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At least 19 records

Drop Tower Statement of Work

This document details the needs and requirements for a propulsion-assisted drop tower system (further referenced simply as Drop Tower) to perform hardware testing at Lawrence Livermore National Laboratory (LLNL). LLNL is managed and operated by Lawrence Livermore National Security, LLC (LLNS) for the Department of Energy (DOE). LLNL requires a robust testing platform that will allow for the characterization of interactions between objects of interest. The initial siting of the equipment will be located in an existing test facility (B191). When another test facility becomes online, the objective will be to move the test capability to the new facility as a final location (B132N). The Drop Tower will be a cornerstone capability for testing and model validation for LLNL interested programs.

42 ENGINEERING↗

Diode pumped solid state kilohertz disk laser system for time-resolved combustion diagnostics under microgravity at the drop tower Bremen

We describe a specially designed diode pumped solid state laser system based on the disk laser architecture for combustion diagnostics under microgravity (μg) conditions at the drop tower in Bremen. The two-stage oscillator-amplifier-system provides an excellent beam profile (TEM{sub 00}) at narrowband operation (Δλ < 1 pm) and is tunable from 1018 nm to 1052 nm. The laser repetition rate of up to 4 kHz at pulse durations of 10 ns enables the tracking of processes on a millisecond time scale. Depending on the specific issue it is possible to convert the output radiation up to the fourth harmonic around 257 nm. The very compact laser system is integrated in a slightly modified drop capsule and withstands decelerations of up to 50 g (>11 ms). At first the concept of the two-stage disk laser is briefly explained, followed by a detailed description of the disk laser adaption to the drop tower requirements with special focus on the intended use under μg conditions. In order to demonstrate the capabilities of the capsule laser as a tool for μg combustion diagnostics, we finally present an investigation of the precursor-reactions before the droplet ignition using 2D imaging of the Laser Induced Fluorescence of formaldehyde.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

Photos of Lansmont PDT 80 drop test machine at Los Alamos

The Los Alamos RP-SVS Radiation Protection Services group designed and constructed a drop tower facility for TA- 55 support work. The drop mechanism was supplied by the Lansmont company in Monterey CA. Los Alamos staffers Murray Moore and Yong Tao have noticed that the system is not dropping loads correctly, and they have photographed aspects of the PDT- 80 model system. The first 10 photos show the platen loaded with a cylindrical steel bar. The next 10 photos are of the roller-cam mechanism in the drop tower, and the last 2 photos indicate the amount of looseness in the platen when it is being pulled by a person.

47 OTHER INSTRUMENTATION↗

Experimental and Numerical Investigations on Dynamic Mechanical Properties of TPMS Structures

Triply Periodic Minimal Surface (TPMS) lattice structures have been of increasing interest due to their light weighting, enhanced mechanical properties, and energy absorption characteristics for automotive and biomedical applications. With the advent of additive manufacturing and geometric modeling software, TPMS lattices with complex geometries can be realized. In this work, TPMS lattice structures were fabricated with PLA using fused filament fabrication (FFF) and their dynamic properties are characterized through drop tower experiments. Although lightweight TPMS lattices are beneficial for their impact absorption capability, most of the existing works are limited to quasi-static compression and dynamic impact tests are rarely performed. The current study investigates the stress-strain and energy absorption characteristics of TPMS lattices through drop tower testing and numerical modeling. Finite element modeling for TPMS lattices is carried out to validate the experimental responses. The mechanical properties, deformation, and failure mechanisms of TPMS lattices under dynamic impact are summarized for potential future applications.

