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.
Sandia is participating in the third phase of an is a contributing partner to a U.S.-German "Joint Project" entitled "Comparison of current constitutive models and simulation procedures on the basis of model calculations of the thermo-mechanical behavior and healing of rock salt." The first goal of the project is to check the ability of numerical modeling tools to correctly describe the relevant deformation phenomena in rock salt under various influences. Achieving this goal will lead to increased confidence in the results of numerical simulations related to the secure storage of radioactive wastes in rock salt, thereby enhancing the acceptance of the results. These results may ultimately be used to make various assertions regarding both the stability analysis of an underground repository in salt, during the operating phase, and the long-term integrity of the geological barrier against the release of harmful substances into the biosphere, in the post-operating phase.
The assurance of a HLW repository’s performance and safety, for the required period of performance, depends on numerical predictions of long-term repository behavior. As a consequence, all aspects of the computational models used to predict the long-term behavior must be examined for adequacy. This includes the computational software used to solve the discretized mathematical equations that represent the geomechanics in the computational models. One way, and perhaps among the best, to evaluate the overall computational software used to solve complex problems with many interacting nonlinearities, such as found in the response of a potential HLW repository in rock salt, is by the use of benchmark calculations whereby identically-defined parallel calculations are performed by two or more groups using independent but comparable capabilities. In this paper, the detailed definitions of two benchmark problems are presented that are consistent with idealizations of two WIPP in-situ full-scale underground experiments—WIPP Rooms B & D. It is hoped that the benchmark problems defined here will be useful to the salt community at large and allow others to benefit from their availability. These problems, or ones similar to these, can be used to assess the current generation of computational software available for modeling potential rock salt repositories.
Because of relatively recent decisions by the current administration and its renewed assessment of the nuclear life- cycle, the various deep geologic disposal medium options are once again open for consideration. This paper focuses on addressing the favorable creep properties and behavior of rock salt, from the computational modeling perspective, as it relates to its potential use as a disposal medium for a deep geologic repository. The various components that make up a computational modeling capability to address the thermo-mechanical behavior of rock salt over a wide range of time and space are presented here. Several example rock salt calculations are also presented to demonstrate the applicability and validity of the modeling capability described herein to address repository-scale problems. The evidence shown points to a mature computational capability that can generate results relevant to the design and assessment of a potential rock salt HLW repository. The computational capability described here can be used to help enable fuel cycle sustainability by appropriately vetting the use of geologic rock salt for use as a deep geologic disposal medium.
This report describes the progress in fiscal year 2010 in developing the Waste Integrated Performance and Safety Codes (IPSC) in support of the U.S. Department of Energy (DOE) Office of Nuclear Energy Advanced Modeling and Simulation (NEAMS) Campaign. The goal of the Waste IPSC is to develop an integrated suite of computational modeling and simulation capabilities to quantitatively assess the long-term performance of waste forms in the engineered and geologic environments of a radioactive waste storage or disposal system. The Waste IPSC will provide this simulation capability (1) for a range of disposal concepts, waste form types, engineered repository designs, and geologic settings, (2) for a range of time scales and distances, (3) with appropriate consideration of the inherent uncertainties, and (4) in accordance with robust verification, validation, and software quality requirements. Waste IPSC activities in fiscal year 2010 focused on specifying a challenge problem to demonstrate proof of concept, developing a verification and validation plan, and performing an initial gap analyses to identify candidate codes and tools to support the development and integration of the Waste IPSC. The current Waste IPSC strategy is to acquire and integrate the necessary Waste IPSC capabilities wherever feasible, and develop only those capabilities that cannot be acquired or suitably integrated, verified, or validated. This year-end progress report documents the FY10 status of acquisition, development, and integration of thermal-hydrologic-chemical-mechanical (THCM) code capabilities, frameworks, and enabling tools and infrastructure.
The objective of the U.S. Department of Energy Office of Nuclear Energy Advanced Modeling and Simulation Waste Integrated Performance and Safety Codes (NEAMS Waste IPSC) is to provide an integrated suite of computational modeling and simulation (M&S) capabilities to quantitatively assess the long-term performance of waste forms in the engineered and geologic environments of a radioactive-waste storage facility or disposal repository. To meet this objective, NEAMS Waste IPSC M&S capabilities will be applied to challenging spatial domains, temporal domains, multiphysics couplings, and multiscale couplings. A strategic verification and validation (V&V) goal is to establish evidence-based metrics for the level of confidence in M&S codes and capabilities. Because it is economically impractical to apply the maximum V&V rigor to each and every M&S capability, M&S capabilities will be ranked for their impact on the performance assessments of various components of the repository systems. Those M&S capabilities with greater impact will require a greater level of confidence and a correspondingly greater investment in V&V. This report includes five major components: (1) a background summary of the NEAMS Waste IPSC to emphasize M&S challenges; (2) the conceptual foundation for verification, validation, and confidence assessment of NEAMS Waste IPSC M&S capabilities; (3) specifications for the planned verification, validation, and confidence-assessment practices; (4) specifications for the planned evidence information management system; and (5) a path forward for the incremental implementation of this V&V plan.
