Constitutive modeling is an important aspect of computational solid mechanics. Sandia National Laboratories has always had a considerable effort in the development of constitutive models for complex material behavior. However, for this development to be of use the models need to be implemented in our solid mechanics application codes. In support of this important role, the Library of Advanced Materials for Engineering (LAME) has been developed in Engineering Sciences. The library allows for simple implementation of constitutive models by model developers and access to these models by application codes. The library is written in C++ and has a very simple object oriented programming structure. This report summarizes the current status of LAME.
Downhole sonar surveys from the four active U.S. Strategic Petroleum Reserve sites have been modeled and used to generate a four-volume sonar atlas, showing the three-dimensional geometry of each cavern. This volume 2 focuses on the Big Hill SPR site, located in southeastern Texas. Volumes 1, 3, and 4, respectively, present images for the Bayou Choctaw SPR site, Louisiana, the Bryan Mound SPR site, Texas, and the West Hackberry SPR site, Louisiana. The atlas uses a consistent presentation format throughout. The basic geometric measurements provided by the down-cavern surveys have also been used to generate a number of geometric attributes, the values of which have been mapped onto the geometric form of each cavern using a color-shading scheme. The intent of the various geometrical attributes is to highlight deviations of the cavern shape from the idealized cylindrical form of a carefully leached underground storage cavern in salt. The atlas format does not allow interpretation of such geometric deviations and anomalies. However, significant geometric anomalies, not directly related to the leaching history of the cavern, may provide insight into the internal structure of the relevant salt dome.
The PANL software determines path through an Adversary Sequence Diagram (ASD) with minimum Probability of Interruption, P(I), given the ASD information and data about site detection, delay, and response force times. To accomplish this, the software generates each path through the ASD, then applies the Estimate of Adversary Sequence Interruption (EASI) methodology for calculating P(I) to each path, and keeps track of the path with the lowest P(I). Primary use is for training purposes during courses on physical security design. During such courses PANL will be used to demonstrate to students how more complex software codes are used by the US Department of Energy to determine the most-vulnerable paths and, where security needs improvement, how such codes can help determine physical security upgrades.
A typical aircraft can experience over 2,000 fatigue cycles (cabin pressurizations) and even greater flight hours in a single year. An unavoidable by-product of aircraft use is that crack, impact, and corrosion flaws develop throughout the aircraft's skin and substructure elements. Economic barriers to the purchase of new aircraft have placed even greater demands on efficient and safe repair methods. The use of bonded composite doublers offers the airframe manufacturers and aircraft maintenance facilities a cost effective method to safely extend the lives of their aircraft. Instead of riveting multiple steel or aluminum plates to facilitate an aircraft repair, it is now possible to bond a single Boron-Epoxy composite doubler to the damaged structure. The FAA's Airworthiness Assurance Center at Sandia National Labs (AANC), Boeing, and Federal Express completed a pilot program to validate and introduce composite doubler repair technology to the U.S. commercial aircraft industry. This project focused on repair of DC-10 fuselage structure and its primary goal was to demonstrate routine use of this repair technology using niche applications that streamline the design-to-installation process. As composite doubler repairs gradually appear in the commercial aircraft arena, successful flight operation data is being accumulated. These commercial aircraft repairs are not only demonstrating the engineering and economic advantages of composite doubler technology but they are also establishing the ability of commercial maintenance depots to safely adopt this repair technique. This report presents the array of engineering activities that were completed in order to make this technology available for widespread commercial aircraft use. Focused laboratory testing was conducted to compliment the field data and to address specific issues regarding damage tolerance and flaw growth in composite doubler repairs. Fatigue and strength tests were performed on a simulated wing repair using a substandard design and a flawed installation. In addition, the new Sol-Gel surface preparation technique was evaluated. Fatigue coupon tests produced Sol-Gel results that could be compared with a large performance database from conventional, riveted repairs. It was demonstrated that not only can composite doublers perform well in severe off-design conditions (low doubler stiffness and presence of defects in doubler installation) but that the Sol-Gel surface preparation technique is easier and quicker to carry out while still producing optimum bonding properties. Nondestructive inspection (NDI) methods were developed so that the potential for disbond and delamination growth could be monitored and crack growth mitigation could be quantified. The NDI methods were validated using full-scale test articles and the FedEx aircraft installations. It was demonstrated that specialized NDI techniques can detect flaws in composite doubler installations before they reach critical size. Probability of Detection studies were integrated into the FedEx training in order to quantify the ability of aircraft maintenance depots to properly monitor these repairs. In addition, Boeing Structural Repair and Nondestructive Testing Manuals were modified to include composite doubler repair and inspection procedures. This report presents the results from the FedEx Pilot Program that involved installation and surveillance of numerous repairs on operating aircraft. Results from critical NDI evaluations are reported in light of damage tolerance assessments for bonded composite doublers. This work has produced significant interest from airlines and aircraft manufacturers. The successful Pilot Program produced flight performance history to establish the durability of bonded composite patches as a permanent repair on commercial aircraft structures. This report discusses both the laboratory data and Pilot Program results from repair installations on operating aircraft to introduce composite doubler repairs into mainstream commercial aircraft use.
