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This station, the first of five on the inside portion of the exhibit, explains hydrotesting at Los Alamos, as well as other supporting technologies, such as proton radiography and the Z-Machine. The main station consists of a title monitor, main monitor, pushbutton monitor, and tabletop.
Hydrotest failure analysis of arc welded, solid propellant rocket motor case
With a multi-lab and university team, we propose to develop new methods for a Hydrodynamic and Radiographic Toolbox (HART) that will enable a fuller and more extensive use of experimental radiographic data towards better characterizing and reducing uncertainties in predictive modeling of weapons performance. We will achieve this by leveraging recent developments in areas of computational imaging, statistical and machine learning, and reduced order modeling of hydrodynamics. In terms of software practices, by partnering with XCP (RISTRA Project) we will conform to recent XCP standards that are inline with modern software practices and standards and ensure compatibility and ease of inter-operability with existing codes. Three new activities under this proposal include (a) the development and use of deep learning-based surrogates to accelerate reconstruction and variational inference of density fields from radiographs of hydrotests, (b) a model-data fusion strategy that couples deep learning-based density reconstructions with fast hydrodynamics simulators to better constrain the reconstruction, and (c) a method for treating asymmetries using techniques adopted from limited view tomography. All three new activities will be based on improved treatment of scatter, noise, beam spot movement, detector blur, and flat fielding in the forward model, and a use of sophisticated priors to aid in the re construction. The improvements to the forward model and improved algorithmic design of the reconstruction when complete will be contained in the iterative reconstruction code SHIVA—a code project that we have recently initiated. The many ways in which machine learning can be used in the reconstruction work will be contained in a code HERMES that has been initiated with DTRA support. For example, the significant levels of acceleration that will likely be achieved by the use of machine learning techniques will permit us (and are required) to quantify uncertainties in density retrievals. Next, the two-way coupling between density reconstruction and model-based simulation of the hydrodynamics will be contained in code EREBUS, and will permit a fuller realization of the potential of the data to constrain the hydrodynamic model and better address issues related to asymmetries in the problem. Finally, we anticipate that the better consistency with physics achieved in our reconstructions will allow them to be used by X-Division more so than today.
Diamagnetic-loop (DML) measurements can inform efforts to improve radiographic resolution. DML is non-invasive, so time-resolved data is available on every shot while tuning or executing a hydrotest. The time-resolved beam size can be deduced from the DML data. LIA beam-transport dynamics affecting beam size can be monitored while testing mitigation measures (e.g., beam halo suppression). Time-resolved beam size at final focus provides immediate information about spot size enlargement due to blur, and effectiveness of mitigation efforts. DML measures magnetic flux produced by a rotating beam, so it also enables monitoring of Larmor emittance that can enlarge the spot size. Beam rotation adds in quadrature with emittance, hence “Larmor emittance." Observing zero bias-field DML flux monitors beam rotation resulting from imperfect nulling of flux linking the cathode, and/or broken LIA transport symmetry (e.g., steering, quads, etc.).
A new experimental setup for diagnosing hydrotest performance was designed, built, and implemented at DARHT. The setup consists of 128 points of fourth generation (Gen4) multiplexed photonic Doppler velocimetry (MPDV) and 128 separate points of modulation based ranging (MBR) to serve as a direct complement to the MPDV. The diagnostics were designed to overcome limitations in the third generation of the MPDV diagnostic that limited laser launch power to ~10 mW per point. As the main failure mechanism identified in the third generation MPDV system arose from stimulated Brillouin scattering, a nonlinear optical phenomenon inherent in standard single mode fiber, the fourth generation MPDV system reduced the number of time-multiplexed channels by a factor of two. This has allowed laser launch power to be increased to as much as 200 mW per channel which is a 20 times increase in the signal to noise ratio (SNR) as compared with the third generation system. This document will first discuss the previous limitations and describe the design of the system. This will be followed by the results of a simple flyer plate experiment used to demonstrate the improved SNR as well as calibrate the phase errors in the system that MBR is sensitive to.
