Publications

A new failure analysis technique has been developed for backside and frontside localization of open and shorted interconnections on ICs. This scanning optical microscopy technique takes advantage of the interactions between IC defects and localized heating using a focused infrared laser ({lambda} = 1,340 nm). Images are produced by monitoring the voltage changes across a constant current supply used to power the IC as the laser beam is scanned across the sample. The method utilizes the Seebeck Effect to localize open interconnections and Thermally-Induced Voltage Alteration (TIVA) to detects shorts. The interaction physics describing the signal generation process and several examples demonstrating the localization of opens and shorts are described. Operational guidelines and limitations are also discussed.

The near eutectic 60Sn-40Pb alloy is the most commonly used solder for electrical interconnections in electronic packages. This alloy has a number of processing advantages (suitable melting point of 183 C and good wetting behavior). However, under conditions of cyclic strain and temperature (thermomechanical fatigue), the microstructure of this alloy undergoes a heterogeneous coarsening and failure process that makes the prediction of solder joint lifetime complex. A viscoplastic constitutive model for solder with an internal state variable that tracks microstructural evolution is currently under development. This constitutive model was implemented in to several finite element codes. With this computational capability, the thermomechanical response of solder interconnects, including microstructural evolution, can be predicted. This capability was applied to predict the thermomechanical response of a ball grid array (BGA) solder interconnect. BGAs with both homogeneous and heterogeneous initial microstructures were evaluated. In this paper, the constitutive model used to describe the solder will first be briefly discussed. The results of computational studies to determine the thermomechanical response of BGA solder interconnects will then be presented.

Radiation detectors have been included in several remote monitoring field trial systems to date. The present study considers detectors at Embalse, Argentina, and Oarai, Japan. At Embalse four gamma detectors have been operating in the instrumentation tubes of spent fuel storage silos for up to three years. Except for minor fluctuations, three of the detectors have operated normally. One of the detectors appears never to have operated correctly. At Oarai two gamma detectors have been monitoring a spent-fuel transfer hatch for over 18 months. These detectors have operated normally throughout the period, although one shows occasional noise spikes.

Materials Protection, Control and Accounting (MPC and A) equipment upgrades are complete at the Institute of Theoretical and Experimental Physics (ITEP), a site that has significant quantities of weapons-potential nuclear materials. Cooperative work was initiated at this Moscow facility as a part of the US-Russian program to upgrade MPC and A systems. An initial site visit and assessment were conducted in September 1996 to establish communication between ITEP, the US Department of Energy (DOE), and participating US National Laboratories. Subsequently, an agreement was reached to develop two master plans for MPC and A upgrades. Los Alamos National Laboratory (LANL) and Oak Ridge National Laboratory (ORNL) assisted in developing a plan for Material Control and Accounting (MC and A) upgrades, and Sandia National Laboratories (SNL) assisted in developing a plan for Physical Protection System (PPS) upgrades. The MC and A plan included MC and A training, a mass measurement program, nondestructive assay instrumentation, item identification (bar coding), physical inventory taking, portal and hand-held nuclear material monitors, and a nuclear materials accounting system. The PPS plan included basic PPS design training, Central Alarm Station (CAS) relocation and equipment upgrades, a site and critical-building access control system, intrusion detection, alarm assessment, and guard force communications.

The US Department of Energy (DOE) and the Russian Special Scientific and Production State Enterprise Eleron have teamed to lead a project to enhance the overall security of Russian Ministry of Atomic Energy (MINATOM) transportation of Special Nuclear Material (SNM) shipments. The effort is called the Railcar Transportation Security Project and is part of the overall DOE Material Protection, Control, and Accounting (MPC and A) program addressing the enhancement of nuclear material control, accounting, and physical protection for Russian SNM. The goal of this MPC and A project is to significantly increase the security of Russian MINATOM highly enriched SNM rail shipments. To accomplish this, the MPC and A Railcar Transportation Security program will provide an enhanced, yet cost effective, railcar transportation security system. The system incorporates a balance between the traditional detection, communications, delay, and response security elements to significantly improve the security of MINATOM SNM shipments. The strategy of this program is to use rapid upgrades to implement mature security technologies as quickly as possible. The rapid upgrades emphasize rapidly deployable delay elements, enhanced radio communications, and intrusion detection and surveillance. Upgraded railcars have begun operation during FY98. Subsequent upgrades will build upon the rapid upgrades and eventually be integrated into a final deployed system configuration. This paper provides an overview of the program, with a summary of performance of the deployed railcars.

