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Aerospace designers seek lightweight, high-strength structures to lower launch weight while creating structures that are capable of withstanding launch loadings. Most 'light-weighting' is done through an expensive, time-consuming, iterative method requiring experience and a repeated design/test/redesign sequence until an adequate solution is obtained. Little successful work has been done in the application of generalized 3D optimization due to the difficulty of analytical solutions, the large computational requirements of computerized solutions, and the inability to manufacture many optimized structures with conventional machining processes. The Titanium Cholla LDRD team set out to create generalized 3D optimization routines, a set of analytically optimized 3D structures for testing the solutions, and a method of manufacturing these complex optimized structures. The team developed two new computer optimization solutions: Advanced Topological Optimization (ATO) and FlexFEM, an optimization package utilizing the eXtended Finite Element Method (XFEM) software for stress analysis. The team also developed several new analytically defined classes of optimized structures. Finally, the team developed a 3D capability for the Laser Engineered Net Shaping{trademark} (LENS{reg_sign}) additive manufacturing process including process planning for 3D optimized structures. This report gives individual examples as well as one generalized example showing the optimized solutions and an optimized metal part.

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TYPE SAND Report YEAR 2007

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An aqueous route to [Ta6O19]8- and solid-state studies of isostructural niobium and tantalum oxide complexes

Anderson, Travis M.; Alam, Todd M.; Rodriguez, M.A.

Tantalate materials play a vital role in our high technology society: tantalum capacitors are found in virtually every cell phone. Furthermore, electronic characteristics and the incredibly inert nature of tantalates renders them ideal for applications such as biomedical implants, nuclear waste forms, ferroelectrics, piezoelectrics, photocatalysts and optical coatings. The inert and insoluble nature of tantalates is not fundamentally understood; and furthermore poor solubility renders fabrication of novel or optimized tantalates very difficult. We have developed a soft chemical route to water-soluble tantalum oxide clusters that can serve as both precursors for novel tantalate materials and ideal models for experimental and computational approaches to understanding the unusually inert behavior of tantalates. The water soluble cluster, [Ta6O19]8- is small, highly symmetric, and contains the representative oxygen types of a metal oxide surface, and thus ideally mimics a complex tantalate surface in a simplistic form that can be studied unambiguously. Furthermore; in aqueous solution, these highly charged and super-basic clusters orchestrate surprising acid-base behavior that most likely plays an important role in the inertness of related oxide surfaces. Our unique synthetic approach to the [Ta6O19]8- cluster allowed for unprecedented enrichment with isotopic labels (17O), enabling detailed kinetic and mechanistic studies of the behavior of cluster oxygens, as well as their acid-base behavior. This SAND report is a collection of two publications that resulted from these efforts.

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TYPE SAND Report YEAR 2007

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Fluorosilicone and silicone o-ring aging study

Bernstein, Robert B.

Fluorosilicone o-ring aging studies were performed. These studies examined the compressive force loss of fluorosilicone o-rings at accelerated (elevated) temperatures and were then used to make predictions about force loss at room temperature. The results were non-Arrhenius with evidence for a lowering in Arrhenius activation energies as the aging temperature was reduced. The compression set of these fluorosilicone o-rings was found to have a reasonably linear correlation with the force loss. The aging predictions based on using the observed curvature of the Arrhenius aging plots were validated by field aged o-rings that yielded degradation values reasonably close to the predictions. Compression set studies of silicone o-rings from a previous study resulted in good correlation to the force loss predictions for the fluorosilicone o-rings from this study. This resulted in a preliminary conclusion that an approximately linear correlation exists between compression set and force decay values for typical fluorosilicone and silicone materials, and that the two materials age at similar rates at low temperatures. Interestingly, because of the observed curvature of the Arrhenius plots available from longer-term, lower temperature accelerated exposures, both materials had faster force decay curves (and correspondingly faster buildup of compression set) at room temperature than anticipated from typical high-temperature exposures. A brief study on heavily filled conducting silicone o-rings resulted in data that deviated from the linear relationship, implying that a degree of caution must be exercised about any general statement relating force decay and compression set.

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TYPE SAND Report YEAR 2007

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