Waste IPSC Objective is to develop an integrated suite of high performance computing capabilities to simulate radionuclide movement through the engineered components and geosphere of a radioactive waste storage or disposal system: (1) with robust thermal-hydrologic-chemical-mechanical (THCM) coupling; (2) for a range of disposal system alternatives (concepts, waste form types, engineered designs, geologic settings); (3) for long time scales and associated large uncertainties; (4) at multiple model fidelities (sub-continuum, high-fidelity continuum, PA); and (5) in accordance with V&V and software quality requirements. THCM Modeling collaborates with: (1) Other Waste IPSC activities: Sub-Continuum Processes (and FMM), Frameworks and Infrastructure (and VU, ECT, and CT); (2) Waste Form Campaign; (3) Used Fuel Disposition (UFD) Campaign; and (4) ASCEM.
This report describes the specification of a challenge problem and associated challenge milestones for the Waste Integrated Performance and Safety Codes (IPSC) supporting the U.S. Department of Energy (DOE) Office of Nuclear Energy Advanced Modeling and Simulation (NEAMS) Campaign. The NEAMS challenge problems are designed to demonstrate proof of concept and progress towards IPSC goals. The goal of the Waste IPSC is to develop an integrated suite of modeling and simulation capabilities to quantitatively assess the long-term performance of waste forms in the engineered and geologic environments of a radioactive waste storage or disposal system. The Waste IPSC will provide this simulation capability (1) for a range of disposal concepts, waste form types, engineered repository designs, and geologic settings, (2) for a range of time scales and distances, (3) with appropriate consideration of the inherent uncertainties, and (4) in accordance with robust verification, validation, and software quality requirements. To demonstrate proof of concept and progress towards these goals and requirements, a Waste IPSC challenge problem is specified that includes coupled thermal-hydrologic-chemical-mechanical (THCM) processes that describe (1) the degradation of a borosilicate glass waste form and the corresponding mobilization of radionuclides (i.e., the processes that produce the radionuclide source term), (2) the associated near-field physical and chemical environment for waste emplacement within a salt formation, and (3) radionuclide transport in the near field (i.e., through the engineered components - waste form, waste package, and backfill - and the immediately adjacent salt). The initial details of a set of challenge milestones that collectively comprise the full challenge problem are also specified.
Geomechanical analyses have been performed to investigate potential mine interactions with wellbores that could occur in the Potash Enclave of Southeastern New Mexico. Two basic models were used in the study; (1) a global model that simulates the mechanics associated with mining and subsidence and (2) a wellbore model that examines the resulting interaction impacts on the wellbore casing. The first model is a 2D approximation of a potash mine using a plane strain idealization for mine depths of 304.8 m (1000 ft) and 609.6 m (2000 ft). A 3D wellbore model then considers the impact of bedding plane slippage across single and double cased wells cemented through the Salado formation. The wellbore model establishes allowable slippage to prevent casing yield.
Sandia National Laboratories (SNL) is a multi-program national laboratory in the business of national security, whose primary mission is nuclear weapons (NW). It is a prime contractor to the USDOE, operating under the NNSA and is one of the three NW national laboratories. It has a long history of involvement in the area of geomechanics, starting with the some of the earliest weapons tests at Nevada. Projects in which geomechanics support (in general) and computational geomechanics support (in particular) are at the forefront at Sandia, range from those associated with civilian programs to those in the defense programs. SNL has had significant involvement and participation in the Waste Isolation Pilot Plant (low-level defense nuclear waste), the Yucca Mountain Project (formerly proposed for commercial spent fuel and high-level nuclear waste), and the Strategic Petroleum Reserve (the nation's emergency petroleum store). In addition, numerous industrial partners seek-out our computational/geomechanics expertise, and there are efforts in compressed air and natural gas storage, as well as in CO{sub 2} Sequestration. Likewise, there have also been collaborative past efforts in the areas of compactable reservoir response, the response of salt structures associated with reservoirs, and basin modeling for the Oil & Gas industry. There are also efforts on the defense front, ranging from assessment of vulnerability of infrastructure to defeat of hardened targets, which require an understanding and application of computational geomechanics. Several examples from some of these areas will be described and discussed to give the audience a flavor of the type of work currently being performed at Sandia in the general area of geomechanics.