Hydrodynamic testing at Los Alamos National Laboratory would benefit from a process improvement for the requirements process. Cameo was used as a digital solution for requirements management to allow Lead Engineers to track requirements more effectively. This was identified as a process improvement throughout this Capstone project. This report includes a project proposal, business case, literature review, methodology, project plan, data analysis, decision-making report, financial analysis report, discussion, and conclusion. Initially, this project focused on figuring out a solution for the hydrotest requirement process improvements. The scope narrowed to focus on the use of Cameo for requirement capture and management. During this Capstone, four tests had digital models produced for requirements management in Cameo. The initial model was the baseline, with core requirements used across the tests. Commonalities in tests were used and the core requirements allowed for process efficiencies. In the data analysis, it was seen that overall, the implementation of using Cameo for requirements resulted in a decreasing trend for both schedule and normalized cost. Tests have different complexity levels which is also a factor in how long the requirements process will take. Additional data is needed to continue analyzing process improvements. Through decisionmaking and financial analysis, the recommendation was to use Cameo for requirements process improvement. Multiple experts provided feedback for requirements that were then captured within models. Numerous tangible and intangible benefits were identified with this process improvement. For return on investment, the metric of success was schedule reduction, which was overall seen. Four tests were analyzed, so future analysis will be needed. There is also not a great financial risk because the main cost would be purchasing more licenses. Individuals must generate requirements whether using this software or not. Overall, training is needed to help improve the skillsets of Lead Engineers but is already being supported on a regular frequency. A desktop guide was started associated with explaining the process, however, it is a work in progress. The team plans on adding additional information in the digital models to help status when requirements are met using verification methods and artifacts. From working on this project an improved understanding of Cameo and requirements was the result. There are future opportunities to extend the usage for requirements management and progress will continue after this project.
If you're at Los Alamos National Laboratory and happen to encounter Matt Johnson, don't be surprised if this busy leader smiles and stops to ask you how he can help. That’s the essence of the type of manager—and person—he is. As the leader of the Pit Technologies division at the Lab, Matt oversees six groups that cover national security manufacturing, operations and professional support. Matt started his career at the Lab in 2002. His first assignments included work with confinement vessels used at firing sites such as Nevada National Security Site. Matt's deep knowledge of high-strength steel made him a perfect fit for the research and fabrication of these explosive-proof containers. Shortly after joining the Lab, Matt accepted the position as the Welding and Joining team leader supporting national security manufacturing, the hydrotest program and welding efforts across the NNSA complex. Over time, Matt made his way across many programs at the Laboratory.
Flexseal assemblies, TVC actuators, hydraulic supply system, TVC electronic control unit, flight instrumentation system, ordnance system electronics, and hydrotest of SRM case segments are discussed, applied to typical component recertification test procedures.
This center operates a number of sophisticated wind tunnels in order to fulfill the needs of its researchers. Compressed air, which is kept in steel storage vessels, is used to power many of these tunnels. Some of these vessels have been in use for many years, and Langley is currently recertifying these vessels to insure their continued structural integrity. One of the first facilities to be recertified under this program was the Langley 8-foot high-temperature structures tunnel. This recertification involved (1) modification, hydrotesting, and inspection of the vessels; (2) repair of all relevant defects; (3) comparison of the original design of the vessel with the current design criteria of Section 8, Division 2, of the 1974 ASME Boiler and Pressure Vessel Code; (4) fracture-mechanics, thermal, and wind-induced vibration analyses of the vessels; and (5) development of operating envelopes and a future inspection plan for the vessels. Following these modifications, analyses, and tests, the vessels were recertified for operation at full design pressure (41.4 MPa (6000 psi)) within the operating envelope developed.
The design, analysis, fabrication and testing of a Kevlar-49/HBRF-55A filament wound chamber is reported. The chamber was fabricated and successfully tested to 80% of the design burst pressure. Results of the data reduction and analysis from the hydrotest indicate that the chamber design and fabrication techniques used for the chamber were adequate and the chamber should perform adequately in a static test.
