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Pressure vessel burst test program - Progress paper No. 3

An updated progress report is provided on a program developed to study through test and analysis, the characteristics of blast waves and fragmentation generated by ruptured gas filled pressure vessels. Prior papers on this USAF/NASA/General Physics program were presented to the AIAA in July 1990 and June 1991. Ten pressure vessels have been burst using pneumatic pressure. Tests were designed to explore burst characteristics and used an instrumented arena. Data trends for current experiments are presented. This paper is the third progress report on the program and addresses: (1) a brief review of current methods for assessing vessel safety and burst parameters, (2) a review of pneumatic burst testing operations and testing results, including a comparison to current methods for burst assessment, and (3) a review of the basis for the current test program including planned testing.

Cain, Maurice R.↗

Calculation of Flow Fields from Bow-Wave Profiles for the Downstream Region of Blunt-Nosed Circular Cylinders in Axial Hypersonic Flight

A method by which known bow-wave profiles may be analyzed to give the flow fields around blunt-nosed cylinders in axial hypersonic flow is presented. In the method, the assumption is made that the pressure distribution curve in a transverse plane is similar to that given by blast- wave theory. Numerical analysis based on the one-dimensional energy and continuity equations then leads to distributions of all the flow variables in the cross section, for either a perfect gas or a real gas. The entire flow field need not be solved. Attention can be confined to any desired station. The critical question is the validity of the above assumption. It is tested for the case of a hemisphere cylinder in flight at 20,000 ft/sec. The flow is analyzed for three stations along the cylindrical afterbody, and found to compare very closely with the results of an exact (inviscid) solution. The assumed form of the pressure distribution occurs at stations as close as 1.2 diameters to the body nose. However, it is suggested that the assumption may not apply this far forward in general, particularly when bodies of nonsmooth contour are considered.

Seiff, Alvin↗

Response of laminated composite flat panels to sonic boom and explosive blast loadings

This paper deals with a theoretical analysis of the dynamic response of shear deformable symmetrically laminated rectangular composite flat panels exposed to sonic boom and explosive blast loadings. The pertinent governing equations incorporating transverse shear deformation, transverse normal stress, as well as the higher-order effects are solved by using the integral-transform technique. The obtained results are compared with their counterparts obtained within the framework of the first-order transverse shear deformation and the classical plate theories and some conclusions concerning their range of applicability are outlined. The paper also contains a detailed analysis of the influence played by the various parameters characterizing the considered pressure pulses as well as the material and geometry of the plate.

Librescu, L.↗

Summary of Blast Shield and Material Testing for Development of Solid Debris Collection at the National Ignition Facility (NIF)