An interdisciplinary team of scientists and engineers having broad expertise in materials processing and properties, materials characterization, and computational mechanics was assembled to develop science-based modeling/simulation technology to design and reproducibly manufacture high performance and reliable, complex microelectronics and microsystems. The team's efforts focused on defining and developing a science-based infrastructure to enable predictive compaction, sintering, stress, and thermomechanical modeling in ''real systems'', including: (1) developing techniques to and determining materials properties and constitutive behavior required for modeling; (2) developing new, improved/updated models and modeling capabilities, (3) ensuring that models are representative of the physical phenomena being simulated; and (4) assessing existing modeling capabilities to identify advances necessary to facilitate the practical application of Sandia's predictive modeling technology.
The ease and ability to predict sintering shrinkage and densification with the Skorohod-Olevsky viscous sintering (SOVS) model within a finite-element (FE) code have been improved with the use of an Arrhenius-type viscosity function. The need for a better viscosity function was identified by evaluating SOVS model predictions made using a previously published polynomial viscosity function. Predictions made using the original, polynomial viscosity function do not accurately reflect experimentally observed sintering behavior. To more easily and better predict sintering behavior using FE simulations, a thermally activated viscosity function based on creep theory was used with the SOVS model. In comparison with the polynomial viscosity function, SOVS model predictions made using the Arrhenius-type viscosity function are more representative of experimentally observed viscosity and sintering behavior. Additionally, the effects of changes in heating rate on densification can easily be predicted with the Arrhenius-type viscosity function. Another attribute of the Arrhenius-type viscosity function is that it provides the potential to link different sintering models. For example, the apparent activation energy, Q, for densification used in the construction of the master sintering curve for a low-temperature cofire ceramic dielectric has been used as the apparent activation energy for material flow in the Arrhenius-type viscosity function to predict heating rate-dependent sintering behavior using the SOVS model.
All ceramics and powder metals, including the ceramics components that Sandia uses in critical weapons components such as PZT voltage bars and current stacks, multi-layer ceramic MET's, ahmindmolybdenum & alumina cermets, and ZnO varistors, are manufactured by sintering. Sintering is a critical, possibly the most important, processing step during manufacturing of ceramics. The microstructural evolution, the macroscopic shrinkage, and shape distortions during sintering will control the engineering performance of the resulting ceramic component. Yet, modeling and prediction of sintering behavior is in its infancy, lagging far behind the other manufacturing models, such as powder synthesis and powder compaction models, and behind models that predict engineering properties and reliability. In this project, we developed a model that was capable of simulating microstructural evolution during sintering, providing constitutive equations for macroscale simulation of shrinkage and distortion during sintering. And we developed macroscale sintering simulation capability in JAS3D. The mesoscale model can simulate microstructural evolution in a complex powder compact of hundreds or even thousands of particles of arbitrary shape and size by 1. curvature-driven grain growth, 2. pore migration and coalescence by surface diffusion, 3. vacancy formation, grain boundary diffusion and annihilation. This model was validated by comparing predictions of the simulation to analytical predictions for simple geometries. The model was then used to simulate sintering in complex powder compacts. Sintering stress and materials viscous module were obtained from the simulations. These constitutive equations were then used by macroscopic simulations for simulating shrinkage and shape changes in FEM simulations. The continuum theory of sintering embodied in the constitutive description of Skorohod and Olevsky was combined with results from microstructure evolution simulations to model shrinkage and deformation during. The continuum portion is based on a finite element formulation that allows 3D components to be modeled using SNL's nonlinear large-deformation finite element code, JAS3D. This tool provides a capability to model sintering of complex three-dimensional components. The model was verified by comparing to simulations results published in the literature. The model was validated using experimental results from various laboratory experiments performed by Garino. In addition, the mesoscale simulations were used to study anisotropic shrinkage in aligned, elongated powder compacts. Anisotropic shrinkage occurred in all compacts with aligned, elongated particles. However, the direction of higher shrinkage was in some cases along the direction of elongation and in other cases in the perpendicular direction depending on the details of the powder compact. In compacts of simple-packed, mono-sized, elongated particles, shrinkage was higher in the direction of elongation. In compacts of close-packed, mono-sized, elongated particles and of elongated particles with a size and shape distribution, the shrinkage was lower in the direction of elongation. We also explored the concept of a sintering stress tensor rather than the traditional sintering stress scalar concept for the case of anisotropic shrinkage. A thermodynamic treatment of this is presented. A method to calculate the sintering stress tensor is also presented. A user-friendly code that can simulate microstructural evolution during sintering in 2D and in 3D was developed. This code can run on most UNIX platforms and has a motif-based GUI. The microstructural evolution is shown as the code is running and many of the microstructural features, such as grain size, pore size, the average grain boundary length (in 2D) and area (in 3D), etc. are measured and recorded as a function of time. The overall density as the function of time is also recorded.
