis is required to insure the experimental effort provides behavior in the correct loading regime. Preliminary scoping calculations of foam impact onto the Shuttle Columbia's wing leading edge determined if enough energy was available to damage the leading edge panel. These analyses also determined the strain-rate regimes for various materials to provide the material test conditions. Experimental testing of the reinforced carbon-carbon wing panels then proceeded to provide the material behavior in a variety of configurations and strain-rates for flown or conditioned samples of the material. After determination of the important failure mechanisms of the material, validation experiments were designed to provide a basis of comparison for the analytical effort. Using this basis, the final analyses were used for test configuration, instrumentation location, and calibration definition in support of full-scale testing of the panels in June 2003. These tests subsequently confirmed the accident cause.
The primary goals of the present study are to: (1) determine how and why MEMS-scale friction differs from friction on the macro-scale, and (2) to begin to develop a capability to perform finite element simulations of MEMS materials and components that accurately predicts response in the presence of adhesion and friction. Regarding the first goal, a newly developed nanotractor actuator was used to measure friction between molecular monolayer-coated, polysilicon surfaces. Amontons law does indeed apply over a wide range of forces. However, at low loads, which are of relevance to MEMS, there is an important adhesive contribution to the normal load that cannot be neglected. More importantly, we found that at short sliding distances, the concept of a coefficient of friction is not relevant; rather, one must invoke the notion of 'pre-sliding tangential deflections' (PSTD). Results of a simple 2-D model suggests that PSTD is a cascade of small-scale slips with a roughly constant number of contacts equilibrating the applied normal load. Regarding the second goal, an Adhesion Model and a Junction Model have been implemented in PRESTO, Sandia's transient dynamics, finite element code to enable asperity-level simulations. The Junction Model includes a tangential shear traction that opposes the relative tangential motion of contacting surfaces. An atomic force microscope (AFM)-based method was used to measure nano-scale, single asperity friction forces as a function of normal force. This data is used to determine Junction Model parameters. An illustrative simulation demonstrates the use of the Junction Model in conjunction with a mesh generated directly from an atomic force microscope (AFM) image to directly predict frictional response of a sliding asperity. Also with regards to the second goal, grid-level, homogenized models were studied. One would like to perform a finite element analysis of a MEMS component assuming nominally flat surfaces and to include the effect of roughness in such an analysis by using a homogenized contact and friction models. AFM measurements were made to determine statistical information on polysilicon surfaces with different roughnesses, and this data was used as input to a homogenized, multi-asperity contact model (the classical Greenwood and Williamson model). Extensions of the Greenwood and Williamson model are also discussed: one incorporates the effect of adhesion while the other modifies the theory so that it applies to the case of relatively few contacting asperities.