The ability to collect solid debris from the target chamber following a NIF shot has application for both capsule diagnostics, particularly for fuel-ablator mix, and measuring cross sections relevant to the Stockpile Stewardship program and nuclear astrophysics. Simulations have shown that doping the capsule with up to 10 15 atoms of an impurity not otherwise found in the capsule does not affect its performance. The dopant is an element that will undergo nuclear activations during the NIF implosion, forming radioactive species that can be collected and measured after extraction from the target chamber. For diagnostics, deuteron or alpha induced reactions can be used to probe the fuel-ablator mix. For measuring neutron cross sections, the dopant should be something that is sensitive to the 14 MeV neutrons produced through the fusion of deuterium and tritium. Developing the collector is a challenge due to the extreme environment of the NIF chamber. The collector surface is exposed to a large photon flux from x-rays and unconverted laser light before it is exposed to a debris wind that is formed from vaporized material from the target chamber center. The photons will ablate the collector surface to some extent, possibly impeding the debris from reaching the collector and sticking. In addition, the collector itself must be mechanically strong enough to withstand the large amount of energy it will be exposed to, and it should be something that will be easy to count and chemically process. In order to select the best material for the collector, a variety of different metals have been tested in the NIF chamber. They were exposed to high-energy laser shots in order to evaluate their postshot surface characterization, morphology, degree of melt, and their ability to retain debris from the chamber center. The first set of samples consisted of 1 mm thick pieces of aluminum that had been fielded in the chamber as blast shields protecting the neutron activation diagnostic. Ten of these pieces were fielded at the equator and one was fielded on the pole. The shields were analyzed using a combination of scanning electron microscopy (SEM), energy dispersive spectroscopy (EDS), x-ray fluorescence (XRF), neutron activation analysis (NAA) and chemical leaching followed by mass spectrometry. On each shield, gold debris originating from the gold hohlraum was observed, as well as large quantities of debris that were present in the center of the target chamber at the time of the shot (i.e., stainless steel, indium, copper, etc.) Debris was visible in the SEM as large blobs or splats of material that had encountered the surface of the aluminum and stuck. The aluminum itself had obviously melted and condensed, and some of the large debris splats arrived after the surface had already hardened. Melt depth was determined by cross sectioning the pieces and measuring the melted surface layers via SEM. After the SEM analysis was completed, the pieces were sent for NAA at the USGS reactor and were analyzed by U. Greife at the Colorado School of Mines. The NAA showed that the majority of gold mass present on the shields was not in the form of large blobs and splats, but was present as small particulates that had most likely formed as condensed vapor. Further analysis showed that the gold was entrained in the melted aluminum surface layers and did not extend down into the bulk of the aluminum. Once the gold mass was accounted for from the NAA, it was determined that the aluminum fielded at the equator was collecting a fraction of the total gold hohlraum mass equivalent to 120% ± 10% of the solid angle subtended by the shield. The attached presentation has more information on the results of the aluminum blast shield analysis. In addition to the information given in the presentation, the surfaces of the shields have been chemically leached and submitted for mass spectrometric analysis. The results from that analysis are expected to arrive after the due date of this report and will be written up at a later time. Based on the results of the aluminum blast shield analysis, it was determined that additional materials needed to be tested as potential collectors in the NIF chamber. 1-2 mm thick pieces of tantalum, niobium, vanadium, silver, titanium, molybdenum, and graphite foil were fielded in the Wedge Range Filter (WRF) mount at a distance of 50 cm from target chamber center during the shock timing campaign. The pieces were subsequently removed and analyzed in a similar fashion to the aluminum shields. As of this writing, the pieces are still under analysis, but initial results indicate that gold debris was collected on the various materials. Currently, the pieces are being cross-sectioned so that the melt depths of each material can be compared. In addition, NAA and/or mass spectrometry will be performed in order to determine the total gold mass that was collected on each surface.

36 MATERIALS SCIENCE↗

Will Your Battery Survive a World With Fast Chargers?

Fast charging is attractive to battery electric vehicle (BEV) drivers for its ability to enable long-distance travel and quickly recharge depleted batteries on short notice. However, such aggressive charging and the sustained vehicle operation that result could lead to excessive battery temperatures and degradation. Properly assessing the consequences of fast charging requires accounting for disparate cycling, heating, and aging of individual cells in large BEV packs when subjected to realistic travel patterns, usage of fast chargers, and climates over long durations (i.e., years). The U.S. Department of Energy's Vehicle Technologies Office has supported the National Renewable Energy Laboratory's development of BLAST-V-the Battery Lifetime Analysis and Simulation Tool for Vehicles-to create a tool capable of accounting for all of these factors. We present on the findings of applying this tool to realistic fast charge scenarios. The effects of different travel patterns, climates, battery sizes, battery thermal management systems, and other factors on battery performance and degradation are presented. We find that the impact of realistic fast charging on battery degradation is minimal for most drivers, due to the low frequency of use. However, in the absence of active battery cooling systems, a driver's desired utilization of a BEV and fast charging infrastructure can result in unsafe peak battery temperatures. We find that active battery cooling systems can control peak battery temperatures to safe limits while allowing the desired use of the vehicle.