Sintering is one of the oldest processes used by man to manufacture materials dating as far back as 12,000 BC. While it is an ancient process, it is also necessary for many modern technologies such a multilayered ceramic packages, wireless communication devices, and many others. The process consists of thermally treating a powder or compact at a temperature below the melting point of the main constituent, for the purpose of increasing its strength by bonding together of the particles. During sintering, the individual particles bond, the pore space between particles is eliminated, the resulting component can shrinks by as much as 30 to 50% by volume, and it can distort its shape tremendously. Being able to control and predict the shrinkage and shape distortions during sintering has been the goal of much research in material science. And it has been achieved to varying degrees by many. The object of this project was to develop models that could simulate sintering at the mesoscale and at the macroscale to more accurately predict the overall shrinkage and shape distortions in engineering components. The mesoscale model simulates microstructural evolution during sintering by modeling grain growth, pore migration and coarsening, and vacancy formation, diffusion and annihilation. In addition to studying microstructure, these simulation can be used to generate the constitutive equations describing shrinkage and deformation during sintering. These constitutive equations are used by continuum finite element simulations to predict the overall shrinkage and shape distortions of a sintering crystalline powder compact. Both models will be presented. Application of these models to study sintering will be demonstrated and discussed. Finally, the limitations of these models will be reviewed.
Software has been developed and extended to allow finite element (FE) modeling of ceramic powder compaction using a cap-plasticity constitutive model. The underlying, general-purpose FE software can be used to model even the most complex three-dimensional (3D) geometries envisioned. Additionally, specialized software has been developed within this framework to address a general subclass of axisymmetric compacts that are common in industry. The expertise required to build the input deck, run the FE code, and post-process the results for this subclass of compacts is embedded within the specialized software. The user simply responds to a series of prompts, evaluates the quality of the FE mesh that is generated, and analyzes the graphical results that are produced. The specialized software allows users with little or no FE expertise to benefit from the tremendous power and insight that FE analysis can bring to the design cycle. The more general underlying software provides complete flexibility to model more complicated geometries and processes of interest to ceramic component manufacturers but requires significantly more user interaction and expertise.
Geologic, and historical well failure, production, and injection data were analyzed to guide development of three-dimensional geomechanical models of the Belridge diatomite field, California. The central premise of the numerical simulations is that spatial gradients in pore pressure induced by production and injection in a low permeability reservoir may perturb the local stresses and cause subsurface deformation sufficient to result in well failure. Time-dependent reservoir pressure fields that were calculated from three-dimensional black oil reservoir simulations were coupled uni-directionally to three-dimensional non-linear finite element geomechanical simulations. The reservoir models included nearly 100,000 gridblocks (100--200 wells), and covered nearly 20 years of production and injection. The geomechanical models were meshed from structure maps and contained more than 300,000 nodal points. Shear strain localization along weak bedding planes that causes casing dog-legs in the field was accommodated in the model by contact surfaces located immediately above the reservoir and at two locations in the overburden. The geomechanical simulations are validated by comparison of the predicted surface subsidence with field measurements, and by comparison of predicted deformation with observed casing damage. Additionally, simulations performed for two independently developed areas at South Belridge, Sections 33 and 29, corroborate their different well failure histories. The simulations suggest the three types of casing damage observed, and show that although water injection has mitigated surface subsidence, it can, under some circumstances, increase the lateral gradients in effective stress, that in turn can accelerate subsurface horizontal motions. Geomechanical simulation is an important reservoir management tool that can be used to identify optimal operating policies to mitigate casing damage for existing field developments, and applied to incorporate the effect of well failure potential in economic analyses of alternative infilling and development options.
In the manufacture of ceramic components, near-net-shape parts are commonly formed by uniaxially pressing granulated powders in rigid dies. Density gradients that are introduced into a powder compact during press-forming often increase the cost of manufacturing, and can degrade the performance and reliability of the finished part. Finite element method (FEM) modeling can be used to predict powder compaction response, and can provide insight into the causes of density gradients in green powder compacts; however, accurate numerical simulations require accurate material properties and realistic constitutive laws. To support an effort to implement an advanced cap plasticity model within the finite element framework to realistically simulate powder compaction, the authors have undertaken a project to directly measure as many of the requisite powder properties for modeling as possible. A soil mechanics approach has been refined and used to measure the pressure dependent properties of ceramic powders up to 68.9 MPa (10,000 psi). Due to the large strains associated with compacting low bulk density ceramic powders, a two-stage process was developed to accurately determine the pressure-density relationship of a ceramic powder in hydrostatic compression, and the properties of that same powder compact under deviatoric loading at the same specific pressures. Using this approach, the seven parameters that are required for application of a modified Drucker-Prager cap plasticity model were determined directly. The details of the experimental techniques used to obtain the modeling parameters and the results for two different granulated alumina powders are presented.