A combined engineering and geochemistry approach is recommended for the stabilization of waste in decommissioned tanks and contaminated soils at the AX Tank Farm, Hanford, WA. A two-part strategy of desiccation and gettering is proposed for treatment of the in-tank residual wastes. Dry portland cement and/or fly ash are suggested as an effective and low-cost desiccant for wicking excess moisture from the upper waste layer. Getters work by either ion exchange or phase precipitation to reduce radionuclide concentrations in solution. The authors recommend the use of specific natural and man-made compounds, appropriately proportioned to the unique inventory of each tank. A filler design consisting of multilayered cementitous grout with interlayered sealant horizons should serve to maintain tank integrity and minimize fluid transport to the residual waste form. External tank soil contamination is best mitigated by placement of grouted skirts under and around each tank, together with installation of a cone-shaped permeable reactive barrier beneath the entire tank farm. Actinide release rates are calculated from four tank closure scenarios ranging from no action to a comprehensive stabilization treatment plan (desiccant/getters/grouting/RCRA cap). Although preliminary, these calculations indicate significant reductions in the potential for actinide transport as compared to the no-treatment option.

A database has been created for use with the Jacobs-Cowperthwaite-Zwisler-3 equation-of-state (JCZ3-EOS) to determine thermochemical equilibrium for detonation and expansion states of energetic materials. The JCZ3-EOS uses the exponential 6 intermolecular potential function to describe interactions between molecules. All product species are characterized by r*, the radius of the minimum pair potential energy, and {var_epsilon}/k, the well depth energy normalized by Boltzmann`s constant. These parameters constitute the JCZS (S for Sandia) EOS database describing 750 gases (including all the gases in the JANNAF tables), and have been obtained by using Lennard-Jones potential parameters, a corresponding states theory, pure liquid shock Hugoniot data, and fit values using an empirical EOS. This database can be used with the CHEETAH 1.40 or CHEETAH 2.0 interface to the TIGER computer program that predicts the equilibrium state of gas- and condensed-phase product species. The large JCZS-EOS database permits intermolecular potential based equilibrium calculations of energetic materials with complex elemental composition.

The ability to locate an individual atom on a surface, remove it in a controlled fashion, and determine its chemical identity makes the atom-probe field-ion microscope an extremely powerful tool for the analysis of solid surfaces. By itself, the field ion microscope has contributed significantly to our understanding of surface atomic structure, single-atom surface diffusion, and the detailed interactions that occur between atoms and defects on surfaces.1 When used in combination with the atom-probe mass spectrometer there have been several additional areas within the traditional definition of "surface science"where the chemical identification capability of the atom probe has led to new insights. In this paper these applications are reviewed focusing on two specific areas: surface segregation in intermetallic alloys and chemical reactions on metal surfaces. The equilibrium distribution of component species in the near surface region of solid solution alloy may be different from the distribution in the bulk.

The time-averaged, daylight fractional statistical cloud coverages as a function of cloud optical thickness and selected values of cloud transmission were determined for various geographic areas using D1 data from the International Satellite Cloud Climatology Project (ISCCP). The regions of interest chosen for this report are: global earth, global sea, global land, global coast, and the six 30{degree}-latitude bands over sea, over land, and over coast with longitude 0{degree}--360{degree}. This statistical information is deduced from data determined from satellite measurements of terrestrial, atmospheric and cloud properties by the International Satellite Cloud Climatology Project. In particular the results are based on the ISCCP D1 data base.

