Vol. 54, Special Issue        February 2002

Engineering science, manufacturing, and production

Laboratory-quality diagnostics, namely particle image velocimetry and planar laser induced fluorescence, were transitioned to a field-test facility and applied to obtain velocity and species concentration validation-quality data. We made measurements in turbulent one-meter-diameter helium plumes and methane and hydrogen fires. These unique data have been analyzed and applied for validation of an unsteady numerical simulation using the Large Eddy Simulation technique. These data continue to provide validation of transport models in the ASCI fire code, FUEGO, and to guide development of new models. (9100, 8300)

The Sierra reusable software framework, which provides the physics-independent and computer-dependent portions of several new ASCI analysis codes, passed two major milestones. The first milestone required developing an extensive list of technical capabilities and releasing Sierra to the ASCI sites. A formal review certified successful completion of this milestone, calling Sierra ³a unique simulation capability of unprecedented breadth and sophistication.² The second milestone occurred when Sandia released the first Sierra-based code, the Calore thermal analysis code. (8700, 8900, 9100, 9200, 9300, 9500) John Zepper, jdzeppe@sandia.gov

Sandiaıs Microelectronics Development Lab (MDL) delivered its first War Reserve (WR), Diamond Stamped Integrated Circuit (IC). WR represents the extreme level of quality needed for ICs used in nuclear weapons and other critical applications. This demonstrates the ability of the MDL to be a backup production source for WR components. Produced under the umbrella of the Manufacture Development Engineering program, the IC incorporates tens of thousands of sub-micron transistors on a single chip. Timothy Mirabal, mirabatj@sandia.gov

To meet significant increases in production delivery requirements in FY02, Center 14100 has used Lean Manufacturing methodologies on all three of the Neutron Generator Active Ceramics production lines. In rod production, where Lean has been fully deployed, we have cut cycle time by over 50 percent, labor costs are down 20-30 percent, and our manufacturing yield has increased from 94 percent to 96 percent. (14100, 12300) Steve Lockwood, sjlockw@sandia.gov

The Sandia Production Program, which is made up of Neutron Generator Production and the Concurrent Design and Manufacturing Program (CDM), achieved 100 percent delivery to negotiated schedule and DOE product acceptance on first time submittals for all products. This is the first time in the Programıs history this has been achieved. During the past year, The CDM Program was awarded a Defense Programs award of excellence. (1700, 2500, 2600,14000, 14100, 14400, 10200, 2900) John Sayre, jasayre@sandia.gov

Last modified: February 28 , 2002

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