Publications

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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.

We present results from an experimental technique used to estimate the strength of Ta at extreme pressures (150 GPa) and strain rates (107s-1). A graded-density impactor (GDI) was fabricated using 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 with a 2-stage light gas gun, and shock-ramp-release velocity profiles were measured over timescales of ∼10 ns. Results are presented for the direct impact of the film onto LiF windows, which allows for a dynamic characterization of the GDI, as well as from impact onto thin (∼40μm) sputtered Ta samples backed by a LiF window. The measurements were coupled with mesoscale numerical simulations to infer the strength of Ta, and the results agree well with other high-pressure platforms, particularly when strain-rate, microstructural, and thermodynamic-path differences are considered.

The mechanical response of additively manufactured (AM) stainless steel 304L has been investigated across a broad range of loading conditions, covering 11 decades of strain rate, and compared with the behaviors of traditional ingot-derived (wrought) material. In general, the AM material exhibits a greater strength and reduced ductility compared with the baseline wrought form. These differences are consistently found from quasi-static and high strain rate tests. A detailed investigation of the microstructure, the defect structure, the phase, and the composition of both forms reveals differences that may contribute to the differing mechanical behaviors. Compared with the baseline wrought material, dense AM stainless steel 304L has a more complex grain structure with substantial sub-structure, a fine dispersion of ferrite, increased dislocation density, oxide dispersions and larger amounts of nitrogen. In-situ neutron diffraction studies conducted during quasi-static loading suggest that the increased strength of AM material is due to its initially greater dislocation density. The flow strength of both forms is correlated with dislocation density through a square root dependence akin to a Taylor-like relationship. Neutron diffraction measurements of lattice strains also correlate with a crystal plasticity finite element simulations of the tensile test. Other simulations predict a significant degree of elastic and plastic anisotropy due to crystallographic texture. Hopkinson tests at higher strain rates $\dot{ε}$ = 500 and 2500 s^-1 ) also show a greater strength for AM stainless steel 304L; although, the differences compared with wrought are reduced at higher strain rates. Gas gun impact tests, including reverse ballistic, forward ballistic and spall tests, consistently reveal a larger dynamic strength in the AM material. The Hugoniot Elastic Limit (HEL) of AM SS 304L exceeds that of wrought material although considerable variability is observed with the AM material. Forward ballistic testing demonstrates spall strengths of AM material (3.27 -- 3.91 GPa) that exceed that of the wrought material (2.63 -- 2.88 GPa). The Hugoniot equation-of-state for AM samples matches archived data for this metal alloy.

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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.

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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.

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In order to generate new properties of metals exposed to high pressure states, it is desirable to study samples loaded in one-dimensional strain. Previous work to obtain these ideal conditions, involve a technique where the sample was recovered at late times to examine its microstructure. In those experiments, the shock-loading was produced by impacting the sample with a flyer plate. In the present work, we modified the sample recovery assembly and optimized it for ramp wave loading. We describe the 2-D calculations performed with the ALEGRA MHD code that led to improved recovery assembly efficiency. Preliminary comparisons of the simulations with measurements of the sample deformation from an experiment indicate excellent agreement. © 2009 American Institute of Physics.

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Polycrystalline diamond compact (PDC) bits have gained i wide popularity in the petroleum industry for drilling soft and; moderately firm formations. However, in hard formation applications, the PDC bit still has limitations, even though recent developments in PDC cutter designs and materials steadily imj proves PDC bit performance. The limitations of PDC bits for drilling hard formations is an important technical obstacle that must be overcome before using the PDC bit to develop competii tively priced electricity from enhanced geothermal systems, as well as deep continental gas fields. Enhanced geothermal energy is a very promising source for generating electrical energy and therefore, there is an urgent need to further enhance PDC bit per-j formance in hard formations. In this paper, the cutting efficiency of the PDC bit has been) analyzed based on the development of an analytical single PDC cutter force model. The cutting efficiency of a single PDC cutterj is defined as the ratio of the volume removed by a cutter over the force required to remove that volume of rock. The cutting I efficiency is found to be a function of the back rake angle, the depth of cut and the rock property, such as the angle of internal' friction. The highest cutting efficiency is found to occur at specific back rake angles of the cutter based on the material properties of the rock. The cutting efficiency directly relates to the internal angle of friction of the rock being cut. The results of this analysis can be integrated to study PDC bit performance. It can also provide a guideline to the application' and design of PDC bits for specific rocks.

