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Manufacturing high reliability weapon grade transformers in small lots

Archer, Wendel E.

Sandia has used flyback transformers for many years, primarily to charge capacitors for capacitive discharge units. Important characteristics of the transformer design are to meet inductance, turns ratio, and high voltage breakdown requirements as well as not magnetically saturating during each energy transfer cycle. Sandia has taken over production responsibility for magnetic components from a previous GE/LM, General Electric/Lockheed Martin, facility in Florida that produced {approximately} 50 K units per year. Vanguard Electronics is working with Sandia to transfer many of these designs to Vanguard`s small manufacturing facility in Gardena, CA. The challenge is to achieve the required high reliability and meet all the other electrical requirements with such small quantities of parts, {approximately} 100 per year. DOE requirements include high reliability {le} 3 failures per 10,000 components per 20 years while meeting numerous other environmental requirements. The basic design and prove-in required four lots of preproduction parts, extensive environmental testing, and numerous design changes. The manufacturing problems that affected performance of the transformer will be presented. These include encapsulation voids and core alignment. Also, some extended life test data that predicts long term reliability of newly produced transformers versus older designs will be compared.

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Statistical modeling of targets and clutter in single-look non-polarimetric SAR imagery

Salazar II, Jose S.

This paper presents a Generalized Logistic (gLG) distribution as a unified model for Log-domain synthetic aperture Radar (SAR) data. This model stems from a special case of the G-distribution known as the G{sup 0}-distribution. The G-distribution arises from a multiplicative SAR model and has the classical K-distribution as another special case. The G{sup 0}-distribution, however, can model extremely heterogeneous clutter regions that the k-distribution cannot model. This flexibility is preserved in the unified gLG model, which is capable of modeling non-polarimetric SAR returns from clutter as well as man-made objects. Histograms of these two types of SAR returns have opposite skewness. The flexibility of the gLG model lies in its shape and shift parameters. The shape parameter describes the differing skewness between target and clutter data while the shift parameter compensates for movements in the mean as the shape parameter changes. A Maximum Likelihood (ML) estimate of the shape parameter gives an optimal measure of the skewness of the SAR data. This measure provides a basis for an optimal target detection algorithm.

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Recommendations for a proposed standard for performing systems analysis

Whitehead, Donnie W.

In August 1995, the Nuclear Regulatory Commission (NRC) issued a policy statement proposing improved regulatory decisionmaking by increasing the use of PRA [probabilistic risk assessment] in all regulatory matters to the extent supported by the state-of-the-art in PRA methods and data. A key aspect in using PRA in risk-informed regulatory activities is establishing the appropriate scope and attributes of the PRA. In this regard, ASME decided to develop a consensus PRA Standard. The objective is to develop a PRA Standard such that the technical quality of nuclear plant PRAs will be sufficient to support risk-informed regulatory applications. This paper presents examples recommendations for the systems analysis element of a PRA for incorporation into the ASME PRA Standard.

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Microfabrication of membrane-based devices by deep-reactive ion etching (DRIE) of silicon

Manginell, Ronald

Deep reactive ion etching (DRIE) of silicon was utilized to fabricate dielectric membrane-based devices such as microhotplates, valves and flexural plate wave (FPW) devices. Through-wafer DRIE is characterized by fast etch rates ({approximately} 3 {micro}m/min), crystal orientation independence, vertical sidewall profiles and CMOS compatibility. Low-stress silicon nitride, a popular membrane material, has an appreciable DRIE etch rate. To overcome this limitations DRIE can be accompanied by a brief wet chemical etch. This approach has been demonstrated using KOH or HF/Nitric/Acetic etchants, both of which have significantly lower etch rates on silicon nitride than does DRIE. The DRIE etch properties of composite membranes consisting of silicon dioxide and silicon nitride layers are also under evaluation due to the higher DRIE selectivity to silicon dioxide.

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Characterization of molecular recognition in gas sensors

Ricco, A.J.

Molecular recognition is an important topic when searching for new, selective coating materials for chemical sensing. Recently, the general idea of molecular recognition in the gas phase was challenged by Grate et al. However, in earlier thickness-shear mode resonator (TSMR) investigations, convincing evidence was presented for specific recognition of particular analyte target molecules. In this study, the authors systematically investigated coatings previously shown to be highly selective, such as the bucket-like cyclodextrins for chiral recognition, Ni-camphorates for the specific detection of the bases pyridine and DMMP (dimethylmethylphosphonate), and phthalocyanines to specifically detect benzene, toluene, and xylene (BTX).