Pokkalla, Deepak↗

Lifetime extension drop-test of real-world corroded 5 Quart Hagan nuclear material storage container

A 5Qt Hagan container with a 20-year history of nuclear material storage was challenged with three successive drop tests at a height of 3.7 meters. The total mass of the test package was 12.1 kg. The 1st and 2nd drop tests (center of gravity over the container bottom corner but 180 degrees apart on the container bottom face) passed the pre- and post- impact helium leak criterion at less than 1.00E-6 atm-cc/sec (ambient cubic centimeters per second). The 3rd and final test (center of gravity over top corner) failed with a post-impact gross leak of 1.1E-1 atmcc/sec. The RRFMC (Respirable Release Fraction Measurement Chamber) is a drop tower test system that is critical for the sustainability of the SAVY-4000™ series and Hagan-type (NFT Inc. Golden CO) nuclear material storage containers. These are the primary in-use nuclear material storage container types at the Los Alamos National Laboratory TA-55 facility. Results are presented to expand the technical knowledge basis for container lifetime, regarding actual exposure to corrosive gas species on the container inner surfaces. The primary source of general corrosion throughout the container is gaseous hydrogen chloride (HCl). This gas is generated by the degradation of the polyvinylchloride (PVC) bag-out bag. Additionally, in most cases, the nuclear material itself also releases HCl gas (due to residual chemical components associated with the material formation). The RRFMC drop tower gives the end-user the ability record and analyze high-speed video and photography and if needed aerosol mass release measurements. In this report the principal issue is the physical deformation of the 5Qt Hagan container. There were no mass release experiments of test aerosol mass in the present study.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DROP DURABILITY ASSESSMENT OF ELECTRONIC ASSEMBLIES UNDER OFF-AXIS LOADING WITH SKEWED FIXTURES

This thesis studies drop durability of electronic assemblies when the acceleration vector is oriented at 45° to the out-of-plane direction of the circuit card. The off-axis drop tests are accomplished with a skewed fixture and are conducted as a proxy for multiaxial drop testing. Advanced shock testing and vibration test methods have been developed over the last few decades to better represent real-world field environments during ground-based laboratory testing. However, many of these test methods require expensive and specialized equipment not available in most laboratories. An alternative approach for approximating simultaneous loading along multiple axes on conventional equipment utilizes skewed fixtures which have seen use in off-axis random vibration and drop impact testing. These methods generally rely on the conversion of a uniaxial input load from the test equipment (using a uniaxial drop tower or shaker) into a multiaxial load when resolved in the reference frame of the test article (mounted on a skewed fixture). Skewed fixture design is presented and recommendations for conducting skewed angle drop testing are introduced based on local measurements along the skewed face of the fixture to accurately monitor the impact event. Characterization tests were performed with a skewed fixture, at simultaneous acceleration loads from 500 to 3,000 g in two (in-plane and out-of-plane) directions, while meeting standard time domain tolerances. Upon experimental characterization, drop shock durability tests were conducted on a printed circuit assembly (PCA). Mean drops-to-failure were measured and quantified with Weibull statistics. Dominant solder joint failure modes were identified via failure analysis. Prior work on inclined angle impact testing is limited, and the majority of solder joint interconnect level fatigue studies are conducted considering perpendicular loading normal the circuit card. Low-cycle fatigue curves are generated based on plastic strain and plastic work density within the solder joint. A multiscale nonlinear finite element model is used to relate board-level flexure to solder joint interconnect level plastic strain. A high strain rate solder constitutive model allows for accurate modeling of solder plasticity resulting from high-impact drop shock. Fatigue parameters are computed from the Coffin-Manson relation and Palmgren-Miner damage accumulation. This work serves to apply established low-cycle fatigue methods for conventional drop shock loading (impact normal to circuit card) to non-perpendicular loading with a skewed fixture.

Hower, Jonathan [Kansas City National Security Cam↗

Comparison of interlaminar damage modeling strategies for hybrid composite/aluminum laminates subjected to low-velocity impact