The Waste Isolation Pilot Plant (WIPP) is under development by the US Department of Energy (DOE) for the geologic disposal of transuranic (TRU) waste that has been generated at government defense installations in the United States. The WIPP is located in an area of low population density in southeastern New Mexico. Waste disposal will take place in excavated chambers in a bedded salt formation approximately 655 m below the land surface. This presentation describes a performance assessment (PA) carried out at Sandia National Laboratories (SNL) to support the Compliance Certification Application (CCA) made by the DOE to the US Environmental Protection Agency (EPA) in October, 1996, for the certification of the WIPP for the disposal of TRU waste. Based on the CCA supported by the PA described in this presentation, the EPA has issued a preliminary decision to certify the WIPP for the disposal of TRU waste. At present (April 1998), it appears likely that the WIPP will be in operation by the end of 1998.

The appropriate treatment of uncertainty is now widely recognized as an essential component of performance assessments (PAs) for complex systems. When viewed at a high-level, the uncertainty in such analyses can typically be partitioned into two types: (1) stochastic uncertainty, which arises because the system can behave in many different ways and is thus a property of the system itself, and (2) subjective uncertainty, which arises from a lack of knowledge about quantities that are believed to have (or, at least, are assumed to have) fixed values and is thus a property of the analysts carrying out the study. The 1996 PA for the Waste Isolation Pilot Plant (WIPP) carried out at Sandia National Laboratories (SNL) will be used to illustrate the treatment of these two types of uncertainty in a real analysis. In particular, this PA supported a compliance certification application (CCA) by the US Department of Energy (DOE) to the US Environmental Protection Agency (EPA) for the certification of the WIPP for the geologic disposal of transuranic waste. Insights on the conceptual and computational structure of PAs for complex systems gained from these and other analyses are being incorporated into a new software system under development at SNL to facilitate the performance of analyses that maintain a separation between stochastic and subjective uncertainty.

Cost or performance targets for new bit technologies can be established with the aid of a drilling cost model. In this paper the authors make simplifying assumptions in a detailed drilling cost model that reduce the comparison of two technologies to a linear function of relative cost and performance parameters. This simple model, or analysis tool, is not intended to provide absolute well cost but is intended to compare the relative costs of different methods or technologies to accomplish the same drilling task. Comparing the simplified model to the detailed well cost model shows that the simple linear cost model provides a very efficient tool for screening certain new drilling methods, techniques, and technologies based on economic value. This tool can be used to divide the space defined by the set of parameters: bit cost, bit life, rate of penetration, and operational cost into two areas with a linear boundary. The set of all the operating points in one area will result in an economic advantage in drilling the well with the new technology, while any set of operating points in the other area indicates that any economic advantage is either questionable or does not exist. In addition, examining the model results can develop insights into the economics associated with bit performance, life, and cost. This paper includes development of the model, examples of employing the model to develop should cost or should perform goals for new bit technologies, a discussion of the economic insights in terms of bit cost and performance, and an illustration of the consequences when the basic assumptions are violated.

This report documents the history of the major buildings in Sandia National Laboratories` Technical Area II. It was prepared in support of the Department of Energy`s compliance with Section 106 of the National Historic Preservation Act. Technical Area II was designed and constructed in 1948 specifically for the final assembly of the non-nuclear components of nuclear weapons, and was the primary site conducting such assembly until 1952. Both the architecture and location of the oldest buildings in the area reflect their original purpose. Assembly activities continued in Area II from 1952 to 1957, but the major responsibility for this work shifted to other sites in the Atomic Energy Commission`s integrated contractor complex. Gradually, additional buildings were constructed and the original buildings were modified. After 1960, the Area`s primary purpose was the research and testing of high-explosive components for nuclear weapons. In 1994, Sandia constructed new facilities for work on high-explosive components outside of the original Area II diamond-shaped parcel. Most of the buildings in the area are vacant and Sandia has no plans to use them. They are proposed for decontamination and demolition as funding becomes available.

This work develops some practical approximations needed to simulate a high plasma density volume bounded by walls made of dielectrics or metals which may be either biased or floating in potential. Solving Poisson`s equation in both the high-density bulk and the sheath region poses a difficult computational problem due to the large electron plasma frequency. A common approximation is to assume the electric field is computed in the ambipolar approximation in the bulk and to couple this to a sheath model at the boundaries. Unfortunately, this treatment is not appropriate when some surfaces are biased with respect to others and a net current is present within the plasma. This report develops some ideas on the application of quasi-static external electric fields to plasmas and the self-consistent treatment of boundary conditions at the surfaces. These constitute a generalization of Ohm`s law for a plasma body that entails solving for the internal fields within the plasma and the potential drop and currents through the sheaths surrounding the plasma.

