Graded density impactors (GDIs) have long been of interest to provide off-Hugoniot loading capabilities for impact systems. We describe a new technique which utilizes sputter deposition to produce an approximately 40 µm-thick film containing alternating layers of Al and Cu. The thicknesses of the respective layers are adjusted to give an effective density gradient through the film. The GDIs were launched into samples of interest with a 2-stage light gas gun, and the resulting shock-ramp-release velocity profiles were measured over timescales of ~10 ns with a new velocimetry probe. Results are shown for the direct impact of the film onto a LiF window, which allows for the dynamic characterization of the GDI, as well as from impact onto a thin (~40 µm) sputtered Ta sample backed by a LiF window. These measurements were coupled into mesoscale numerical simulations to infer the strength of Ta at the high rate (107 s-1), and high pressure (1 MBar) conditions this unique capability provides. Initial results suggest this is a viable strength platform which fills a critical gap and aids in cross-platform comparisons with other high-pressure strength platforms.
This report outlines the fiscal year (FY) 2019 status of an ongoing multi-year effort to develop a general, microstructurally-aware, continuum-level model for representing the dynamic response of material with complex microstructures. This work has focused on accurately representing the response of both conventionally wrought processed and additively manufactured (AM) 304L stainless steel (SS) as a test case. Additive manufacturing, or 3D printing, is an emerging technology capable of enabling shortened design and certification cycles for stockpile components through rapid prototyping. However, there is not an understanding of how the complex and unique microstructures of AM materials affect their mechanical response at high strain rates. To achieve our project goal, an upscaling technique was developed to bridge the gap between the microstructural and continuum scales to represent AM microstructures on a Finite Element (FE) mesh. This process involves the simulations of the additive process using the Sandia developed kinetic Monte Carlo (KMC) code SPPARKS. These SPPARKS microstructures are characterized using clustering algorithms from machine learning and used to populate the quadrature points of a FE mesh. Additionally, a spall kinetic model (SKM) was developed to more accurately represent the dynamic failure of AM materials. Validation experiments were performed using both pulsed power machines and projectile launchers. These experiments have provided equation of state (EOS) and flow strength measurements of both wrought and AM 304L SS to above Mbar pressures. In some experiments, multi-point interferometry was used to quantify the variation is observed material response of the AM 304L SS. Analysis of these experiments is ongoing, but preliminary comparisons of our upscaling technique and SKM to experimental data were performed as a validation exercise. Moving forward, this project will advance and further validate our computational framework, using advanced theory and additional high-fidelity experiments. ACKNOWLEDGEMENTS The authors greatly appreciate the support of Mike Saavedra in machining the experimental samples. The authors would also like to thank the Dynamic Integrated Compression facility (DICE) staff for executing the Thor experiments: Brian Stoltzfus, Randy Hickman, Keith Hodge, Joshua Usher, Lena Pacheco, and Eric Breden. The authors would also like to thank the staff at the Shock Thermodynamics Applied Research (STAR) facility for executing the plate impact experiments: Scott Alexander, Bill Reinhart, Bernardo Farfan, Rocky Palomino, John Martinez, and Rafael Sanchez. Lastly, the authors would like to acknowledge the development support of Jason Sanchez in ALEGRA to incorporate our upscaling method and Michael Powell for helping with post processing scripts for results analysis.
Materials in nuclear and conventional weapons can reach multi-megabar pressures and 1000s of degree temperatures on timescales ranging from microseconds to nanoseconds. Understanding the response of complex materials under these conditions is important for designing and assessing changes to nuclear weapons. In the next few decades, a major concern will be evaluating the behavior of aging materials and remanufactured components. The science to enable the program to underwrite decisions quickly and confidently on use, remanufacturing, and replacement of these materials will be critical to NNSA’s new Stockpile Responsiveness Program. Material response is also important for assessing the risks posed by adversaries or proliferants. Dynamic materials research, which refers to the use of high-speed experiments to produce extreme conditions in matter, is an important part of NNSA’s Stockpile Stewardship Program.