There are commercial and military applications in which a material needs to serve as a barrier that must subsequently be removed. In many cases it is desirable that once the barrier has served its function that it then be reduced to small pieces. For example, in pipelines and in downhole drilling applications, valves are needed to function as barriers that can sustain high pressures. Later the valves must be removed and essentially disappear or be rendered to such a small size that they do not interfere with the functioning of other equipment. Military applications include covers on missile silos or launch vehicles. Other applications might require that a component be used once as an actuator or for passive energy storage, and then be irreversibly removed, again so as not to interfere with the function or motion of other parts of the device. Brittle materials, especially those that are very strong, or are pre-stressed, are ideal candidates for these applications. Stressed glass can be produced in different sizes and shapes and the level of strength and pre-stress, both of which control the fragmentation, can be manipulated by varying the processing. Stressed glass can be engineered to fracture predictably at a specific stress level. Controlling the central tension allows the fragment size to be specified. The energy that is stored in the residual stress profile that results from ion exchange or thermal tempering processes can be harnessed to drive fragmentation of the component once it has been deliberately fractured. Energy can also be stored in the glass by mechanical loading. Energy from both of these sources can be released either to perform useful work or to initiate another reaction. Once the stressed glass has been used as a barrier or actuator it can never be ''used'' again because it fragments into many small unrecognizable pieces during the actuation. Under some circumstances it will interfere with the motion or functioning of other parts of a device. Our approach was to use stressed glass to develop capabilities for making components that can be used as barriers, as actuating devices that passively store energy, or as a mechanical weaklink that is destroyed by some critical shock or crush load. The objective of this project was to develop one or more prototype devices using stressed glass technology and demonstrate their potential for applications of interest. This work is intended to provide critical information and technologies for Sandia's NP&A and MT&A customers, and is relevant to commercial applications for these same materials. Most of the studies in this project were conducted using the Corning 0317 sodium aluminosilicate glass composition.
This Pollution Prevention Opportunity Assessment (PPOA) was conducted for the Sandia National Laboratories/California (SNL/CA) Environmental Management Department between May 2006 and March 2007, to evaluate the current site-wide recycling program for potential opportunities to improve the efficiency of the program. This report contains a summary of the information collected and analyses performed with recommended options for implementation. The SNL/NM Pollution Prevention (P2) staff worked with the SNL/CA P2 Staff to arrive at these options.
This manual describes a library for aerosol kinetics and transport, called CADS (Cantera Aerosol Dynamics Simulator), which employs a section-based approach for describing the particle size distributions. CADS is based upon Cantera, a set of C++ libraries and applications that handles gas phase species transport and reactions. The method uses a discontinuous Galerkin formulation to represent the particle distributions within each section and to solve for changes to the aerosol particle distributions due to condensation, coagulation, and nucleation processes. CADS conserves particles, elements, and total enthalpy up to numerical round-off error, in all of its formulations. Both 0-D time dependent and 1-D steady state applications (an opposing-flow flame application) have been developed with CADS, with the initial emphasis on developing fundamental mechanisms for soot formation within fires. This report also describes the 0-D application, TDcads, which models a time-dependent perfectly stirred reactor.