The Photovoltaic Manufacturing Technology (PVMaT) project is a partnership between the US government (through the US Department of Energy [DOE]) and the PV industry. Part of its purpose is to conduct manufacturing technology research and development to address the issues and opportunities identified by industry to advance photovoltaic (PV) systems and components. The project was initiated in 1990 and has been conducted in several phases to support the evolution of PV industrial manufacturing technology. Early phases of the project stressed PV module manufacturing. Starting with Phase 4A and continuing in Phase 5A, the goals were broadened to include improvement of component efficiency, energy storage and manufacturing and system or component integration to bring together all elements for a PV product. This paper summarizes PV manufacturers` accomplishments in components, system integration, and alternative manufacturing methods. Their approaches have resulted in improved hardware and PV system performance, better system compatibility, and new system capabilities. Results include new products such as Underwriters Laboratories (UL)-listed AC PV modules, modular inverters, and advanced inverter designs that use readily available and standard components. Work planned in Phase 5A1 includes integrated residential and commercial roof-top systems, PV systems with energy storage, and 300-Wac to 4-kWac inverters.

The Photovoltaic Systems Assistance Center (PVSAC) of Sandia National Laboratories (SNL) has been supporting the development and implementation of off-grid PV hybrid power systems for many years. Technical support has included: refining hardware; understanding system design techniques; obtaining operation and maintenance data; studying use of energy produced. As part of the program, the PVSAC has provided technical expertise on hybrid systems to many federal agencies including the National Park Service, the Forest Service, the Bureau of Land Management, and the Department of Defense. The goal of these partnerships has been to ensure that reliable and safe PV hybrid systems are specified and procured. At present, a critical review of performance and costs of several representative PV hybrid systems is underway. This paper presents a summary of the performance and economical analyses conducted on three PV hybrid systems.

In the Phase 2 project, Abacus Controls Inc. did research and development of hybrid systems that combine the energy sources from photovoltaics, batteries, and diesel-generators and demonstrated that they are economically feasible for small power plants in many parts of the world. The Trimode Power Processor reduces the fuel consumption of the diesel-generator to its minimum by presenting itself as the perfect electrical load to the generator. A 30-kW three-phase unit was tested at Sandia National Laboratories to prove its worthiness in actual field conditions. The use of photovoltaics at remote locations where reliability of supply requires a diesel-generator will lower costs to operate by reducing the run time of the diesel generator. The numerous benefits include longer times between maintenance for the diesel engine and better power quality from the generator. 32 figs.

This report summarizes the results of a study to develop and evaluate low temperature glass sealing technologies for photovoltaic applications. This work was done as part of Cooperative Research and Development Agreement (CRADA) No. SC95/01408. The sealing technologies evaluated included low melting temperature glass frits and solders. Because the glass frit joining required a material with a melting temperature that exceeded the allowable temperature for the active elements on the photovoltaic panels a localized heating scheme was required for sealing the perimeter of the glass panels. Thermal and stress modeling were conducted to identify the feasibility of this approach and to test strategies designed to minimize heating of the glass panel away from its perimeter. Hardware to locally heat the glass panels during glass frit joining was designed, fabricated, and successfully tested. The same hardware could be used to seal the glass panels using the low temperature solders. Solder adhesion to the glass required metal coating of the glass. The adhesion strength of the solder was dependent on the surface finish of the glass. Strategies for improving the polyisobutylene (PIB) adhesive currently being used to seal the panels and the use of Parylene coatings as a protective sealant deposited on the photovoltaic elements were also investigated. Starting points for further work are included.

This study was initiated when a new type of breakdown occurred in a high voltage experimental test assembly. An anomalous current pulse was observed, which indicated partial discharges, some leading to total breakdowns. High voltage insulator defects are shown along with their effect on the electrostatic fields in the breakdown region. OPERA electromagnetic field modeling software is used to calculate the fields and present a cause for the discharge. Several design modifications are investigated and one of the simplest resulted in a 25% decrease in the field at the discharge surface.