Gold nanostructured materials exhibit important size- and shape-dependent properties that enable a wide variety of applications in photocatalysis, nanoelectronics and phototherapy. Here we show the use of superfast dynamic compression to synthesize extended gold nanostructures, such as nanorods, nanowires and nanosheets, with nanosecond coalescence times. Using a pulsed power generator, we ramp compress spherical gold nanoparticle arrays to pressures of tens of GPa, demonstrating pressure-driven assembly beyond the quasi-static regime of the diamond anvil cell. Our dynamic magnetic ramp compression approach produces smooth, shockless (that is, isentropic) one-dimensional loading with low-temperature states suitable for nanostructure synthesis. Transmission electron microscopy clearly establishes that various gold architectures are formed through compressive mesoscale coalescences of spherical gold nanoparticles, which is further confirmed by in-situ synchrotron X-ray studies and large-scale simulation. This nanofabrication approach applies magnetically driven uniaxial ramp compression to mimic established embossing and imprinting processes, but at ultra-short (nanosecond) timescales.
Gas-gun experiments have probed the compression and release behavior of impact-loaded 304L stainless steel specimens that were machined from additively manufactured (AM) blocks as well as baseline ingot-derived bar stock. The AM technology permits direct fabrication of net-or near-net-shape metal parts. For the present investigation, velocity interferometer (VISAR) diagnostics provided time-resolved measurements of sample response for onedimensional (i.e., uniaxial strain) shock compression to peak stresses ranging from 0.2 to 7.0 GPa. The acquired waveprofile data have been analyzed to determine the comparative Hugoniot Elastic Limit (HEL), Hugoniot equation of state, spall strength, and high-pressure yield strength of the AM and conventional materials. The possible contributions of various factors, such as composition, porosity, microstructure (e.g., grain size and morphology), residual stress, and/or sample axis orientation relative to the additive manufacturing deposition trajectory, are considered to explain differences between the AM and baseline 304L dynamic material results.
Complementary gas-gun experiments and computational simulations have examined the time-resolved motion and post-mortem deformation of cylindrical metal samples subjected to impact loading. The effect of propagation distance on a compressive waveform generated in a sample by planar impact at one end was determined using a velocity interferometer to track the longitudinal motion at the center of the opposing rear (i.e., free) surface. Samples (25.4-mm diameter) were fabricated from aluminum (types 6061 and 7075), copper (OFHC = oxygen free, high conductivity), stainless steel (type 316), and cobalt alloy L-605 (AMS 5759; also referenced as Haynes®25 alloy). For each material, waveforms obtained for a 25.4-mm long cylinder corresponded to two-dimensional strain at the measurement point. The wave-profile data have been analyzed to (i) establish key dynamic material modeling parameters, (ii) assess the functionality of the Sierra Solid Mechanics-Presto (Sierra/SM) code, and (iii) identify the need for additional testing, material modeling, and/or code development. The results of subsequent simulations have been compared to benchmark recovery experiments that showed the residual plastic deformation incurred by cylinders following end, side, and corner impacts. ∗Sandia National Laboratories is a multi-program laboratory managed and operated by Sandia Corporation, a wholly owned subsidiary of Lockheed Martin Corporation, for the U.S. Department of Energy's National Nuclear Security Administration under contract DE-AC04-94AL85000.
