Publications

Abstract not provided.

Life Extension Program (LEP) is a program to repair/replace components of nuclear weapons to ensure the ability to meet military requirements. The W78/88-1 LEP encompasses the modernization of two major nuclear weapon reentry systems into an interoperable warhead. Several design concepts exist to provide different options for robust safety and security themes, maximum non-nuclear commonality, and cost. Simulation is one capability used to evaluate the mechanical performance of the designs in various operational environments, plan for system and component qualification efforts, and provide insight into the survivability of the warhead in environments that are not currently testable. The simulation efforts use several Sandia-developed tools through the Advanced Simulation and Computing program, including Cubit for mesh generation, the DART Model Manager, SIERRA codes running on the HPC TLCC2 platforms, DAKOTA, and ParaView. Several programmatic objectives were met using the simulation capability including: (1) providing early environmental specification estimates that may be used by component designers to understand the severity of the loads their components will need to survive, (2) providing guidance for load levels and configurations for subassembly tests intended to represent operational environments, and (3) recommending design options including modified geometry and material properties. These objectives were accomplished through regular interactions with component, system, and test engineers while using the laboratory's computational infrastructure to effectively perform ensembles of simulations. Because NNSA has decided to defer the LEP program, simulation results are being documented and models are being archived for future reference. However, some advanced and exploratory efforts will continue to mature key technologies, using the results from these and ongoing simulations for design insights, test planning, and model validation.

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This report describes an FY13 effort to develop the latest version of the Sandia Cooler, a breakthrough technology for air-cooled heat exchangers that was developed at Sandia National Laboratories. The project was focused on fabrication, assembly and demonstration of ten prototype systems for the cooling of high power density electronics, specifically high performance desktop computers (CPUs). In addition, computational simulation and experimentation was carried out to fully understand the performance characteristics of each of the key design aspects. This work culminated in a parameter and scaling study that now provides a design framework, including a number of design and analysis tools, for Sandia Cooler development for applications beyond CPU cooling.

Deflections of an impeller due to centripetal forces are calculated using finite element analysis. The lateral, or out of plane, deflections are an important design consideration for this particular impeller because it incorporates an air bearing with critical gap tolerances. The target gap distance is approximately 10 microns at a rotational velocity of 2500 rpm. The centripetal forces acting on the impeller cause it deflect in a concave fashion, decreasing the initial gap distance as a function of radial position. This deflection is characterized for a previous and updated impeller design for comparative purposes. The impact of design options such as material selection, geometry dimensions, and operating rotational velocity are also explored, followed by a sensitivity study with these parameters bounded by specific design values. A modal analysis is also performed to calculate the impeller's natural frequencies which are desired to be avoided during operation. The finite element modeling techniques continue to be exercised by the impeller design team to address specific questions and evaluate conceptual designs, some of which are included in the Appendix.

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