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SAW arrays using dendrimers and pattern recognition to detect volatile organics

Ricco, A.J.

chemical sensor arrays eliminate the need to develop a high-selectivity material for every analyte. The application of pattern recognition to the simultaneous responses of different microsensors enables the identification and quantification of multiple analytes with a small array. Maximum materials diversity is the surest means to create an effective array for many analytes, but using a single material family simplifies coating development. Here the authors report the successful combination of an array of six dendrimer films with mass-sensitive SAW (surface acoustic wave) sensors to correctly identify 18 organic analytes over wide concentration ranges, with 99.5% accuracy. The set of materials for the array is selected and the results evaluated using Sandia`s Visual-Empirical Region of Influence (VERI) pattern recognition (PR) technique. The authors evaluated eight dendrimer films and one self-assembled monolayer (SAM) as potential SAW array coatings. The 18 organic analytes they examined were: cyclohexane, n-hexane, i-octane, kerosene, benzene, toluene, chlorobenzene, carbon tetrachloride, trichloroethylene, methanol, n-propanol, pinacolyl alcohol, acetone, methyl isobutyl ketone, dimethylmethylphosphate, diisopropylmethylphosphonate, tributylphosphate, and water.

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Chemical mechanical polishing: An enabling fabrication process for surface micromachining technologies

Sniegowski, Jeffry J.

Chemical-Mechanical-Polishing (CMP), first used as a planarization technology in the manufacture of multi-level metal interconnects for high-density Integrated Circuits (IC), is readily adapted as an enabling technology in MicroElectroMechanical Systems (MEMS) fabrication, particularly polysilicon surface micromachining. The authors have demonstrated that CMP enhances the design and manufacturability of MEMS devices by eliminating several photolithographic definition and film etch issues generated by severe topography. In addition, CMP planarization readily allows multi-level polysilicon structures comprised of 4- or more levels of polysilicon, eliminates design compromise generated by non-planar topography, and provides an avenue for integrating different process technologies. A recent investigation has also shown that CMP is a valuable tool for assuring acceptable optical flatness of micro-optical components such as micromirrors. Examples of these enhancements include: an extension of polysilicon surface-micromachining fabrication to a 5-level technology, a method of monolithic integration of electronics and MEMS, and optically flat micromirrors.

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The START III bargaining space

Karas, Thomas H.

The declining state of the Russian military and precarious Russian economic condition will give the US considerable advantages at the START III bargaining table. Taking the US-RF asymmetries into account, this paper discusses a menu of START III measures the US could ask for, and measures it could offer in return, in attempting to negotiate an equitable treaty. Measures the US might seek in a START III treaty include: further reductions in deployed strategic nuclear warheads, irreversibility of reductions through warhead dismantlement; beginning to bring theater nuclear weapons under mutual control, and increased transparency into the Russian nuclear weapons complex. The US may, however, wish to apply its bargaining advantages to attempting to achieve the first steps toward two long-range goals that would enhance US security: bringing theater nuclear weapons into the US-RF arms control arena, and increasing transparency into the Russian nuclear weapons complex. In exchange for measures relating to these objectives, the US might consider offering to Russia: Further strategic weapons reductions approaching levels at which the Russians believe they could maintain a degree of parity with the US; Measures to decrease the large disparities in potential deliver-system uploading capabilities that appear likely under current START II/START III scenarios; and Financial assistance in achieving START II/START III reductions as rapidly as is technically possible.

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An unstructured-grid, parallel, projection solver for computing low-speed flows

Christon, Mark

This paper presents an overview of the issues associated with applying a domain-decomposition message-passing paradigm to the parallel implementation of both explicit and semi-implicit projection algorithms. The use of an element-based domain decomposition with an efficient solution strategy for the pressure field is shown to yield a scalable, parallel solution method capable of treating complex flow problems where high-resolution grids are required. In addition, the use of an SSOR or Jacobi preconditioned conjugate gradient solver with an A-conjugate projection reduces the computational time for the solution of the pressure field, and yields parallel efficiencies above 80% for computations with O(250) elements per processor. The parallel projection solver is verified using a series of 2-D and 3-D benchmarks designed to evaluate time-accurate flow solution methods. Finally, the extension of the projection algorithm to reacting flows is demonstrated for a time-dependent vortex-shedding problem.

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Developing safety culture-rocket science or common sense?

Mahn, Jeffrey A.

