Publications

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The solderability of an immersion Ag finish was evaluated after the exposure of test specimens to a Battelle Class II environment, which accelerates the storage conditions of light industrial surroundings. The solderability metric was the contact angle, (θC), as determined by the meniscometer/wetting balance technique. Auger surface and depth profile analyses were utilized to identify changes in the coating chemistry. The solderability test results indicate that there was no appreciable loss in solderability when the immersion Ag coated coupons were packaged in vapor phase corrosion (VPC) inhibitor bags and/or inhibitor bags with VPC inhibitor paper and aged for 8 hours, 1 week or 2 weeks in the Battelle Class II environment. An increase in surface carbon concentration after aging did not appear to significantly affect solderability. Copyright © 2006 ASM International®.

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In recent years, efforts have been made within the nuclear weapons complex (National Nuclear Security Administration) of the Department of Energy (DOE) to replace Resource Conservation and Recovery Act (RCRA) regulated solvents (i.e., flammable, toxic, corrosive, and reactive) and ozone-depleting chemicals (ODC) with more benign alternatives. Within the National Nuclear Security Administration (NNSA) and the Department of Defense (DoD) sectors, these solvents are used for cleaning hardware during routine maintenance operations. A primary goal of this study is to replace flammable solvents used in wiping applications. Two cleaners, including a hydrofluoroether (HFE) and an azeotrope of the HFE and isopropyl alcohol (IPA), have been studied as potential replacements for flammable solvents. Cleaning efficacy, short-term and long-term materials compatibility, corrosion, drying times, flammability, environment, safety and health (ES&H) and accelerated aging issues were among the experiments used to screen candidate solvents by the interagency team performing this work. This report presents cleaning efficacy results as determined by the contact angle Goniometer as well as materials compatibility results of various metal alloys and polymers. The results indicate that IPA (baseline cleaner) and the HFE/IPA azeotrope are roughly equivalent in their ability to remove fluorinated grease, silicone grease, and a simulated finger print contaminant from various metal alloys. All of the ASTM sandwich and immersion corrosion tests with IPA, HFE or the HFE/IPA azeotrope on metal alloys showed no signs of corrosion. Furthermore, no deleterious effects were noted for polymeric materials immersed in IPA, HFE, or the HFE/IPA azeotrope.

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While surface cleaning is the most common process step in DOE manufacturing operations, the link between a successful adhesive bond and the surface clean performed before adhesion is not well understood. An innovative approach that combines computer modeling expertise, fracture mechanics understanding, and cleaning experience to address how to achieve a good adhesive bond is discussed here to develop a capability that would result in reduced cleaning development time and testing, improved bonds, improved manufacturability, and even an understanding that leads to improved aging. A simulation modeling technique, polymer reference interaction site model applied near wall (Wall PRISM), provided the capability to include contaminants on the surface. Calculations determined an approximately 8% reduction in the work of adhesion for 1% by weight of ethanol contamination on the structure of a silicone adhesive near a surface. The demonstration of repeatable coatings and quantitative analysis of the surface for deposition of controlled amounts of contamination (hexadecane and mineral oil) was based on three deposition methods. The effect of the cleaning process used on interfacial toughness was determined. The measured interfacial toughness of samples with a Brulin cleaned sandblasted aluminum surface was found to be {approximately} 15% greater than that with a TCE cleaned aluminum surface. The sensitivity of measured fracture toughness to various test conditions determined that both interfacial toughness and interface corner toughness depended strongly on surface roughness. The work of adhesion value for silicone/silicone interface was determined by a contact mechanics technique known as the JKR method. Correlation with fracture data has allowed a better understanding between interfacial fracture parameters and surface energy.