25 ENERGY STORAGE↗

FY14 Milestone: Simulated Impacts of Life-Like Fast Charging on BEV Batteries

Fast charging is attractive to battery electric vehicle (BEV) drivers for its ability to enable long-distance travel and quickly recharge depleted batteries on short notice. However, such aggressive charging and the sustained vehicle operation that results could lead to excessive battery temperatures and degradation. Properly assessing the consequences of fast charging requires accounting for disparate cycling, heating, and aging of individual cells in large BEV packs when subjected to realistic travel patterns, usage of fast chargers, and climates over long durations (i.e., years). The U.S. Department of Energy's Vehicle Technologies Office has supported NREL's development of BLAST-V 'the Battery Lifetime Analysis and Simulation Tool for Vehicles' to create a tool capable of accounting for all of these factors. The authors present on the findings of applying this tool to realistic fast charge scenarios. The effects of different travel patterns, climates, battery sizes, battery thermal management systems, and other factors on battery performance and degradation are presented. The primary challenge for BEV batteries operated in the presence of fast charging is controlling maximum battery temperature, which can be achieved with active battery cooling systems.

25 ENERGY STORAGE↗

SOMD LOX/Methane Assessment, Data Analysis Subteam: MOX-E Test Series Analysis Summary

Fundamental explosive testing was conducted by the NASA/MSFC Blast Team (N2L) to determine yields produced from cryogenic liquid mixtures of methane and oxygen for a range of oxygen-to-fuel ratios. The blast wave overpressure and high-speed video data were processed by the NASA led multi-agency data analysis team. This document serves to provide a summary of the optimized data analysis produced and the resulting conclusions regarding the yields achieved during this test program.

Combustion↗

Analysis of Possible Explosions at Kennedy Space Center Due to Spontaneous Ignition of Hypergolic Propellants

NASA's Constellation Program plan currently calls for the replacement of the Space Shuttle with the ARES I & V spacecraft and booster vehicles to send astronauts to the moon and beyond. Part of the ARES spacecraft is the Orion Crew Exploration Vehicle (CEV), which includes the Crew Module (CM) and Service Module (SM). The Orion CM's main propulsion system and supplies are provided by the SM. The SM is to be processed off line and moved to the Vehicle Assembly Building (V AB) for stacking to the first stage booster motors prior to ARES move to the launch pad. The new Constellation Program philosophy to process in this manner has created a major task for the KSC infrastructure in that conventional QD calculations are no longer viable because of the location of surrounding facilities near the VAB and the Multi Purpose Processing Facility (MPPF), where the SM will be serviced with nearly 18,000 pounds of hypergolic propellants. The Multi-Payload Processing Facility (MPPF) complex, constructed by NASA in 1994, is located just off E Avenue south of the Operations and Checkout (O&C) building in the Kennedy Space Center industrial area. The MPPF includes a high bay and a low bay. The MPPF high bay is 40.2 m (132 ft) long x 18.9 m (60 ft) wide with a ceiling height of 18.9 m (62 ft). The low bay is a 10.4 m (34 ft) long x 10.4 m (34 ft) wide processing area and has a ceiling height of6.1 m (20 ft). The MPPF is currently used to process non-hazardous payloads. Engineering Analysis Inc. (EAI), under contract with ASRC Aerospace, Inc. in conjunction with the Explosive Safety Office, NASA, Kennedy Space Center (KSC), has carried out an analysis of the effects of explosions at KSC in or near various facilities produced by the spontaneous ignition ofhypergolic fuel stored in the CEV SM. The facilities considered included (1) Vehicle Assembly Building (VAB) (2) Multi-Payload Processing Facility (MPPF) (3) Canister Rotation Facility (CRF) Subsequent discussion deals with the MPPF analysis. Figure 1 provides a view of the MPPF from the northwest. An interior view ofthe facility is shown in Figure 2. The study was concerned with both blast hazards and hazardous fragments which exceed existing safety standards, as described in Section 2.0. The analysis included both blast and fragmentation effects and was divided into three parts as follows: (1) blast (2) primary fragmentation (3) secondary fragmentation Blast effects are summarized in Section 3.0, primary fragmentation in Section 4.0, and secondary fragmentation (internal and external) in Section 5.0. Conclusions are provided in Section 6.0, while references cited are included in Section 7.0. A more detailed description of the entire study is available in a separate document.