Despite evidence of significant management contributions to the causes of major accidents, recent events at Millstone Nuclear Power Station in the US and Ontario Hydro in Canada might lead one to conclude that the significance of safety culture, and the role of management in developing and maintaining an appropriate safety culture, is either not being understood or not being taken serious as integral to the safe operation of some complex, high-reliability operations. It is the purpose of this paper to address four aspects of management that are particularly important to safety culture, and to illustrate how development of an appropriate safety culture is more a matter of common sense than rocket science.

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Selecting a process paradigm for an emergent disruptive technology: Evidence from the emerging microsystems technology base

Smith, J.H.; Walsh, S.T.

Emergent technologies often suffer from a lack of an installed manufacturing base and an obvious dominant manufacturing technique. Firms which base their search for competitive advantage on emergent disruptive technologies must make hard production choices and endure major manufacturing discontinuities. The authors as well as many other firms, are now facing these challenges with the embrace of microsystems technologies. They add to the literature by providing a set of criteria for firms investing in emergent disruptive technologies. Sandia has long been associated as a pioneer in the development of new manufacturing techniques. Microsystems is just the current in a long line of manufacturing technologies that have been considered for mission critical system applications. The authors as well as others, have had to make the hard choice of investing in specific microsystems manufacturing techniques. Important considerations in the technique choice include: the existing internal manufacturing bases, commonality with existing commercial manufacturing infrastructure, current and projected critical performance characteristics, learning curves, the promise to add new but un-thought-of functionally to existing systems, and the anticipated ability to qualify devices built from the technique for mission critical applications.

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InGaAs/InP heterojunction bipolar transistors for ultra-low power circuit applications

Chang, P.C.

For many modern day portable electronic applications, low power high speed devices have become very desirable. Very high values of f{sub T} and f{sub MAX} have been reported with InGaAs/InP heterojunction bipolar transistors (HBTs), but only under high bias and high current level operating conditions. An InGaAs/InP ultra-lowpower HBT with f{sub MAX} greater than 10 GHz operating at less than 20 {micro}A has been reported for the first time in this work. The results are obtained on a 2.5 x 5 {micro}m{sup 2} device, corresponding to less than 150 A/cm{sup 2} of current density. These are the lowest current levels at which f{sub MAX} {ge} 10 GHz has been reported.

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Detecting corrosion in plastic encapsulated micro-electronics packages

Sorensen, N.R.; Braithwaite, J.W.; Peterson, D.W.; Sweet, J.N.

In the past, most defense microelectronics components were packaged in ceramic, hermetic enclosures. PEMs are not hermetic because the plastic molding compounds are permeable to moisture. This lack of hermeticity creates an unknown liability, especially with respect to corrosion of the metallization features. This potential liability must be addressed to ensure long-term reliability of these systems is maintained under conditions of long-term dormant storage. However, the corrosion process is difficult to monitor because it occurs under the encapsulating plastic and is therefore not visible. The authors have developed techniques that allow them to study corrosion of Al bondpads and traces under relevant atmospheric corrosion conditions. The cornerstone of this capability is the ATC 2.6, a microelectronic test device designed at Sandia National Laboratories. Corrosion tests were performed by exposing test chips to aggressive environments. The electrical response of the ATC indicated an increase in bondpad resistance with exposure time. Note that the change in resistance is not uniform from one bondpad to another. This illustrates the stochastic nature of the corrosion process. The change in resistance correlated with visual observation of corrosion of the bondpads on the unencapsulated test chips.

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Multispectral image classification of MRI data using an empirically-derived clustering algorithm

Horn, Kevin M.

Multispectral image analysis of magnetic resonance imaging (MRI) data has been performed using an empirically-derived clustering algorithm. This algorithm groups image pixels into distinct classes which exhibit similar response in the T{sub 2} 1st and 2nd-echo, and T{sub 1} (with ad without gadolinium) MRI images. The grouping is performed in an n-dimensional mathematical space; the n-dimensional volumes bounding each class define each specific tissue type. The classification results are rendered again in real-space by colored-coding each grouped class of pixels (associated with differing tissue types). This classification method is especially well suited for class volumes with complex boundary shapes, and is also expected to robustly detect abnormal tissue classes. The classification process is demonstrated using a three dimensional data set of MRI scans of a human brain tumor.

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Precise time synchronization data acquisition with remote systems

Berg, Dale E.