Low-velocity impact of hybrid metal-composite structures was investigated experimentally and computationally. Composite laminates consisting of 2D woven glass fiber reinforced polymer (GFRP) and carbon fiber reinforced polymer (CFRP) were joined with a 6061-T6 aluminum plate using an epoxy adhesive. Two variations of the structure were studied; one consisting of all plies oriented at 0° and one consisting of all plies oriented at 45°. A drop tower was used to impact structures at a range of energies, including energies above and below the threshold at which the aluminum layer was perforated. Numerical simulations were implemented using Sierra/SM, an in-house transient dynamics finite element code developed at Sandia National Laboratories. A Hosford plasticity model was used to describe the response of the aluminum layer. A newly implemented orthotropic continuum damage mechanics (CDM) constitutive model was used to represent the composite laminate. This 3D-CDM model was compared to a cohesive zone model (2D-CDM/CZM) to investigate efficacy of aluminum perforation energy prediction, delamination prediction, and computational cost. Accuracy of each model was evaluated using the experimental results. Each showed good agreement with the tests for both the force and velocity histories, as well as the observed damage mechanisms. The 2D-CDM/CZM model was marginally more accurate in capturing both the composite and aluminum behavior — this model averaged error percentages of -11.2% and 10.8% for residual velocity and peak force, respectively. Meanwhile, the 3D-CDM model predictions yielded average error percentages of -35.5% (velocity) and 22.6% (force). However, the 3D-CDM model generally resulted in a decreased computational cost; the average run time was 14% shorter than the 2D-CDM/CZM model and 3x as many timesteps per hour were computed using the same computational resources. In conclusion, new experimental data on the impact and perforation resistance of metal-composite laminates is presented in addition to numerical predictions of the impact behavior.

Carbon fiber↗

Elucidating the challenges in extracting ultra-slow flame speeds in a closed vessel - A CH 2 F 2 microgravity case study using optical and pressure-rise data

Refrigerants with a low global warming potential (GWP) possess mild flammability. Hence, a fundamental understanding of their combustion characteristics is required to assess their fire-hazardous potential. The laminar burning velocity is one fundamental property to describe these under safety evaluation aspects. However, measuring laminar burning velocities for slow-burning components, such as low-GWP alternatives, is challenging. This is due to influencing effects such as buoyant flame deformation, stretch, radiation, and confinement, especially at the flammability limits. Here, in the present study, we investigated near-limit flames of the representative refrigerant difluoromethane (CH 2 F 2 ) with nitrogen-enriched oxidizer mixtures to elucidate the potentials and limitations at ultra-slow flame speeds of two widely used flame speed measurement methods in the closed vessel configuration: the optical flame speed measurement in the early quasi-isobaric regime and the flame speed determination from the pressure-rise during the later phase of the isochoric combustion process. Experiments were performed under terrestrial- and microgravity, conducted in a specially designed setup suitable for drop tower applications, using both methods in parallel. Recommendations for the extraction of flame speed data are derived from the non-buoyant reference investigations under microgravity and transferred to ultra-slow flames at terrestrial gravity. Near-limit flames under microgravity were found to be significantly affected by stretch effects for the optical method so that flame speed extrapolations to unstretched conditions are prone to errors. Stretch also affects the pressure method’s lower evaluation limit, and errors can be estimated by combining flame speed data from the pressure method and Markstein lengths from optical experiments.

42 ENGINEERING↗

A three-layer magnetic shielding for the MAIUS-1 mission on a sounding rocket

Bose-Einstein-Condensates (BECs) can be used as a very sensitive tool for experiments on fundamental questions in physics like testing the equivalence principle using matter wave interferometry. Since the sensitivity of these experiments in ground-based environments is limited by the available free fall time, the QUANTUS project started to perform BEC interferometry experiments in micro-gravity. After successful campaigns in the drop tower, the next step is a space-borne experiment. The MAIUS-mission will be an atom-optical experiment that will show the feasibility of experiments with ultra-cold quantum gases in microgravity in a sounding rocket. The experiment will create a BEC of 10{sup 5} {sup 87}Rb-atoms in less than 5 s and will demonstrate application of basic atom interferometer techniques over a flight time of 6 min. The hardware is specifically designed to match the requirements of a sounding rocket mission. Special attention is thereby spent on the appropriate magnetic shielding from varying magnetic fields during the rocket flight, since the experiment procedures are very sensitive to external magnetic fields. A three-layer magnetic shielding provides a high shielding effectiveness factor of at least 1000 for an undisturbed operation of the experiment. The design of this magnetic shielding, the magnetic properties, simulations, and tests of its suitability for a sounding rocket flight are presented in this article.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