Additive manufacturing (AM) technology has been developed to fabricate metal components that include complex prototype fabrication, small lot production, precision repair or feature addition, and tooling. However, the mechanical response of the AM materials is a concern to meet requirements for specific applications. Differences between AM materials as compared to wrought materials might be expected, due to possible differences in porosity (voids), grain size, and residual stress levels. When the AM materials are designed for impact applications, the dynamic mechanical properties in both compression and tension need to be fully characterized and understood for reliable designs. In this study, a 304L stainless steel was manufactured with AM technology. For comparison purposes, both the AM and wrought 304L stainless steels were dynamically characterized in compression Kolsky bar techniques. They dynamic compressive stress-strain curves were obtained and the strain rate effects were determined for both the AM and wrought 304L stainless steels. A comprehensive comparison of dynamic compressive response between the AM and wrought 304L stainless steels was performed. SAND2015-0993 C.
Polycrystalline diamond compact (PDC) bits have gained i wide popularity in the petroleum industry for drilling soft and; moderately firm formations. However, in hard formation applications, the PDC bit still has limitations, even though recent developments in PDC cutter designs and materials steadily imj proves PDC bit performance. The limitations of PDC bits for drilling hard formations is an important technical obstacle that must be overcome before using the PDC bit to develop competii tively priced electricity from enhanced geothermal systems, as well as deep continental gas fields. Enhanced geothermal energy is a very promising source for generating electrical energy and therefore, there is an urgent need to further enhance PDC bit per-j formance in hard formations. In this paper, the cutting efficiency of the PDC bit has been) analyzed based on the development of an analytical single PDC cutter force model. The cutting efficiency of a single PDC cutterj is defined as the ratio of the volume removed by a cutter over the force required to remove that volume of rock. The cutting I efficiency is found to be a function of the back rake angle, the depth of cut and the rock property, such as the angle of internal' friction. The highest cutting efficiency is found to occur at specific back rake angles of the cutter based on the material properties of the rock. The cutting efficiency directly relates to the internal angle of friction of the rock being cut. The results of this analysis can be integrated to study PDC bit performance. It can also provide a guideline to the application' and design of PDC bits for specific rocks.
Complementary gas-gun and electro-magnetic pulse tests conducted in Sandia's Dynamic Integrated Compression Experimental (DICE) Facility have, respectively, probed the behavior of electronic-grade Kovar samples under controlled impact and intermediate-strain-rate ICE (Isentropic Compression Experiment) loading. In all tests, velocity interferometer (VISAR) diagnostics provided time-resolved measurements of sample response for conditions involving one-dimensional (i:e:, uniaxial strain) compression and release. Wave-profile data from the gas-gun impact experiments have been analyzed to assess the Hugoniot Elastic Limit (HEL), Hugoniot equation of state, spall strength, and high-pressure yield strength of shocked Kovar. The ICE wave-profile data have been interpreted to determine the locus of isentropic stress-strain states generated in Kovar for deformation rates substantially lower than those associated with a shock process. The impact and ICE results have been compared to examine the influence of loading rate on high-pressure strength.
A series of field tests sponsored by Sandia National Laboratories has simultaneously demonstrated the hard-rock drilling performance of different industry-supplied drag bits as well as Sandia's new Diagnostics-While-Drilling (DWD) system, which features a novel downhole tool that monitors dynamic conditions in close proximity to the bit. Drilling with both conventional and advanced ("best effort") drag bits was conducted at the GTI Catoosa Test Facility (near Tulsa, OK) in a well-characterized lithologic column that features an extended hard-rock interval of Mississippi limestone above a layer of highly abrasive Misener sandstone and an underlying section of hard Arbuckle dolomite. Output from the DWD system was closely observed during drilling and was used to make real-time decisions for adjusting the drilling parameters. This paper summarizes penetration rate and damage results for the various drag bits, shows representative DWD display data, and illustrates the application of these data for optimizing drilling performance and avoiding trouble.
