Publications

We investigate the magnetostriction of field-structured magnetoelastomers, which are an important class of materials that have great potential as both sensors and actuators. Field-structured magnetoelastomers are synthesized by suspending magnetic particles in a polymeric resin and subjecting these to magnetic structuring fields during polymerization. These structuring fields can consist of as many as three orthogonal ac components, allowing a wide variety of particles structures-chains, sheets, or networks-to be formed. A principal issue is how particle structure and loading affects the magnetostriction of these materials. To investigate magnetostriction in these field-structured composites we have constructed a constant stress, optical cantilever apparatus capable of 1 ppm strain resolution. Magnetoelastomers having a wide range of particle loadings and structures are investigated, and it is shown that the observed deformation depends strongly on composite structure. The best magnetoelastomers exhibit a contractive strain of 10 000 ppm, the worst materials exhibit a negative, tensile response, which we show is due to the dominance of demagnetizing field effects over magnetostriction. Finally, some discussion is given to the surprising finding that magnetostriction is proportional to the sample prestrain. Simulations of a chain of particles in an elastomer show that particle clumping transitions can occur, but this does not account for the dependence of magnetostriction on prestrain. © 2006 The American Physical Society.

Field-structured magnetic particle composites are an important new class of materials that have great potential as both sensors and actuators. These materials are synthesized by suspending magnetic particles in a polymeric resin and subjecting these to magnetic fields while the resin polymerizes. If a simple uniaxial magnetic field is used, the particles will form chains, yielding composites whose magnetic susceptibility is enhanced along a single direction. A biaxial magnetic field, comprised of two orthogonal ac fields, forms particle sheets, yielding composites whose magnetic susceptibility is enhanced along two principal directions. A balanced triaxial magnetic field can be used to enhance the susceptibility in all directions, and biased heterodyned triaxial magnetic fields are especially effective for producing composites with a greatly enhanced susceptibility along a single axis. Magnetostriction is quadratic in the susceptibility, so increasing the composite susceptibility is important to developing actuators that function well at modest fields. To investigate magnetostriction in these field-structured composites we have constructed a sensitive, constant-stress apparatus capable of 1 ppm strain resolution. The sample geometry is designed to minimize demagnetizing field effects. With this apparatus we have demonstrated field-structured composites with nearly 10,000 ppm strain.

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The dynamics of particle suspensions in heterodyned triaxial magnetic fields was discussed. Triaxial magnetic fields were used to create complex particle interactions. The interactions were observed after heterodyning of the field component was employed to produce slow oscillations. Analysis suggested the application of triaxial fields for producing improved materials.

Laser beam welding is the principal welding process for the joining of Sandia weapon components because it can provide a small fusion zone with low overall heating. Improved process robustness is desired since laser energy absorption is extremely sensitive to joint variation and filler metal is seldom added. This project investigated the experimental and theoretical advantages of combining a fiber optic delivered Nd:YAG laser with a miniaturized GMAW system. Consistent gas metal arc droplet transfer employing a 0.25 mm diameter wire was only obtained at high currents in the spray transfer mode. Excessive heating of the workpiece in this mode was considered an impractical result for most Sandia micro-welding applications. Several additional droplet detachment approaches were investigated and analyzed including pulsed tungsten arc transfer(droplet welding), servo accelerated transfer, servo dip transfer, and electromechanically braked transfer. Experimental observations and rigorous analysis of these approaches indicate that decoupling droplet detachment from the arc melting process is warranted and may someday be practical.

Aluminum oxide (ALOX) filled epoxy is the dielectric encapsulant in shock driven high-voltage power supplies. ALOX encapsulants display a high dielectric strength under purely electrical stress, but minimal information is available on the combined effects of high voltage and mechanical shock. We report breakdown results from applying electrical stress in the form of a unipolar high-voltage pulse of the order of 10-{micro}s duration, and our findings may establish a basis for understanding the results from proposed combined-stress experiments. A test specimen geometry giving approximately uniform fields is used to compare three ALOX encapsulant formulations, which include the new-baseline 459 epoxy resin encapsulant and a variant in which the Alcoa T-64 alumina filler is replaced with Sumitomo AA-10 alumina. None of these encapsulants show a sensitivity to ionizing radiation. We also report results from specimens with sharp-edged electrodes that cause strong, localized field enhancement as might be present near electrically-discharged mechanical fractures in an encapsulant. Under these conditions the 459-epoxy ALOX encapsulant displays approximately 40% lower dielectric strength than the older Z-cured Epon 828 formulation. An investigation of several processing variables did not reveal an explanation for this reduced performance. The 459-epoxy encapsulant appears to suffer electrical breakdown if the peak field anywhere reaches a critical level. The stress-strain characteristics of Z-cured ALOX encapsulant are measured under high triaxial pressure and we find that this stress causes permanent deformation and a network of microscopic fractures. Recommendations are made for future experimental work.