In general, the design process involves envisioning and developing concepts for a component or system, combining these fractions into an integrated whole and evaluating the final design against functional requirements. A major challenge is developing components or systems to a level of maturity that permits feasibility evaluation of the integrated whole while optimizing opposing performance functions (e.g., thick for strength, but thin for heat transfer). Economic pressure often drives design concepts to conservative bases early in the process. The approach presented in this paper is a highly costeffective means of developing alternative design solutions for given set of design requirements -in this case a radioactive materials (RAM) transportation package.

Polyurethane foam has been employed in impact limiters for large radioactive materials packagings since the early 1980's. Its consistent crush response, controllable structural properties and excellent thermal insulating characteristics have made it attractive as replacement for the widely used cane fiberboard for smaller, drum size packagings. Accordingly, polyurethane foam was chosen for the overpack material for the 9977 and 9978 packagings. The study reported here was undertaken to provide data to support the analyses performed as part of the development of the 9977 and 9978, and compared property values reported in the literature with published property values and test results for foam specimens taken from a prototype 9977 packaging. The study confirmed that, polyurethane foam behaves in a predictable and consistent manner and fully satisfies the functional requirements for impact absorption and thermal insulation.

No abstract

The 9977 / 9978 General Purpose Fissile Package (GPFP), has been designed as a cost-effective, user-friendly replacement for the DOT 6M Specification Package for transporting Plutonium and Uranium metals and oxides. To ensure the capability of the 9977 GPFP to withstand the regulatory crush test, urethane foam was chosen for the impact absorbing overpack. As part of the package development it was necessary to confirm that the urethane foam overpack would provide the required protection for the containment vessel during the thermal test portion of the Hypothetical Accident Conditions Sequential Tests. Development tests of early prototypes were performed, using a furnace. Based on the results of the development tests, detailed design enhancements were incorporated into the final design. Examples of the definitive 9977 design configuration were subjected to an all-engulfing pool fire test, as part of the HAC Sequential Tests, to support the application for certification. Testing has confirmed the package's ability to withstand the HAC thermal tests. INTRODUCTIONThe 9977 / 9978 GPFP has been designed as a replacement for DOT 6M Specification Packaging. As such, it must be able to transport the Plutonium and Uranium metals and oxides, meet the Type B performance requirements, and be economical to build and use. In order to enable the GPFP to withstand the Hypothetical Accident Condition (HAC) Crush Test, urethane foam was chosen for the impact absorbing overpack material. Finite element modeling (FEM) indicated that the rigid urethane foam-filled overpack employed by the GPFP design would be able to withstand the Crush Test.

A numerical technique has been developed to simulate the structural responses of radioactive material packaging components requiring closure-tightening torque to the scenarios of the hypothetical accident conditions (HAC) defined in the Code of Federal Regulations Title 10 part 71 (10CFR 71). A rigorous solution to this type of problem poses a considerable mathematical challenge. Conventional methods for evaluating the residue stresses due to the torque load are either inaccurate or not applicable to dynamic analyses. In addition, the HAC events occur sequentially and the cumulative damage to the package needs to be evaluated. Commonly, individual HAC events are analyzed separately and the cumulative damage is not addressed. As a result, strict compliance of the package with the requirements specified in 10CFR 71 is usually demonstrated by physical testing. The proposed technique utilizes the combination of kinematic constraints, rigid-body motions and structural deformations to overcome some of the difficulties encountered in modeling the effect of cumulative damage in numerical solutions.The analyses demonstrating use of this technique were performed to determine the cumulative damage of torque preload, a 30-foot drop, a 30-foot dynamic crush and a 40-inch free fall onto a mild steel pipe.