Researchers at the National Wind Technology Center have identified a need to acquire data on the rotor of an operating wind turbine at precisely the same time as other data is acquired on the ground or on a non-rotating part of the wind turbine. The researchers will analyze that combined data with statistical and correlation techniques to clearly establish phase information and loading paths and insights into the structural loading of wind turbines. A data acquisition unit has been developed to acquire the data from the rotating system at precise universal times specified by the user. The unit utilizes commercial data acquisition hardware, spread-spectrum radio modems, and a Global Positioning Satellite receiver as well as a custom-built programmable logic device. A prototype of the system is now operational, and initial field deployment is anticipated this summer.

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ISIS; An Information-efficient Spectral Imaging System

Sweatt, W.C.

A specialized hyperspectral imager has been developed that preprocesses the spectra from an image before the light reaches the detectors. This "optical computer" does not allow the flexibility of digital post-processing. However, the processing is done in real time and the system can examine = 2 x 10{sup 6} scene pixels/sec. Therefore, outdoors it could search for pollutants, vegetation types, minerals, or man-made objects. On a high- speed production line it could identify defects in sheet products like plastic wrap or film, or on painted or plastic parts. ISIS is a line scan imager. A spectrally dispersed slit image is projected on a Spatial Light Modulator. The SLM is programmed to take the inner product of the spectral intensity vector and a spectral basis vector. The SLM directs the positive and negative parts of the inner product to different linear detector arrays so the signal difference equals the inner product. We envision a system with one telescope and =4 SLMS.

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Engineered Surety Using the Risk Equation (EnSURE)

Jaeger, Calvin D.

Engineered Surety Using the Risk Equation (EnSURE) is a new approach being developed by Sandia National Laboratories for determining and mitigating risk. The EnSURE approach is based on the risk equation, which can be defined by the following equation: R = (Pa)(1-Pe)(C). Where R is risk, Pa is the likelihood of attack, Pe is the system effectiveness and C is the consequence. EnSURE considers each of the components of risk to help in assessing surety (e.g. security, safety, environmental) and providing for the most cost-effective ways to reduce risk. EnSURE is intended to help in evaluating and reducing the risk from either man-caused or natural events. It will help the decision-makers identify possible targets, evaluate the consequences of an event, assess the risk based on the threat and the existing conditions and then help in the application of mitigating measures. EnSURE is in the development stages. It builds on existing and ongoing development activities at Sandia, as well as the considerable work done in the fields of consequence analysis, risk analysis and intelligence. The components of EnSURE include consequences, constraints, threat, target/goal identification, facility/process characterization, evaluation and analysis, system improvement, and decision making. This paper provides a brief description of EnSURE.

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Security message exchange interoperability scenarios

Tarman, Thomas D.

This contribution describes three interoperability scenarios for the ATM Security Message Exchange (SME) protocol. These scenarios include network-wide signaling support for the Security Services Information Element, partial signaling support wherethe SSIE is only supported in private or workgroup ATM networks, and the case where the SSIE is nonsupported by any network elements (exceptthosethat implement security services). Explanatory text is proposed for inclusion infection 2.3 of the ATM Security Specification, Version 1.0.

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Transient radiation effects in D.O.I. optical materials: KD{sup *}P

Simmons-Potter, K.

Department of Energy and Defense Programs systems are becoming increasingly reliant on the use of optical technologies that must perform under a range of ionizing radiation environments. In particular, the radiation response of materials under consideration for applications in direct optical initiation (D.O.I.) schemes must be well characterized. In this report, transient radiation effects observed in a KD*P crystal are characterized. Under gamma exposure with 2 MeV photons in a 20--30 nsec pulse, the authors observe induced absorption at 1.06 {micro}m that causes a peak decrease in overall sample transmittance of only 10%. This induced loss is seen to recover fully within the first 30 {micro}sec.

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Transient radiation effects in D.O.I. optical materials: Schott filter glass

Simmons-Potter, K.

Department of Energy and Defense Programs systems are becoming increasingly reliant on the use of optical technologies that must perform under a range of ionizing radiation environments. In particular, the radiation response of materials under consideration for applications in direct optical initiation (D.O.I.) schemes must be well characterized. In this report, transient radiation effects observed in Schott filter glass S-7010 are characterized. Under gamma exposure with 2 MeV photons in a 20--30 nsec pulse, the authors observe strong initial induced fluorescence in the red region of the spectrum followed by significant induced absorption over the same spectral region. Peak induced absorption coefficients of 0.113 cm{sup {minus}1} and 0.088 cm{sup {minus}1} were calculated at 800 nm and 660 nm respectively.

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High consequence operations safety symposium 2: Proceedings

Antonio, Robert C.'.