PDC drill bit performance has been greatly improved over the past three decades by innovations in bit design and how these designs are applied. The next leap forward is most likely to come from using high-speed, real-time downhole data to optimize the performance of these sophisticated bits on an application-by-application basis. By effectively managing conditions of lateral, axial and torsional acceleration, damage to cutting structures can be minimized for improved penetration rates. Avoiding these damaging vibrations is essential to increasing bit durability and improving overall drilling economics. This paper describes one set of independent drilling optimization results obtained as part of a series of controlled demonstrations of PDC bits. Sandia National Laboratories on behalf of the U. S. Department of Energy (DOE) managed this work. The effort was organized as a Cooperative Research and Development Agreement (CRADA) established between Sandia and four bit manufacturers with DOE funding and in-kind contributions by the industry partners. The goal of this CRADA was to demonstrate drag bit performance in formations with degrees of hardness typical of those encountered while drilling geothermal wells. The test results indicate that the surface weight-on-bit (WOB), revolutions per minute (RPM) and torque readings traditionally used to guide adjustments in the drilling parameters do not always provide the true picture of what is really taking place at the bit. Instead, a holistic approach combining traditional methods of optimization together with high-speed, real-time data enables far better decisions for improving bit performance and avoiding damaging situations that may have otherwise gone unnoticed.
American Rock Mechanics Association - 40th US Rock Mechanics Symposium, ALASKA ROCKS 2005: Rock Mechanics for Energy, Mineral and Infrastructure Development in the Northern Regions
Sandia National Laboratories has partnered with industry on a multifaceted, baseline experimental study that supports the development of improved drag cutters for advanced drill bits. Different nonstandard cutter lots were produced and subjected to laboratory tests that evaluated the influence of selected design and processing parameters on cutter loads, wear, and durability pertinent to the penetration of hard rock with mechanical properties representative of formations encountered in geothermal or deep oil/gas drilling environments. The focus was on cutters incorporating ultrahard PDC (polycrystalline diamond compact) overlays (i.e., diamond tables) on tungsten-carbide substrates. Parameter variations included changes in cutter geometry, material composition, and processing conditions. Geometric variables were the diamond-table thickness, the cutting-edge profile, and the PDC/substrate interface configuration. Material and processing variables for the diamond table were, respectively, the diamond particle size and the sintering pressure applied during cutter fabrication. Complementary drop-impact, granite-log abrasion, linear cutting-force, and rotary-drilling tests examined the response of cutters from each lot. Substantial changes in behavior were observed from lot to lot, allowing the identification of features contributing major (factor of 10+) improvements in cutting performance for hard-rock applications. Recent field demonstrations highlight the advantages of employing enhanced cutter technology during challenging drilling operations.
Sandia National Laboratories and Security DBS have collaboratively examined the hard-rock drilling performance of a conventional drag-bit design that was run in conjunction with field tests of Sandia's prototype Diagnostics-While- Drilling (DWD) system for acquiring real-time downhole and surface data. This effort constituted the first two phases of work under the terms of a multi-partner Cooperative Research and Development Agreement (CRADA) that has been established between Sandia and four bit manufacturers for the purpose of developing and demonstrating "best effort" drag bits that are capable of drilling difficult formations such as those commonly found at geothermal energy production sites. For both CRADA phases completed to date, the test bit (Security DBS, Model PD 5) drilled in the same well-characterized hard lithologic interval at the GTI Catoosa Test Facility near Tulsa, OK. In each case, extensive time-resolved downhole and surface data were acquired with the DWD system. During Phase 1, an experienced driller controlled the drilling parameters only on the basis of standard rig instrumentation readings. For Phase 2, one or more drilling engineers continuously observed the streaming DWD displays and actively guided the drilling process. Significantly different results were achieved in Phases 1 and 2 for penetration rate and bit life, which are reported along with bit damage assessments and representative data from the unique downhole measurement sub that monitored conditions at the bit. This information has supported the development of designs and DWD-based drilling strategies for the "best effort" bits being tested during CRADA Phase 3.
This report describes development of a system that provides high-speed, real-time downhole data while drilling. Background of the project, its benefits, major technical challenges, test planning, and test results are covered by relatively brief descriptions in the body of the report, with some topics presented in more detail in the attached appendices.