Publications

An unavoidable by-product of a metallic structure's use is the appearance of crack and corrosion flaws. Economic barriers to the replacement of these structures have created an aging infrastructure and placed even greater demands on efficient and safe repair methods. In the past decade, an advanced composite repair technology has made great strides in commercial aviation use. Extensive testing and analysis, through joint programs between the Sandia Labs FAA Airworthiness Assurance Center and the aviation industry, have proven that composite materials can be used to repair damaged aluminum structure. Successful pilot programs have produced flight performance history to establish the durability of bonded composite patches as a permanent repair on commercial aircraft structures. With this foundation in place, this effort is adapting bonded composite repair technology to civil structures. The use of bonded composite doublers has the potential to correct the difficulties associated with current repair techniques and the ability to be applied where there are no rehabilitation options. It promises to be cost-effective with minimal disruption to the users of the structure. This report concludes a study into the application of composite patches on thick steel structures typically used in mining operations. Extreme fatigue, temperature, erosive, and corrosive environments induce an array of equipment damage. The current weld repair techniques for these structures provide a fatigue life that is inferior to that of the original plate. Subsequent cracking must be revisited on a regular basis. The use of composite doublers, which do not have brittle fracture problems such as those inherent in welds, can help extend the structure's fatigue life and reduce the equipment downtime. Two of the main issues for adapting aircraft composite repairs to civil applications are developing an installation technique for carbon steel and accommodating large repairs on extremely thick structures. This study developed and proved an optimum field installation process using specific mechanical and chemical surface preparation techniques coupled with unique, in-situ heating methods. In addition, a comprehensive performance assessment of composite doubler repairs was completed to establish the viability of this technology for large, steel structures. The factors influencing the durability of composite patches in severe field environments were evaluated along with related laminate design issues.

A validation study has been conducted for a turbulence model used to close the temporally filtered Navier Stokes (TFNS) equations. A turbulence model was purposely built to support fire simulations under the Accelerated Strategic Computing (ASC) program. The model was developed so that fire transients could be simulated and it has been implemented in SIERRA/Fuego. The model is validated using helium plume data acquired for the Weapon System Certification Campaign (C6) program in the Fire Laboratory for Model Accreditation and Experiments (FLAME). The helium plume experiments were chosen as the first validation problem for SIERRA/Fuego because they embody the first pair-wise coupling of scalar and momentum fields found in fire plumes. The validation study includes solution verification through grid and time step refinement studies. A formal statistical comparison is used to assess the model uncertainty. The metric uses the centerline vertical velocity of the plume. The results indicate that the simple model is within the 95% confidence interval of the data for elevations greater than 0.4 meters and is never more than twice the confidence interval from the data. The model clearly captures the dominant puffing mode in the fire but under resolves the vorticity field. Grid dependency of the model is noted.

The use of surrogate models to approximate computationally expensive simulation models, e.g., large comprehensive finite element models, is widespread. Applications include surrogate models for design, sensitivity analysis, and/or uncertainty quantification. Typically, a surrogate model is defined by a postulated functional form; values for the surrogate model parameters are estimated using results from a limited number of solutions to the comprehensive model. In general, there may be multiple surrogate models, each defined by possibly a different functional form, consistent with the limited data from the comprehensive model. We refer to each as a candidate surrogate model. Methods are developed and applied to select the optimal surrogate model from the collection of candidate surrogate models. The classical approach is to select the surrogate model that best fits the data provided by the comprehensive model; this technique is independent of the model use and, therefore, may be inappropriate for some applications. The proposed approach applies techniques from decision theory, where postulated utility functions are used to quantify the model use. Two applications are presented to illustrate the methods. These include surrogate model selection for the purpose of: (1) estimating the minimum of a deterministic function, and (2) the design under uncertainty of a physical system.

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The conclusions of this paper are: (1) Adsorption/desorption on bulk unmodified zeolites showed isoprene adsorbed by zeolite-L and n-pentane adsorbed by zeolite-Y and ZSM-5; (2) Bulk carbonization is used to passivate zeolite activity toward organic adsorption/decomposition; (3) Based on the bulk modified zeolite separation results, we have determined that the MFI type has the most potential for isoprene enrichment; (4) Modified MFI type membrane are jointly made by Sandia and the Univ. of Colorado. Separation experiments are performed by Goodyear Chemical; (5) Isoprene/n-pentane separations have been demonstrated by using both zeolite membranes and modified bulk zeolites at various temperatures on the Goodyear Pilot-scale unit; and (6) Target zeolite membrane separations values of 6.7% isoprene enrichment have been established by economic analysis calculations by Burns & McDonnell.