From July 29 to 31, 1997, the Surety Assessment Center at Sandia National Laboratories hosted the second international symposium on High Consequence Operations Safety, HCOSSII. The two and one-half day symposium allowed participants to share strategies, methodologies, and experiences in high consequence engineering and system design. The symposium addressed organizational influences on high consequence safety, assessment and analysis processes, lessons-learned from high consequence events, human factors in safety, and software safety. A special session at the end of the symposium featured a presentation by Federal Nuclear Center--All Russian Research Institute of Experimental Physics and Sandia National Laboratories personnel on their joint efforts to establish the International Surety Center for Energy Intensive and High Consequence Systems and Infrastructures.

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3D EM imaging from a single borehole; a numerical feasibility study

Alumbaugh, D.L.

Often the drilling of an oil well is followed by a logging process to characterize the region immediately surrounding the well bore. The electromagnetic (EM) induction tool, which provides the formation resistivity, is among the most frequently run logs. A preliminary study has been conducted to analyze the feasibility of three dimensional (3D) electromagnetic (EM) imaging from a single borehole. The logging tool consists of a vertical magnetic dipole source and multiple 3 component magnetic field receivers offset at different distances from the source. Synthetic data calculated with a 3D finite difference code demonstrate that the phase of the horizontal magnetic fields provides the critical information on the three dimensionality of the medium. A 3D inversion algorithm is then employed to demonstrate the plausibility of 3D inversion using 3 component magnetic field data. Finally, problems associated with introducing biased noise into the horizontal components of the field through misalignment of the logging tool is discussed.

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Infrasound records from U.S. atmospheric tests

Chael, Eric P.

The United States conducted over 100 atmospheric nuclear tests at the Nevada Test Site from 1951 through 1962. Some of the earliest tests caused unexpected damage, primarily broken glass and cracked plaster, in Las Vegas and other surrounding communities. To address this problem, Sandia initiated a program to monitor and predict the pressure waves around NTS. Infrasound recording systems were developed, then field for all tests beginning with Operation Buster in October 1951. Investigators soon discovered that near-surface temperature inversions and wind profiles caused the damaging pressures in Las Vegas. A typical test was recorded at about a dozen stations from the Control Point on NTS to as far away as Pasadena, CA. In addition, some tests in the South Pacific were monitored, as well as numerous chemical explosions. Strip charts recorded signals in the frequency band from 0.05 to 30 Hz, and the paper tapes were achieved at Sandia in the early 1970s. The NTS events ranged in yield from below 1 ton to 74 kilotons; source altitudes varied from near ground level (including some cratering experiments) to as high as 11 km. The resulting data contain a wealth of information on the source function, yield scaling and regional propagation of infrasound signals from atmospheric explosions. The renewed interest in infrasonic monitoring for CTBT verification has prompted the authors to exhume some of the archived records. The authors plan to digitize the signals from several tests and evaluate their applicability to CTBT issues. In addition, they will collect any existing parametric measurements for these records (arrival times, amplitudes, etc.). All data will be converted to CSS database format and made available to the research community. If appropriate, the resulting information could also be included in the Knowledge Base under development for CTBT monitoring.

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Anomaly detection using simulated MTI data cubes derived from HYDICE data

Moya, Mary M.

The US Department of Energy is funding the development of the Multi-spectral Thermal Imager (MTI), a satellite-based multi-spectral (MS) thermal imaging sensor scheduled for launch in October 1999. MTI is a research and development (R and D) platform to test the applicability of multispectral and thermal imaging technology for detecting and monitoring signs of proliferation of weapons of mass destruction. During its three-year mission, MTI will periodically record images of participating government, industrial and natural sites in fifteen visible and infrared spectral bands to provide a variety of image data associated with weapons production activities. The MTI satellite will have spatial resolution in the visible bands that is five times better than LANDSAT TM in each dimension and will have five thermal bands. In this work, the authors quantify the separability between specific materials and the natural background by applying Receiver Operating Curve (ROC) analysis to the residual errors from a linear unmixing. The authors apply the ROC analysis to quantify performance of the MTI. They describe the MTI imager and simulate its data by filtering HYDICE hyperspectral imagery both spatially and spectrally and by introducing atmospheric effects corresponding to the MTI satellite altitude. They compare and contrast the individual effects on performance of spectral resolution, spatial resolution, atmospheric corrections, and varying atmospheric conditions.

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Results 93026–93050 of 99,299
Results 93026–93050 of 99,299