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Complementary gas-gun and electro-magnetic pulse tests conducted in Sandia's Dynamic Integrated Compression Experimental (DICE) Facility have, respectively, probed the behavior of electronic-grade Kovar samples under controlled impact and intermediate-strain-rate ICE (Isentropic Compression Experiment) loading. In all tests, velocity interferometer (VISAR) diagnostics provided time-resolved measurements of sample response for conditions involving one-dimensional (i:e:, uniaxial strain) compression and release. Wave-profile data from the gas-gun impact experiments have been analyzed to assess the Hugoniot Elastic Limit (HEL), Hugoniot equation of state, spall strength, and high-pressure yield strength of shocked Kovar. The ICE wave-profile data have been interpreted to determine the locus of isentropic stress-strain states generated in Kovar for deformation rates substantially lower than those associated with a shock process. The impact and ICE results have been compared to examine the influence of loading rate on high-pressure strength.

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A series of field tests sponsored by Sandia National Laboratories has simultaneously demonstrated the hard-rock drilling performance of different industry-supplied drag bits as well as Sandia's new Diagnostics-While-Drilling (DWD) system, which features a novel downhole tool that monitors dynamic conditions in close proximity to the bit. Drilling with both conventional and advanced ("best effort") drag bits was conducted at the GTI Catoosa Test Facility (near Tulsa, OK) in a well-characterized lithologic column that features an extended hard-rock interval of Mississippi limestone above a layer of highly abrasive Misener sandstone and an underlying section of hard Arbuckle dolomite. Output from the DWD system was closely observed during drilling and was used to make real-time decisions for adjusting the drilling parameters. This paper summarizes penetration rate and damage results for the various drag bits, shows representative DWD display data, and illustrates the application of these data for optimizing drilling performance and avoiding trouble.

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Sandia National Laboratories has partnered with industry on a multifaceted, baseline experimental study that supports the development of improved drag cutters for advanced drill bits. Different nonstandard cutter lots were produced and subjected to laboratory tests that evaluated the influence of selected design and processing parameters on cutter loads, wear, and durability pertinent to the penetration of hard rock with mechanical properties representative of formations encountered in geothermal or deep oil/gas drilling environments. The focus was on cutters incorporating ultrahard PDC (polycrystalline diamond compact) overlays (i.e., diamond tables) on tungsten-carbide substrates. Parameter variations included changes in cutter geometry, material composition, and processing conditions. Geometric variables were the diamond-table thickness, the cutting-edge profile, and the PDC/substrate interface configuration. Material and processing variables for the diamond table were, respectively, the diamond particle size and the sintering pressure applied during cutter fabrication. Complementary drop-impact, granite-log abrasion, linear cutting-force, and rotary-drilling tests examined the response of cutters from each lot. Substantial changes in behavior were observed from lot to lot, allowing the identification of features contributing major (factor of 10+) improvements in cutting performance for hard-rock applications. Recent field demonstrations highlight the advantages of employing enhanced cutter technology during challenging drilling operations.

PDC drill bit performance has been greatly improved over the past three decades by innovations in bit design and how these designs are applied. The next leap forward is most likely to come from using high-speed, real-time downhole data to optimize the performance of these sophisticated bits on an application-by-application basis. By effectively managing conditions of lateral, axial and torsional acceleration, damage to cutting structures can be minimized for improved penetration rates. Avoiding these damaging vibrations is essential to increasing bit durability and improving overall drilling economics. This paper describes one set of independent drilling optimization results obtained as part of a series of controlled demonstrations of PDC bits. Sandia National Laboratories on behalf of the U. S. Department of Energy (DOE) managed this work. The effort was organized as a Cooperative Research and Development Agreement (CRADA) established between Sandia and four bit manufacturers with DOE funding and in-kind contributions by the industry partners. The goal of this CRADA was to demonstrate drag bit performance in formations with degrees of hardness typical of those encountered while drilling geothermal wells. The test results indicate that the surface weight-on-bit (WOB), revolutions per minute (RPM) and torque readings traditionally used to guide adjustments in the drilling parameters do not always provide the true picture of what is really taking place at the bit. Instead, a holistic approach combining traditional methods of optimization together with high-speed, real-time data enables far better decisions for improving bit performance and avoiding damaging situations that may have otherwise gone unnoticed.

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