Brown, Stephen↗

Auto-BLAST (AutoBLAST) [SWR-20-93]

Battery life modeling often involves a lot of manual parameter fitting and is not easy for users to adopt the model and use it. To reduce the difficulties for users to adopt battery lifetime models, an automatic battery lifetime modeling analysis and simulation tool suite, Auto-BLAST, has been developed. Auto-BLAST includes a lithium-loss-base life model, a battery electric model, and an algorithm which automatically fits all key parameters in the electric and life models using user provided data. The models and algorithm are packaged into two user-friendly GUIs, Auto-LifeMod, for easy battery life prognostic model fitting and Auto-LifeSim, for easy battery lifetime simulation. The lithium-loss-based life model adopts a similar model framework that models degradations using aging rate models, using battery cycling data to predict battery degradation and expected lifetime. The electric model is an equivalent circuit model which simulates battery voltage responses based on current/power demand profiles. The auto-fitting algorithm uses the user-input data to generate custom battery life model(s). Two GUIs, wrapping around the life model and the auto-fitting algorithm, provide friendly interfaces for users to generate a life model and use it for case study. One GUI requires summary data from accelerated battery life degradation tests as an input and produces battery life models predicting (a) capacity degradation, and (b) resistance growth of the battery. The GUI displays the electrical model response and the input experimental data against the life model predictions with fitted model parameters and fitting error. The GUI also generates an output file to save the fitted model parameters. The second GUI uses the life model from the first GUI and a user-defined battery cycling profile to predict battery lifetime degradation and expected lifetime. Predicted capacity and resistance vs. time are plotted in the GUI and saved to output file. There is a user guide for both GUIs

Mishra, Partha↗

HOSS: an implementation of the combined finite-discrete element method

Nearly thirty years since its inception, the combined finite-discrete element method (FDEM) has made remarkable strides in becoming a mainstream analysis tool within the field of Computational Mechanics. FDEM was developed to effectively “bridge the gap” between two disparate Computational Mechanics approaches known as the finite and discrete element meth-ods. At Los Alamos National Laboratory (LANL) researchers developed the Hybrid Optimization Software Suite (HOSS) as a hybrid multi-physics platform, based on FDEM, for the simulation of solid material behavior complemented with the latest technological enhancements for full fluid–solid interaction. Furthermore, in HOSS, several newly developed FDEM algorithms have been implemented that yield more accurate material deformation formulations, inter-particle interaction solvers, and fracture and fragmentation solutions. Additionally, an explicit computational fluid dynamics solver and a novel fluid–solid interaction algorithms have been fully integrated (as opposed to coupled) into the HOSS’ solid mechanical solver, allowing for the study of an even wider range of problems. Advancements such as this are leading HOSS to become a tool of choice for multi-physics problems. Finally, HOSS has been successfully applied by a myriad of researchers for analysis in rock mechanics, oil and gas industries, engineering application (structural, mechanical and biomedical engineering), mining, blast loading, high velocity impact, as well as seismic and acoustic analysis. This paper intends to summarize the latest development and application efforts for HOSS.

58 GEOSCIENCES↗

Parallel adaptive fluid-structure interaction simulation of explosions impacting on building structures

We pursue a level set approach to couple an Eulerian shock-capturing fluid solver with space-time refinement to an explicit solid dynamics solver for large deformations and fracture. The coupling algorithms considering recursively finer fluid time steps as well as overlapping solver updates are discussed in detail. Our ideas are implemented in the AMROC adaptive fluid solver framework and are used for effective fluid-structure coupling to the general purpose solid dynamics code DYNA3D. Beside simulations verifying the coupled fluid-structure solver and assessing its parallel scalability, the detailed structural analysis of a reinforced concrete column under blast loading and the simulation of a prototypical blast explosion in a realistic multistory building are presented.