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We consider four asynchronous parallel algorithms for Implicit Monte Carlo (IMC) thermal radiation transport on spatially decomposed meshes. Two of the algorithms are from the production codes KULL from Lawrence Livermore National Laboratory and Milagro from Los Alamos National Laboratory. Improved versions of each of the existing algorithms are also presented. All algorithms were analyzed in an implementation of the KULL IMC package in ALEGRA, a Sandia National Laboratory high energy density physics code. The improved Milagro algorithm performed the best by scaling almost linearly out to 244 processors for well load balanced problems.

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The success of Lagrangian contact modeling leads one to believe that important aspects of this capability may be used for multi-material modeling when only a portion of the simulation can be represented in a Lagrangian frame. We review current experience with two dual mesh technologies where one of these meshes is a Lagrangian mesh and the other is an Arbitrary Lagrangian/Eulerian (ALE) mesh. These methods are cast in the framework of an operator-split ALE algorithm where a Lagrangian step is followed by a remesh/remap step. An interface-coupled methodology is considered first. This technique is applicable to problems involving contact between materials of dissimilar compliance. The technique models the more compliant (soft) material as ALE while the less compliant (hard) material and associated interface are modeled in a Lagrangian fashion. Loads are transferred between the hard and soft materials via explicit transient dynamics contact algorithms. The use of these contact algorithms remove the requirement of node-tonode matching at the soft-hard interface. In the context of the operator-split ALE algorithm, a single Lagrangian step is performed using a mesh to mesh contact algorithm. At the end of the Lagrangian step the meshes will be slightly offset at the interface but non-interpenetrating. The ALE mesh nodes at the interface are then remeshed to their initial location relative to the Lagrangian body faces and the ALE mesh is smoothed, translated and rotated to follow Lagrangian body. Robust remeshing in the ALE region is required for success of this algorithm, and we describe current work in this area. The second method is an overlapping grid methodology that requires mapping of information between a Lagrangian mesh and an ALE mesh. The Lagrangian mesh describes a relatively hard body that interacts with softer material contained in the ALE mesh. A predicted solution for the velocity field is performed independently on both meshes. Element-centered velocity and momentum are transferred between the meshes using the volume transfer capability implemented in contact algorithms. Data from the ALE mesh is mapped to a phantom mesh that surrounds the Lagrangian mesh, providing for the reaction to the predicted motion of the Lagrangian material. Data from the Lagrangian mesh is mapped directly to the ALE mesh. A momentum balance is performed on both meshes to adjust the velocity field to account for the interaction of the material from the other mesh. Subsequent, remeshing and remapping of the ALE mesh is performed to allow large deformation of the softer material. We overview current progress using this approach and discuss avenues for future research and development.

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Study of the triggered plasma opening switch (TPOS) characteristics is in progress via an ion current collection diagnostic (ICCD), in addition to offline apparatus. This initial ion current collection diagnostic has been designed, fabricated, and tested on the TPOS in order to explore the opening profile of the main switch. The initial ion current collection device utilizes five collectors which are positioned perpendicularly to the main switch stage in order to collect radially traveling ions. It has been shown through analytical prowess that this specific geometry can be treated as a planar case of the Child-Langmuir law with only a 6% deviation from the cylindrical case. Additionally, magnetostatic simulations with self consistent space charge emitting surfaces of the main switch using the Trak code are under way. It is hoped that the simulations will provide evidence in support of both the analytical derivations and experimental data. Finally, an improved design of the ICCD (containing 12 collectors in the axial direction) is presently being implemented.

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We provide a common framework for compatible discretizations using algebraic topology to guide our analysis. The main concept is the natural inner product on cochains, which induces a combinatorial Hodge theory. The framework comprises of mutually consistent operations of differentiation and integration, has a discrete Stokes theorem, and preserves the invariants of the DeRham cohomology groups. The latter allows for an elementary calculation of the kernel of the discrete Laplacian. Our framework provides an abstraction that includes examples of compatible finite element, finite volume and finite difference methods. We describe how these methods result from the choice of a reconstruction operator and when they are equivalent.

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