Acoustic emission in 51-cm diameter graphite/epoxy pressure vessels was monitored during pressurization (hydrotesting). Several vessels were subjected to impact by a blunt impactor, but only after the vessels had been proofed; that is, pressurized to 80 percent of nominal burst pressure as determined from control (unimpacted) vessels. AE activity was then monitored throughout a series of successively higher pressure cycles ranging from 10 to 60 percent of ultimate. Each cycle included a ramp up to pressure followed by a 4-min hold period and then pressure unload. The event rate was high, and especially modified AE analyzers had to be used to acquire the data. This paper presents the AE event count versus pressure history of these tests and demonstrates the ability of the AE technique to monitor the growth of damage and to estimate the effect on ultimate strength. The number of events that occurred during pressure holds proved to be a reasonable estimator of vessel performance.
A new technique using external pressure was developed to simulate the lithostatic pressure due to self-gravity of small bodies. A 13-in. diameter cylindrical test chamber with L/D of 1 was fabricated to accommodate firing explosive charges with gas overpressures of up to 6000 psi. The chamber was hydrotested to 9000 psi. The method allows much larger scale factors that can be obtained with existing centrifuges and has the correct spherical geometry of self gravity. A simulant for jointed rock to be used in this fixture was developed using weakly cemented basalt. Various strength/pressure scaling theories can now be examined and tested.
The design, analysis, and preliminary test results for a 25 kWe Free-Piston Stirling engine with integral linear alternators are described. The project is conducted by Mechanical Technology under the direction of LeRC as part of the SP-100 Nuclear Space Power Systems Program. The engine/alternator system is designed to demonstrate the following performance: (1) 25 kWe output at a specific weight less than 8 kg/kW; (2) 25 percent efficiency at a temperature ratio of 2.0; (3) low vibration (amplitude less than .003 in); (4) internal gas bearings (no wear, no external pump); and (5) heater temperature/cooler temperature from 630 to 315 K. The design approach to minimize vibration is a two-module engine (12.5 kWe per module) in a linearly-opposed configuration with a common expansion space. The low specific weight is obtained at high helium pressure (150 bar) and high frequency (105 Hz) and by using high magnetic strength (samarium cobalt) alternator magnets. Engine tests began in June 1985; 16 months following initiation of engine and test cell design. Hydrotest and consequent engine testing to date has been intentionally limited to half pressure, and electrical power output is within 15 to 20 percent of design predictions.
Radioactive waste is stored in underground, carbon-steel double-shell tanks at the Department of Energy Hanford site. The waste is transferred between the tanks and other assets using the transfer lines spanning throughout the various tank farms at Hanford. The transfer lines consist of a pipe-in-pipe design, small diameter pipes, and are not piggable. Recent inspection data of the transfer lines have shown areas with corrosion on both interior of the encasements and exterior of the primary pipes, with nearly 50 percent wall loss on the primary pipes and nearly 25% wall loss on the encasement pipes due to pitting corrosion. The visual inspections of the transfer lines have shown presence of corrosion products near the pipeline risers and beyond. It has been hypothesized that the corrosion is predominantly due to the high humidity conditions and in some cases is driven by the presence of residual hydrotest water in the encasement and the associated contact with the safety significant primary pipe. Therefore, drying of the transfer lines could lead to corrosion mitigation. Experimental studies are being conducted to understand the effect of environmental conditions, especially, relative humidity and temperature, on transfer line grade carbon steel corrosion and on mitigating corrosion. The experimental conditions are selected based on the seasonal temperature changes, and relative humidity conditions ranging from 30 to 100 percent. The experimental data will be used as guidance for maintaining a dry environment that will help mitigate the transfer-line corrosion caused by the high humidity conditions.
Project Y laid the foundation for all work currently performed at LANL. LANL is responsible for the stewardship of most of the U.S. nuclear weapons, facilitates global security and nonproliferation, and has been a Federally Funded Research and Development Center (FFRDC) for more than 75 years.