Deiterding, Ralf↗

Small arms suppression project (LLNL final report)

US Special Operations Command (USSOCOM) was seeking a technological leap in small firearms weapon suppressor technology, because anticipated enemy capabilities are requiring the operators to have smaller detection cross sections to ensure the safe execution of missions. Suppressors have been developed almost exclusively through trial-and-error methods since the time of the original design by Hiram Maxim over one hundred years ago. Consequently USSOCOM deemed it prudent to perform a physicsbased study of weapon suppression to understand performance limits and possibly identify breakthrough technologies. Lawrence Livermore National Laboratory’s (LLNL’s) high performance production level computational tool called ALE3D (Arbitrary Lagrangian-Eulerian 3D and 2D) has unique physics models and numerical algorithms for modeling suppressor dynamics. The flexible and extendable code framework supports fully integrated hydrodynamics, heat transfer, solid and fluid dynamics, and chemistry that can be applied to simulating propellant-driven motion of a bullet down a gun barrel, the transfer of heat from the burning propellant to the barrel and suppressor, the chemistry of muzzle flash, and the shock/acoustic/optical signatures in the near-field. LLNL’s originally anticipated role was to augment ALE3D for this task, by developing the software and analysis methodologies specific to the simulation of blast and muzzle flash phenomena. It was believed that insights provided by our ALE3D simulations in tandem with a coordinated experimental component by our other team members from Oak Ridge National Laboratory (ORNL) and the U. S. Army Armament, Research, Development and Engineering Center (ARDEC), would have excellent prospects of yielding useful suppressor design improvements that could be transitioned to industry and utilized by US Special Operations Command. The three year effort has come to fruition with the development of revolutionary suppressor designs that far outperform any previous or current design by anyone outside this multi-lab team.

42 ENGINEERING↗

Quantifying the Effect of Fast Charger Deployments on Electric Vehicle Utility and Travel Patterns via Advanced Simulation: Preprint

The disparate characteristics between conventional (CVs) and battery electric vehicles (BEVs) in terms of driving range, refill/recharge time, and availability of refuel/recharge infrastructure inherently limit the relative utility of BEVs when benchmarked against traditional driver travel patterns. However, given a high penetration of high-power public charging combined with driver tolerance for rerouting travel to facilitate charging on long-distance trips, the difference in utility between CVs and BEVs could be marginalized. We quantify the relationships between BEV utility, the deployment of fast chargers, and driver tolerance for rerouting travel and extending travel durations by simulating BEVs operated over real-world travel patterns using the National Renewable Energy Laboratory's Battery Lifetime Analysis and Simulation Tool for Vehicles (BLAST-V). With support from the U.S. Department of Energy's Vehicle Technologies Office, BLAST-V has been developed to include algorithms for estimating the available range of BEVs prior to the start of trips, for rerouting baseline travel to utilize public charging infrastructure when necessary, and for making driver travel decisions for those trips in the presence of available public charging infrastructure, all while conducting advanced vehicle simulations that account for battery electrical, thermal, and degradation response. Results from BLAST-V simulations on vehicle utility, frequency of inserted stops, duration of charging events, and additional time and distance necessary for rerouting travel are presented to illustrate how BEV utility and travel patterns can be affected by various fast charge deployments.

25 ENERGY STORAGE↗

The Shock and Vibration Bulletin. Part 3: Structure Medium Interaction, Case Studies in Dynamics

Structure and medium interactions topics are addressed. Topics include: a failure analysis of underground concrete structures subjected to blast loadings, an optimization design procedure for concrete slabs, and a discussion of the transient response of a cylindrical shell submerged in a fluid. Case studies in dynamics are presented which include an examination of a shock isolation platform for a seasparrow launcher, a discussion of hydrofoil fatigue load environments, and an investigation of the dynamic characteristics of turbine generators and low tuned foundations.

Director of Defense Research and Engineering↗

Particulate Emission and Optical Measurements in n-Heptane Low-Swirl Non-Premixed Flames at Elevated Pressures

