Graded density impactors (GDIs) have long been of interest to provide off-Hugoniot loading capabilities for impact systems. We describe a new technique which utilizes sputter deposition to produce an approximately 40 µm-thick film containing alternating layers of Al and Cu. The thicknesses of the respective layers are adjusted to give an effective density gradient through the film. The GDIs were launched into samples of interest with a 2-stage light gas gun, and the resulting shock-ramp-release velocity profiles were measured over timescales of ~10 ns with a new velocimetry probe. Results are shown for the direct impact of the film onto a LiF window, which allows for the dynamic characterization of the GDI, as well as from impact onto a thin (~40 µm) sputtered Ta sample backed by a LiF window. These measurements were coupled into mesoscale numerical simulations to infer the strength of Ta at the high rate (107 s-1), and high pressure (1 MBar) conditions this unique capability provides. Initial results suggest this is a viable strength platform which fills a critical gap and aids in cross-platform comparisons with other high-pressure strength platforms.
This report outlines the fiscal year (FY) 2019 status of an ongoing multi-year effort to develop a general, microstructurally-aware, continuum-level model for representing the dynamic response of material with complex microstructures. This work has focused on accurately representing the response of both conventionally wrought processed and additively manufactured (AM) 304L stainless steel (SS) as a test case. Additive manufacturing, or 3D printing, is an emerging technology capable of enabling shortened design and certification cycles for stockpile components through rapid prototyping. However, there is not an understanding of how the complex and unique microstructures of AM materials affect their mechanical response at high strain rates. To achieve our project goal, an upscaling technique was developed to bridge the gap between the microstructural and continuum scales to represent AM microstructures on a Finite Element (FE) mesh. This process involves the simulations of the additive process using the Sandia developed kinetic Monte Carlo (KMC) code SPPARKS. These SPPARKS microstructures are characterized using clustering algorithms from machine learning and used to populate the quadrature points of a FE mesh. Additionally, a spall kinetic model (SKM) was developed to more accurately represent the dynamic failure of AM materials. Validation experiments were performed using both pulsed power machines and projectile launchers. These experiments have provided equation of state (EOS) and flow strength measurements of both wrought and AM 304L SS to above Mbar pressures. In some experiments, multi-point interferometry was used to quantify the variation is observed material response of the AM 304L SS. Analysis of these experiments is ongoing, but preliminary comparisons of our upscaling technique and SKM to experimental data were performed as a validation exercise. Moving forward, this project will advance and further validate our computational framework, using advanced theory and additional high-fidelity experiments. ACKNOWLEDGEMENTS The authors greatly appreciate the support of Mike Saavedra in machining the experimental samples. The authors would also like to thank the Dynamic Integrated Compression facility (DICE) staff for executing the Thor experiments: Brian Stoltzfus, Randy Hickman, Keith Hodge, Joshua Usher, Lena Pacheco, and Eric Breden. The authors would also like to thank the staff at the Shock Thermodynamics Applied Research (STAR) facility for executing the plate impact experiments: Scott Alexander, Bill Reinhart, Bernardo Farfan, Rocky Palomino, John Martinez, and Rafael Sanchez. Lastly, the authors would like to acknowledge the development support of Jason Sanchez in ALEGRA to incorporate our upscaling method and Michael Powell for helping with post processing scripts for results analysis.
Materials in nuclear and conventional weapons can reach multi-megabar pressures and 1000s of degree temperatures on timescales ranging from microseconds to nanoseconds. Understanding the response of complex materials under these conditions is important for designing and assessing changes to nuclear weapons. In the next few decades, a major concern will be evaluating the behavior of aging materials and remanufactured components. The science to enable the program to underwrite decisions quickly and confidently on use, remanufacturing, and replacement of these materials will be critical to NNSA’s new Stockpile Responsiveness Program. Material response is also important for assessing the risks posed by adversaries or proliferants. Dynamic materials research, which refers to the use of high-speed experiments to produce extreme conditions in matter, is an important part of NNSA’s Stockpile Stewardship Program.
Gold nanostructured materials exhibit important size- and shape-dependent properties that enable a wide variety of applications in photocatalysis, nanoelectronics and phototherapy. Here we show the use of superfast dynamic compression to synthesize extended gold nanostructures, such as nanorods, nanowires and nanosheets, with nanosecond coalescence times. Using a pulsed power generator, we ramp compress spherical gold nanoparticle arrays to pressures of tens of GPa, demonstrating pressure-driven assembly beyond the quasi-static regime of the diamond anvil cell. Our dynamic magnetic ramp compression approach produces smooth, shockless (that is, isentropic) one-dimensional loading with low-temperature states suitable for nanostructure synthesis. Transmission electron microscopy clearly establishes that various gold architectures are formed through compressive mesoscale coalescences of spherical gold nanoparticles, which is further confirmed by in-situ synchrotron X-ray studies and large-scale simulation. This nanofabrication approach applies magnetically driven uniaxial ramp compression to mimic established embossing and imprinting processes, but at ultra-short (nanosecond) timescales.
Gas-gun experiments have probed the compression and release behavior of impact-loaded 304L stainless steel specimens that were machined from additively manufactured (AM) blocks as well as baseline ingot-derived bar stock. The AM technology permits direct fabrication of net-or near-net-shape metal parts. For the present investigation, velocity interferometer (VISAR) diagnostics provided time-resolved measurements of sample response for onedimensional (i.e., uniaxial strain) shock compression to peak stresses ranging from 0.2 to 7.0 GPa. The acquired waveprofile data have been analyzed to determine the comparative Hugoniot Elastic Limit (HEL), Hugoniot equation of state, spall strength, and high-pressure yield strength of the AM and conventional materials. The possible contributions of various factors, such as composition, porosity, microstructure (e.g., grain size and morphology), residual stress, and/or sample axis orientation relative to the additive manufacturing deposition trajectory, are considered to explain differences between the AM and baseline 304L dynamic material results.
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.
Additive manufacturing (AM) technology has been developed to fabricate metal components that include complex prototype fabrication, small lot production, precision repair or feature addition, and tooling. However, the mechanical response of the AM materials is a concern to meet requirements for specific applications. Differences between AM materials as compared to wrought materials might be expected, due to possible differences in porosity (voids), grain size, and residual stress levels. When the AM materials are designed for impact applications, the dynamic mechanical properties in both compression and tension need to be fully characterized and understood for reliable designs. In this study, a 304L stainless steel was manufactured with AM technology. For comparison purposes, both the AM and wrought 304L stainless steels were dynamically characterized in compression Kolsky bar techniques. They dynamic compressive stress-strain curves were obtained and the strain rate effects were determined for both the AM and wrought 304L stainless steels. A comprehensive comparison of dynamic compressive response between the AM and wrought 304L stainless steels was performed. SAND2015-0993 C.