This report documents the results of explosive re-qualification tests of the EDS V26 Vessel that were conducted at Sandia National Laboratories in Albuquerque, New Mexico in May 2015 following the retrofitting of the vessel with a three piece clamp for use on the P2A system. The V26 containment vessel is the second EDS vessel to be fabricated under Code Case 2564 of the ASME Boiler and Pressure Vessel Code, which provides rules for the design of impulsively loaded vessels. The explosive rating for the vessel, based on the code case, is nine (9) pounds TNT-equivalent for up to 637 detonations. The goals of the tests were to qualify the vessel, particularly the clamping system, for explosive use. The explosive tests consisted of a 9 pound bare charge of Composition C-4 (equivalent to 11.25 pounds TNT), followed by a 7.2 pound bare charge of Composition C-4 (equivalent to 9 pounds of TNT). Helium permeation measurements of the seal and strain measurements using a pi tape and strain gauges were made. All vessel acceptance criteria were met.
The objective of the test was to qualify the vessel for its intended use by subjecting it to a 1.25 times overtest. The criteria for success are that the measured strains do not exceed the calculated strains from the vessel analysis, there is no significant additional plastic strain on subsequent tests at the rated design load (shakedown), and there is no significant damage to the vessel and attached hardware that affect form, fit, or function. Testing of the V25 Vessel in 2011 established a precedent for testing V26 [2]. As with V25, two tests were performed to satisfy this objective. The first test used 9 pounds of Composition C-4 (11.25 lbs. TNT-equivalent), which is 125 percent of the design basis load. The second test used 7.2 pounds of Composition C-4 (9 lbs. TNT-equivalent) which is 100 percent of the design basis load. The first test provided the required overtest while the second test served to demonstrate shakedown and the absence of additional plastic deformation. Unlike the V25 vessel, which was mounted in a shipping cradle during testing, the V26 vessel was mounted on the EDS P2U3 trailer prior to testing. Visual inspections of the EDS vessel, surroundings, and diagnostics were completed before and after each test event. This visual inspection included analyzing the seals, fittings, and interior surfaces of the EDS vessel and documenting any abnormalities or damages. Photographs were used to visually document vessel conditions and findings before and after each test event.
Establishing design and inspection criteria for impulsively loaded vessels requires a precise understanding of the damage mechanisms and failure modes experienced by the vessels. To that end, Stress Engineering Services, Inc. performed a metallurgical examination of three impulsively loaded vessels that Sandia National Laboratories had intentionally tested to failure, two by impulsive loading and one by hydrotest after impulsive load testing. The vessels were scale models of Type 316 stainless steel vessels use for disposal of chemical ordnance. The examination identified microstructural effects, mechanical damage, and fractographic features associated with exposure to impulsive loads. In particular, the examination identified damage associated with wave interference patterns and unusual patterns of deformation and cracking associated with residual ferrite stringers within the austenitic matrix of the alloy. The characterization of the damage mechanisms leading to failure has direct relevance to ASME design criteria, to the selection of appropriate materials, and to inspection practices for impulsively loaded vessels.