A series of ground combustion tests conducted at elevated pressures demonstrates in-chamber optical measurements of soot emissions, combined with conventional gaseous and particle emissions sampling techniques. Utilizing a micro-radial-entry counter-swirl (MRX) burner, we successfully stabilized an n-heptane low-swirl, non-premixed spray flame across a wide range of equivalence ratios at pressures reaching 250 psia. Our optical diagnostics feature a temporally gated diffused-backlight illumination extinction imaging (DBI-EI) system, equipped with a 470-nm strobe high-intensity LED array as the illumination source, along with a line-of-sight telecentric camera. By accessing the flame tube, the pulsed DBI-EI provides illuminating optical extinction images, enabling experimental estimation of soot volume fractions within the reaction zone. This imaging technique will allow for real-time observation of soot formation dynamics occurring above the air-blast fuel injector. To further enhance our analysis, we employed simultaneous gaseous and particulate extractive diagnostics, interpreting in-flame particulate information through CO2 sampling, exhaust particle sizing, and particle counting. The processed dataset reveals a promising application of DBI-EI for propulsion emission analysis in high-pressure environments, where optical beam-steering effects can significantly impact results. This report is essential to bridging the divide between in-flame optical diagnostics and exhaust extractive measurements. By achieving an understanding of non-premixed combustion emission characteristics, we attempt to provide invaluable data for computer code validation, advancing the field of combustion research and supporting the development of cleaner, more efficient engines.

high-pressure flame↗

Particulate Emission and Optical Measurements in n-Heptane Low-Swirl Non-Premixed Flames at Elevated Pressures

A series of ground combustion tests conducted at elevated pressures demonstrates in-chamber optical measurements of soot emissions, combined with conventional gaseous and particle emissions sampling techniques. Utilizing a micro-radial-entry counter-swirl (MRX) burner, we successfully stabilized an n-heptane low-swirl, non-premixed spray flame across a wide range of equivalence ratios at pressures reaching 250 psia. Our optical diagnostics feature a temporally gated diffused-backlight illumination extinction imaging (DBI-EI) system, equipped with a 470-nm strobe high-intensity LED array as the illumination source, along with a line-of-sight telecentric camera. By accessing the flame tube, the pulsed DBI-EI provides illuminating optical extinction images, enabling experimental estimation of soot volume fractions within the reaction zone. This imaging technique will allow for real-time observation of soot formation dynamics occurring above the air-blast fuel injector. To further enhance our analysis, we employed simultaneous gaseous and particulate extractive diagnostics, interpreting in-flame particulate information through CO2 sampling, exhaust particle sizing, and particle counting. The processed dataset reveals a promising application of DBI-EI for propulsion emission analysis in high-pressure environments, where optical beam-steering effects can significantly impact results. This report is essential to bridging the divide between in-flame optical diagnostics and exhaust extractive measurements. By achieving an understanding of non-premixed combustion emission characteristics, we attempt to provide invaluable data for computer code validation, advancing the field of combustion research and supporting the development of cleaner, more efficient engines.

high-pressure flame↗

Simulation Assisted Risk Assessment: Blast Overpressure Modeling

A probabilistic risk assessment (PRA) approach has been developed and applied to the risk analysis of capsule abort during ascent. The PRA is used to assist in the identification of modeling and simulation applications that can significantly impact the understanding of crew risk during this potentially dangerous maneuver. The PRA approach is also being used to identify the appropriate level of fidelity for the modeling of those critical failure modes. The Apollo launch escape system (LES) was chosen as a test problem for application of this approach. Failure modes that have been modeled and/or simulated to date include explosive overpressure-based failure, explosive fragment-based failure, land landing failures (range limits exceeded either near launch or Mode III trajectories ending on the African continent), capsule-booster re-contact during separation, and failure due to plume-induced instability. These failure modes have been investigated using analysis tools in a variety of technical disciplines at various levels of fidelity. The current paper focuses on the development and application of a blast overpressure model for the prediction of structural failure due to overpressure, including the application of high-fidelity analysis to predict near-field and headwinds effects.

Lawrence, Scott L.↗

2022 Los Alamos National Laboratory Test and Analysis Abstracts

The abstracts included in this document are: Responsiveness, Modernization, and Radiography Test at the Centrifuge Test Facility; LANL Hostile Blast Testing Capability Development; Digital Image Correlation Measurement of B61 Center Case Fragmentation Test; and Collaborative Analysis Testing Techniques (CATT) Phase 1.

45 MILITARY TECHNOLOGY, WEAPONRY, AND NATIONAL DEF↗