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As part of a pollution prevention program, a study was conducted at Sandia National Laboratories and at the Amarillo, ''Pantex Plant'' to identify a suitable replacement solvent(s) for cleaning hardware during routine maintenance operations. Current cleaning is performed using solvents (e.g. acetone, toluene, MEK, alcohols) that are classified as Resource Conservation and Recovery Act (RCW) materials. The Environmental Protection Agency (EPA) has assigned four characteristics as the criteria for determining whether a material is identified as hazardous under RCRA: Ignitability, Corrosivity, Reactivity and Toxicity. Within the DOE and DoD sector, these solvents are used with hand wipes to clean surfaces prior to O-ring replacement, to remove decals for new labeling, to clean painted surfaces prior to reconditioning, and for other general maintenance purposes. In some cases, low level radioactive contamination during cleaning necessitates that the RCIL4 solvent-containing wipes be classified as mixed waste. To avoid using RCRA materials, cleaning candidates were sought that had a flashpoint greater than 140 F, a pH between 2.5 and 12.5, and did not fail the reactivity and toxicity criteria. Three brominated cleaners, two hydrofluoroether azeotropes and two aliphatic hydrocarbon cleaner formulations were studied as potential replacements. Cleaning efficacy, materials compatibility, corrosion and accelerated aging studies were conducted and used to screen potential candidates. Hypersolve NPB (an n-propyl bromide based formulation) consistently ranked high in removing typical contaminants for weapons applications.

A study is underway to identify a rapid, easy method for determining cleanliness levels during the manufacture of neutron tubes. Due to high reliability concerns associated with neutron tubes, cleanliness levels of metal and ceramic piece parts are critical. Sandia has traditionally used quantitative surface analytical methods, such as Auger Electron Spectroscopy and X-ray Photoelectron Spectroscopy for determining cleanliness levels. A critical disadvantage of these techniques is the time required to perform them. More rapid, reliable methods are needed for in-line testing of neutron tube assemblies. Several methods including contact angle, MESERAN, Fourier Transform Infrared Spectroscopy, and Optically Stimulated Electron Emission measurements are being evaluated as potential candidates. Cleanliness levels for each of these methods have been compared to Auger Electron Spectroscopy results, after processing samples through similar test conditions. An attempt was made to correlate the results from the alternative methods to those of Auger Electron Spectroscopy. Test results are presented.

As part of the Environmentally Conscious Manufacturing (ECM) technology, and in support of various mechanical assembly applications, several aqueous alkaline cleaners were studied as potential candidates for cleaning mechanical piece parts. Historically, ozone depleting and hazardous chlorinated cleaners have been used to degrease mechanical assemblies. In an effort to replace these chemicals, several cleaning processes, including aqueous alkaline cleaners, were screened as potential candidates using a variety of criteria, including aqueous alkaline cleaners, were screened as potential candidates using a variety of criteria, including: cleaning efficiency, materials compatibility, etch rate, corrosion, immersion tests, temperature/humidity exposure, and an exposure to a simulated indoor industrial environment. Cleaning efficiency was determined using visual examination, Auger electron spectroscopy, X-ray photoelectron spectroscopy, MESERAN, and goniometer/contact angle measurements. Several cleaners were identified as potential alternatives based solely on the cleaning results. Some of the cleaners, however, left undesirable residues. This paper will focus on materials compatibility issues of these aqueous cleaners after immersion tests, an etch rate study, and exposures to temperature/humidity and a standard industrial environment.

As part of an Environmentally Conscious Manufacturing (ECM) Program, a study was conducted at Sandia National Laboratories to identify an alternative cleaning process that would effectively replace trichloroethylene (TCE) for cleaning mechanical piece parts of Switch Tube assemblies. Eight aqueous alkaline cleaners, as well as an isopropyl alcohol and isopropyl alcohol/Cyclohexane cleaning process, were studied as potential replacements. Cleaning efficacy, materials compatibility, etch rate and corrosion studies were conducted and used to screen potential candidates. Cleaning efficacy was determined using visual examination, goniometer/contact angle measurements, Auger electron spectroscopy, X-ray Photoelectron spectroscopy and an evaporative rate analysis technique known as MESERAN Surface Analysis. Several cleaners were identified as potential replacements for TCE based solely on the cleaning efficacy results. Some of the cleaners, however, left undesirable residues studies were completed, Brulin 815GD (an aqueous alkaline cleaner) was selected as the replacement for TCE.