Publications

Sandia National Laboratories has constructed an unyielding target at the end of its 2000-foot rocket sled track. This target is made up of approximately 5 million pounds of concrete, an embedded steel load spreading structure, and a steel armor plate face that varies from 10 inches thick at the center to 4 inches thick at the left and right edges. The target/track combination will allow horizontal impacts at regulatory speeds of very large objects, such as a full-scale rail cask, or high-speed impacts of smaller packages. The load-spreading mechanism in the target is based upon the proven design that has been in use for over 20 years at Sandia's aerial cable facility. That target, with a weight of 2 million pounds, has successfully withstood impact forces of up to 25 million pounds. It is expected that the new target will be capable of withstanding impact forces of more than 70 million pounds. During construction various instrumentation was placed in the target so that the response of the target during severe impacts can be monitored. This paper will discuss the construction of the target and provide insights on the testing capabilities at the sled track with this new target.

Typical shock testing requirements specify shock pulses of several hundred to several thousand g's, with pulse duration usually less than a few milliseconds. A requirement to qualify a shipping container to a head-on tractortrailer crash environment led to the development of a new test technique capable of low-g (< 50 g), long-duration (> 100 ms) shock pulses. This technique utilizes nylon webbing engaged in tension to shape the pulse produced by the interaction of two sleds on an indoor track. A combination of experimental and computational methodology was used to successfully develop the test technique to solve a specific testing requirement. The process used to develop the test technique is emphasized in this paper, where a prudent balance between experiment and analysis resulted in a cost effective solution. The results show that the quasi-static load-elongation behavior of the nylon webbing can be used to adequately model the dynamic behavior of the webbing, allowing design of the experimental setup with a simple computational model. The quasi-static load-elongation measurements are described along with the development of the computational model. Results of a full-scale experiment are presented, showing that the required shock pulse could be achieved with this test technique.

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Geotechnical structures such as underground bunkers, tunnels, and building foundations are subjected to stress fields produced by the gravity load on the structure and/or any overlying strata. These stress fields may be reproduced on a scaled model of the structure by proportionally increasing the gravity field through the use of a centrifuge. This technology can then be used to assess the vulnerability of various geotechnical structures to explosive loading. Applications of this technology include assessing the effectiveness of earth penetrating weapons, evaluating the vulnerability of various structures, counter-terrorism, and model validation. This document describes the development of expertise in scale model explosive testing on geotechnical structures using Sandia`s large scale centrifuge facility. This study focused on buried structures such as hardened storage bunkers or tunnels. Data from this study was used to evaluate the predictive capabilities of existing hydrocodes and structural dynamics codes developed at Sandia National Laboratories (such as Pronto/SPH, Pronto/CTH, and ALEGRA). 7 refs., 50 figs., 8 tabs.

Pyroshock is a potentially severe environment produced by the detonation of explosively actuated components and stage separation hardware. Electronic components exposed to pyroshock events during flight or deployment can be damaged by this high frequency, high G shock. Flight qualification of these components may be accomplished using one of many existing techniques to simulate the pyroshock environment in the laboratory. Two new techniques developed at Sandia National Laboratories allow larger components to be tested to a wide variety of pyroshock environments. The frequency content and amplitude of the simulated pyroshock can be easily controlled in a predictable manner. The pyroshock environment is produced by the resonant response of a test fixture that has been excited by a mechanical impact. The resonant fixture has a dominant frequency that can be continuously adjusted over a frequency range that is typically found in most pyroshock environments. The test apparatus and techniques utilized by each method will be described in this paper. Experimental results will be presented which illustrate the capabilities of each method.

Aerospace components are often subjected to pyroshock events during flight and deployment, and must be qualified to this frequently severe environment. Laboratory simulation of pyroshock using a mechanically excited resonant fixture, has gained favor at Sandia for testing small (<8 inch cube) weapon components. With this method, each different shock environment required a different resonant fixture that was designed such that it`s response matched the environment. A new test method has been developed which eliminates the need to have a different resonant fixture for each test requirement. This is accomplished by means of a tunable resonant fixture that has a response which is adjustable over a wide frequency range. The adjustment of the fixture`s response is done in a simple and deterministic way. This report covers the first phase of this research, which includes design conception through fabrication and evaluation of hardware capable of testing components with up to a 10 inch {times} 10 inch base. This method will ultimately allow the testing of much larger items, perhaps as large as entire small satellites.