The ductile failure in metals has long been associated with void nucleation, growth and coalescence. Many micromechanics-based damage models were developed to study the effects of the voids sizes, shape and orientation to the nucleation, growth and coalescence of voids. However, the experimental methods to quantitatively validate these models were lacking. This paper is aimed to experimentally investigate at the microscale and nanoscale the effects of the shapes, sizes, orientation and density to the nucleation, growth and coalescence of voids and their relation to the ductility of the metal. In this work, notched tensile specimens with various radii were designed along different orientations. These specimens were tensile loaded up to different percentage of ultimate failure strain. The deformed specimens were then sectioned both along and perpendicular to the loading direction to microscopically study the voids size, shape and density. On the other hand, microtensile specimens were made out of these already deformed specimens. Using the advanced imaging capabilities of AFM and SEM combined with in-situ loading, the growth and coalescence of voids were in-situ studied at the microscale and nanoscale.
Experimental data for material plasticity and failure model calibration and validation were obtained from 6061-T651 aluminum, in the form of a 4-in. diameter extruded rod. Model calibration data were taken from smooth tension, notched tension, and shear tests. Model validation data were provided from experiments using thin-walled tube specimens subjected to path-dependent combinations of internal pressure, extension, and torsion.
Various techniques and heating methods have been employed to characterize the compressive and tensile behavior of 304L stainless steel over a wide range of test temperatures. Depending on the test temperature, the experimental apparatus required to produce uniform temperatures in the specimens varied significantly. Compression experiments imposed additional difficulty in achieving a uniform temperature throughout the specimen, but were attainable using secondary heating of the test platens. The 304L material was characterized in tension at quasi-static rates and in compression over an extensive range of strain rates to the very high strain rate regime. Strain rate effects were experimentally determined and a reversal in the strain rate effect was discovered at some temperature and strain rate combinations. Dynamic recrystallization was observed at some temperature and strain rate regimes.
Honeycomb is a structure that consists of two-dimensional regular arrays of open cells. High-density aluminum honeycomb has been used in weapon assemblies to mitigate shock and protect payload because of its excellent crush properties. In order to use honeycomb efficiently and to certify the payload is protected by the honeycomb under various loading conditions, a validated honeycomb crush model is required and the mechanical properties of the honeycombs need to be fully characterized. Volume I of this report documents an experimental study of the crush behavior of high-density honeycombs. Two sets of honeycombs were included in this investigation: commercial grade for initial exploratory experiments, and weapon grade, which satisfied B61 specifications. This investigation also includes developing proper experimental methods for crush characterization, conducting discovery experiments to explore crush behaviors for model improvement, and identifying experimental and material uncertainties.
The work reported here was conducted to address issues raised regarding mechanical testing of attachment screws described in SAND2005-6036, as well as to increase the understanding of screw behavior through additional testing. Efforts were made to evaluate fixture modifications and address issues of interest, including: fabrication of 45{sup o} test fixtures, measurement of the frictional load from the angled fixture guide, employment of electromechanical displacement transducers, development of a single-shear test, and study the affect of thread start orientation on single-shear behavior. A286 and 302HQ, No.10-32 socket-head cap screws were tested having orientations with respect to the primary loading axis of 0{sup 0}, 45{sup o}, 60{sup o}, 75{sup o} and 90{sup o} at stroke speeds 0,001 and 10 in/sec. The frictional load resulting from the angled screw fixture guide was insignificant. Load-displacement curves of A286 screws did not show a minimum value in displacement to failure (DTF) for 60{sup o} shear tests. Tests of 302HQ screws did not produce a consistent trend in DTF with load angle. The effect of displacement rate on DTF became larger as shear angle increased for both A286 and 302HQ screws.
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.
Resist substrates used in the LIGA process must provide high initial bond strength between the substrate and resist, little degradation of the bond strength during x-ray exposure, acceptable undercut rates during development, and a surface enabling good electrodeposition of metals. Additionally, they should produce little fluorescence radiation and give small secondary doses in bright regions of the resist at the substrate interface. To develop a new substrate satisfying all these requirements, we have investigated secondary resist doses due to electrons and fluorescence, resist adhesion before exposure, loss of fine features during extended development, and the nucleation and adhesion of electrodeposits for various substrate materials. The result of these studies is a new anodized aluminum substrate and accompanying methods for resist bonding and electrodeposition. We demonstrate successful use of this substrate through all process steps and establish its capabilities via the fabrication of isolated resist features down to 6 {micro}m, feature aspect ratios up to 280 and electroformed nickel structures at heights of 190 to 1400 {micro}m. The minimum mask absorber thickness required for this new substrate ranges from 7 to 15 {micro}m depending on the resist thickness.
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.