VIPIR: A High-Throughput Drop-Weight Impact Instrument for Imaging the Initiation and Propagation of Reactions in Energetic Materials

Characterizing the handling safety and sensitivity of explosives has been a challenging area of study for over 60 years. Historically one of the most accessible and widely utilized experiments has been the drop-weight impact test, which involves dropping a weight on a small sample sandwiched between two anvils. Because this experiment generally only utilizes sound thresholds to determine whether or not a sample reacted, the physical and chemical properties governing sensitivity remain convolved. Better understanding of chemical and material characteristics is needed to give the chemistry and engineering communities a predictive tool to determine the handling sensitivity of explosives prior to pursuing expensive and potentially hazardous synthesis and formulation operations. Here, we are developing a high throughput drop tower instrument capable of imaging the deformation and flow of energetic materials during impact and the resulting thermal ignition and propagation events. This instrument is based on previous designs but has been modified for higher throughput and tailorable modifications in the future. Herein, we present key design features that enable high-speed visible and thermal imaging of explosive initiation by sub-shock impacts, as well as preliminary results in which ignition sites were observed in an erythritol tetranitrate sample.

47 OTHER INSTRUMENTATION↗

COLLIDING DECIMETER DUST

Collisional evolution is a key process in planetesimal formation and decimeter bodies play a key role in the different models. However, the outcome of collisions between two dusty decimeter bodies has never been studied experimentally. Therefore, we carried out microgravity collision experiments in the Bremen drop tower. The agglomerates consist of quartz with irregularly shaped micrometer-sized grains and the mean volume filling factor is 0.437 {+-} 0.004. The aggregates are cylindrical with 12 cm in height and 12 cm in diameter, and typical masses are 1.5 kg. These are the largest and most massive dust aggregates studied in collisions to date. We observed rebound and fragmentation but no sticking in the velocity range between 0.8 and 25.7 cm s{sup -1}. The critical fragmentation velocity for split up of an aggregate is 16.2 {+-} 0.4 cm s{sup -1}. At lower velocities the aggregates bounce off each other. In this velocity range, the coefficient of restitution decreases with increasing collision velocity from 0.8 to 0.3. While the aggregates are very weak, the critical specific kinetic energy for fragmentation Q{sub {mu}=1} is a factor of six larger than expected. Collisions of large bodies in protoplanetary disks are supposed to be much faster and the generation of smaller fragments is likely. In planetary rings, collision velocities are of the order of a few cm s{sup -1} and are thereby in the same range investigated in these experiments. The coefficient of restitution of dust agglomerates and regolith-covered ice particles, which are common in planetary rings, are similar.

79 ASTRONOMY AND ASTROPHYSICS↗

Macroscopic dust in protoplanetary disks—from growth to destruction

The collision dynamics of dusty bodies are crucial for planetesimal formation. Decimeter agglomerates are especially important in the different formation models. Therefore, in continuation of our experiments on mutual decimeter collisions, we investigate collisions of centimeter onto decimeter dust agglomerates in a small drop tower under vacuum conditions (p ≲ 5 × 10{sup –1} mbar) at a mean collision velocity of 6.68 ± 0.67 m s{sup –1}. We use quartz dust with irregularly shaped micrometer grains. Centimeter projectiles with different diameters, masses, and heights are used, their typical volume filling factor is Φ {sub p,} {sub m} = 0.466 ± 0.02. The decimeter agglomerates have a mass of about 1.5 kg, a diameter and height of 12 cm, and a mean filling factor of Φ {sub t,} {sub m} = 0.44 ± 0.004. At lower collision energies, only the projectile gets destroyed and mass is transferred to the target. The accretion efficiency decreases with increasing obliquity and increasing difference in filling factor, if the projectile is more compact than the target. The accretion efficiency increases with increasing collision energy for collision energies under a certain threshold. Beyond this threshold at 298 ± 25 mJ, catastrophic disruption of the target can be observed. This corresponds to a critical fragmentation strength Q* = 190 ± 16 mJ kg{sup –1}, which is a factor of four larger than expected. Analyses of the projectile fragments show a power-law size distribution with an average exponent of –3.8 ± 0.3. The mass distributions suggest that the fraction of smallest fragments increases for higher collision energies. This is interesting for impacts of small particles on large target bodies within protoplanetary disks, as smaller fragments couple better to the surrounding gas and re-accretion by gas drag is more likely.