This paper proposes a definition for a Non-Islanding Inverter. This paper also presents methods that can be used to implement such an inverter, along with references to prior work on the subject. Justification for the definition is provided on both a theoretical basis and results from tests conducted at Sandia National Laboratories and Ascension Technology, Inc.

A suite of Probabilistic Risk Assessment Compatible Fire Models (RACFMs) has been developed to represent the hazard posed by a pool fire to weapon systems transported on the B52-H aircraft. These models represent both stand-off (i.e., the weapon system is outside of the flame zone but exposed to the radiant heat load from fire) and fully-engulfing scenarios (i.e., the object is fully covered by flames). The approach taken in developing the RACFMs for both scenarios was to consolidate, reconcile, and apply data and knowledge from all available resources including: data and correlations from the literature, data from an extensive full-scale fire test program at the Naval Air Warfare Center (NAWC) at China Lake, and results from a fire field model (VULCAN). In the past, a single, effective temperature, T{sub f}, was used to represent the fire. The heat flux to an object exposed to a fire was estimated using the relationship for black body radiation, {sigma}T{sub f}{sup 4}. Significant improvements have been made by employing the present approach which accounts for the presence of temperature distributions in fully-engulfing fires, and uses best available correlations to estimate heat fluxes in stand-off scenarios.

The Regulations and Training Projects are part of the US-Russian Federation Materials Protection, Control, and Accounting (MPC&A) cooperative program to protect Russian Navy Fuels. This paper describes the general status of the projects, progress achieved to date, and long-term plans for further work in producing regulatory documents and training to support this ewffort. The regulatory development will result in a document set that will include general requirements and rules for the Russian Navy MPC&A as well as specific instructions for operation and maintenance of each facility. The goals of the training program are to instill in managers a culture of sustainable commitment to MPC&A through the understanding of its principles and philosophies. In addition, the training program will help ensure that upgrades are effectively utilized and maintained by training operators and maintenance personnel in MPC&A principles as well in as the detailed operations of the systems.

This paper describes the Active-Bridge Oscillator (ABO), a new concept in high-stability oscillator design. The ABO is ab ridge-type oscillator design that is easly to design and overcomes many of the operational and design difficulties associated with standard bridge oscillator designs. The ABO will oscillate with a very stable output amplitude over a wide range of operating conditions without the use of an automatic-level-control (ALC). A standard bridge oscillator design requires an ALC to maintain the desired amplitude of oscillation. for this and other reasons, bridge oscilaltors are not used in mainstream designs. Bridge oscillators are generally relegated to relatively low-volume, high-performance applications. The Colpitts and Pierce designs are the most popular oscillators but are typically less stable than a bridge-type oscillator.

Smoke from plastics can cause immediate problems in electrical equipment in the form of shorting and increased leakage currents, as well as long-term corrosion (metal loss). The short-term problems can be especially serious for critical control instrumentation such as that found in nuclear reactors or telecommunications systems. The US Nuclear Regulatory Commission and Sandia National Laboratories are sponsoring a program to determine the modes and probabilities of digital equipment failure during exposure to smoke and up to 24 hours after the exposure. Early tests on computer systems have shown that the most common immediate problems are temporary and are likely to be caused by increased leakage currents. High-voltage circuits are especially vulnerable since the charged particles in smoke are drawn to those surfaces. To study failure probabilities, smoke exposure tests with real-time measurements will be carried out to determine how the electrical properties of the environment are affected by smoke concentration and content. Digital communication cable will be included in the tests because temporary shorts that cannot be detected through dc measurements may cause interruptions in communications between computers. The reaction of the equipment to changed electrical properties of the environment will be modeled. Equipment that can be used for testing and modeling is being solicited.

The sequential manner in which materials and processes for a manufactured product are selected is inherently less than optimal. Designers` tendency to choose processes and materials with which they are familiar exacerbate this problem. A method for concurrent selection of materials and a joining process based on product requirements using a knowledge-based, constraint satisfaction approach is presented.