To reduce costs and hazardous wastes associated with the production of lead-based active ceramic components, an injection molding process is being investigated to replace the current machining process. Here, lead zirconate titanate (PZT) ceramic particles are suspended in a thermoplastic resin and are injected into a mold and allowed to cool. The part is then bisque fired and sintered to complete the densification process. To help design this new process we use a finite element model to describe the injection molding of the ceramic paste. Flow solutions are obtained using a coupled, finite-element based, Newton-Raphson numerical method based on the GOMA/ARIA suite of Sandia flow solvers. The evolution of the free surface is solved with an advanced level set algorithm. This approach incorporates novel methods for representing surface tension and wetting forces that affect the evolution of the free surface. Thermal, rheological, and wetting properties of the PZT paste are measured for use as input to the model. The viscosity of the PZT is highly dependent both on temperature and shear rate. One challenge in modeling the injection process is coming up with appropriate constitutive equations that capture relevant phenomenology without being too computationally complex. For this reason we model the material as a Carreau fluid and a WLF temperature dependence. Two-dimensional (2D) modeling is performed to explore the effects of the shear in isothermal conditions. Results indicate that very low viscosity regions exist near walls and that these results look similar in terms of meniscus shape and fill times to a simple Newtonian constitutive equation at the shear-thinned viscosity for the paste. These results allow us to pick a representative viscosity to use in fully three-dimensional (3D) simulation, which because of numerical complexities are restricted to using a Newtonian constitutive equation. Further 2D modeling at nonisothermal conditions shows that the choice of representative Newtonian viscosity is dependent on the amount of heating of the initially room temperature mold. An early 3D transient model shows that the initial design of the distributor is sub-optimal. However, these simulations take several months to run on 4 processors of an HP workstation using a preconditioner/solver combination of ILUT/GMRES with fill factors of 3 and PSPG stabilization. Therefore, several modifications to the distributor geometry and orientations of the vents and molds have been investigated using much faster 3D steady-state simulations. The pressure distribution for these steady-state calculations is examined for three different distributor designs to see if this can indicate which geometry has the superior design. The second modification, with a longer distributor, is shown to have flatter, more monotonic isobars perpendicular to the flow direction indicating a better filling process. The effects of the distributor modifications, as well as effects of the mold orientation, have also been examined with laboratory experiments in which the flow of a viscous Newtonian oil entering transparent molds is recorded visually. Here, the flow front is flatter and voids are reduced for the second geometry compared to the original geometry. A horizontal orientation, as opposed to the planned vertical orientation, results in fewer voids. Recently, the Navier-Stokes equations have been stabilized with the Dohrman-Bochev PSPP stabilization method, allowing us to calculate transient 3D simulations with computational times on the order of days instead of months. Validation simulations are performed and compared to the experiments. Many of the trends of the experiments are captured by the level set modeling, though quantitative agreement is lacking mainly due to the high value of the gas phase viscosity necessary for numerical stability, though physically unrealistic. More correct trends are predicted for the vertical model than the horizontal model, which is serendipitous as the actual mold is held in a vertical geometry. The full, transient mold filling calculations indicate that the flow front is flatter and voids may be reduced for the second geometry compared to the original geometry. The validated model is used to predict mold filling for the actual process with the material properties for the PZT paste, the original distributor geometry, and the mold in a vertical orientation. This calculation shows that voids may be trapped at the four corners of the mold opposite the distributor.
The Nuclear Weapons Guidance Team is an interagency committee led by Earl Whiteman, DOE that chartered the generation of EP40100, Concurrent Qualification and its successor EP401099, Concurrent Engineering and Qualification. As this new philosophy of concurrent operations has evolved and as implementation has been initiated, conflicts and insufficiencies in the remaining Engineering Procedures (EPs) have become more apparent. At the Guidance Team meeting in November 1995, this issue was explored and several approaches were considered. It was concluded at this meeting, that a smaller set of interagency EPs described in a hierarchical system could provide the necessary interagency direction to support complex-wide implementation. This set consolidates many existing EP processes where consistency and commonality are critical to success of the extended enterprise. The Guidance Team subsequently chartered an interagency team to initiate development activity associated with the envisioned new EP set. This team had participation from seven Nuclear Weapons Complex (NWC) sites as well as DOE/AL and DP-14 (team members are acknowledged later in this report). Per the Guidance Team, this team, referred to as the Architecture Subcommittee, was to map out and define an EP Architecture for the interagency EPs, make recommendations regarding a more agile process for EP approval and suggest an aggressive timeline to develop the combined EPs. The Architecture Subcommittee was asked to brief their output at the February Guidance Team meeting. This SAND report documents the results of the Architecture Subcommittee`s recommendations.
The end of the cold war has resulted in many changes for the Nuclear Weapons Complex (NWC). We now work in a smaller complex, with reduced resources, a smaller stockpile, and no new phase 3 weapons development programs. This new environment demands that we re-evaluate the way we design and produce nuclear weapons. The Defense Program (DP) Business Practices Re-engineering activity was initiated to improve the design and production efficiency of the DP Sector. The activity had six goals: (1) to identify DP business practices that are exercised by the Product Realization Process (PRP); (2) to determine the impact (positive, negative, or none) of these practices on defined, prioritized customer criteria; (3) to identify business practices that are candidates for elimination or re-engineering; (4) to select two or three business practices for re-engineering; (5) to re-engineer the selected business practices; and (6) to exercise the re-engineered practices on three pilot development projects. Business practices include technical and well as administrative procedures that are exercised by the PRP. A QFD exercise was performed to address (1)-(4). The customer that identified, defined, and prioritized the criteria to rate the business practices was the Block Change Advisory Group. Five criteria were identified: cycle time, flexibility, cost, product performance/quality, and best practices. Forty-nine business practices were identified and rated per the criteria. From this analysis, the group made preliminary recommendations as to which practices would be addressed in the re-engineering activity. Sixteen practices will be addressed in the re-engineering activity. These practices will then be piloted on three projects: (1) the Electronic Component Assembly (ECA)/Radar Project, (2) the B61 Mod 11, and (3) Warhead Protection Program (WPP).
Agencies that are prime contractors to the Department of Energy (DOE) have developed and are currently instituting a quality initiative which applies a QML-like methodology to a complete discrete semiconductor process. Our goal is to demonstrate that improving the quality of this process is a more efficient method than screening to improve the quality of the semiconductor. The QML methodology, MIL-I-38535, is used to achieve this goal for integrated circuits. Our methods, for discrete semiconductor, applies many of the principles found in this specification to provide structured continuous improvement. Improvement in product performance reduces incoming inspection requirements, resulting in reduced cost and product lead time. This paper describes our methodology for this initiative, which consists of a certification, qualification, and monitoring (CQM) program for the complete semiconductor process. This process includes all technical and administrative activities that effect the quality of a device, beginning with circuit design and ending with the installation of the manufactured device into the electronic component assembly. For the initial application, our CQM program is being implemented on a small signal transistor. Four companies are involved in the partnership: Sandia National Laboratories, a design agency and prime contractor to the DOE; Allied-Signal Aerospace Company, Kansas City Division, a production agency and prime contractor to the DOE (for electronic component assembly); Alliance Electronics, a prime contractor and supplier (for procurement and testing); and Motorola Inc., Semiconductor Products Sector, a manufacturer. 2 refs.