Publications

Abstract not provided.

The foam material of interest in this investigation is a rigid closed-cell polyurethane foam PMDI with a nominal density of 20 pcf (320 kg/m3). Three separate types of compression experiments were conducted on foam specimens. The heterogeneous deformation of foam specimens and strain concentration at the foam-steel interface were obtained using the 3-dimensional digital image correlation (3D-DIC) technique. These experiments demonstrated that the 3D-DIC technique is able to obtain accurate and full-field large deformation of foam specimens, including strain concentrations. The experiments also showed the effects of loading configurations on deformation and strain concentration in foam specimens. These DIC results provided experimental data to validate the previously developed viscoplastic foam model (VFM). In the first experiment, cubic foam specimens were compressed uniaxially up to 60%. The full-field surface displacement and strain distributions obtained using the 3D-DIC technique provided detailed information about the inhomogeneous deformation over the area of interest during compression. In the second experiment, compression tests were conducted for cubic foam specimens with a steel cylinder inclusion, which imitate the deformation of foam components in a package under crush conditions. The strain concentration at the interface between the steel cylinder and the foam specimen was studied in detail. In the third experiment, the foam specimens were loaded by a steel cylinder passing through the center of the specimens rather than from its end surface, which created a loading condition of the foam components similar to a package that has been dropped. To study the effects of confinement, the strain concentration and displacement distribution over the defined sections were compared for cases with and without a confinement fixture.

The LENS Qualification team had the goal of performing a process qualification for the Laser Engineered Net Shaping{trademark}(LENS{reg_sign}) process. Process Qualification requires that a part be selected for process demonstration. The AY1E0125 D-Bottle Bracket from the W80-3 was selected for this work. The repeatability of the LENS process was baselined to determine process parameters. Six D-Bottle brackets were deposited using LENS, machined to final dimensions, and tested in comparison to conventionally processed brackets. The tests, taken from ES1E0003, included a mass analysis and structural dynamic testing including free-free and assembly-level modal tests, and Haversine shock tests. The LENS brackets performed with very similar characteristics to the conventionally processed brackets. Based on the results of the testing, it was concluded that the performance of the brackets made them eligible for parallel path testing in subsystem level tests. The testing results and process rigor qualified the LENS process as detailed in EER200638525A.

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.

Abstract not provided.