79 ASTRONOMY AND ASTROPHYSICS↗

A novel drop weight impact setup for testing reinforced concrete beams

A novel method of testing reinforced concrete beams under impact using a drop tower is described. The method consists of configuring the support conditions and instrumenting both the loading end of the hammer and support points in such a way that a proper dynamic analysis of the impact event can be performed and rational data can be derived.

42 ENGINEERING↗

Battery Safety Testing

Abuse tests are designed to determine the safe operating limits of HEV\PHEV energy storage devices. Testing is intended to achieve certain worst-case scenarios to yield quantitative data on cell\module\pack response, allowing for failure mode determination and guiding developers toward improved materials and designs. Standard abuse tests with defined start and end conditions are performed on all devices to provide comparison between technologies. New tests and protocols are developed and evaluated to more closely simulate real world failure conditions. While robust mechanical models for vehicles and vehicle components exist, there is a gap for mechanical modeling of EV batteries. The challenge with developing a mechanical model for a battery is the heterogeneous nature of the materials and components (polymers, metals, metal oxides, liquids). Our work will provide empirical data on the mechanical behavior of batteries under compressive load to understand how a battery may behave in a vehicle crash scenario. This work is performed in collaboration with the U.S. Council for Automotive Research (USCAR) and Computer Aided Engineering of Batteries (CAEBAT). These programs have supported the design and development of a drop tower testing apparatus to close the gap between cell/string level testing and full scale crash testing with true dynamic rate effects.

25 ENERGY STORAGE↗

Battery Testing FY 2017 Annual Progress Report

Abuse tests are designed to determine the safe operating limits of HEV\PHEV energy storage devices. Testing is intended to achieve certain worst-case scenarios to yield quantitative data on cell\module\pack response, allowing for failure mode determination and guiding developers toward improved materials and designs. Standard abuse tests with defined start and end conditions are performed on all devices to provide comparison between technologies. New tests and protocols are developed and evaluated to more closely simulate real-world failure conditions. When scaling from cell to the battery level, a detailed understanding of cell interactions provides insight on safety performance. Single point failures from a cell or group of cells can be initiated by a number of triggers including internal short circuit, misuse or abuse, or component failure at the battery or system level. Propagation of a single failure event (regardless of the initiation trigger) through an entire battery, system, or vehicle is an unacceptable outcome with regards to EV battery safety. In this FY, our work has focused on evaluating the propagation of a single cell thermal runaway event through a battery using a variety of design considerations with an emphasis on passive thermal management impacts. This has been coupled with thermal modeling by NREL for these testing conditions. In addition, alternative failure initiation methods have been evaluated to provide direct comparisons of possible energy injection between modes. This data was compiled to better identify what propagation test method is appropriate given certain battery designs. Expanding the analysis of short circuit current during failure propagation has been done for EV relevant chemistries. Ongoing test development and validation to obtain these values has been achieved. While robust mechanical models for vehicles and vehicle components exist, there is a gap for mechanical modeling of EV batteries. The challenge with developing a mechanical model for a battery is the heterogeneous nature of the materials and components (polymers, metals, metal oxides, liquids). Our work will provide empirical data on the mechanical behavior of batteries under compressive load to understand how a battery may behave in a vehicle crash scenario. This work is performed in collaboration with the U.S. Council for Automotive Research (USCAR) and Computer Aided Engineering of Batteries (CAEBAT). These programs have supported the design and development of a drop tower testing apparatus to close the gap between cell/string level testing and full scale crash testing with true dynamic rate effects.

25 ENERGY STORAGE↗