Publications

Under the sponsorship of the Department of Energy, Office of Utility Technologies, the Energy Storage System Analysis and Development Department at Sandia National Laboratories (SNL) conducted a cost analysis of energy storage systems for electric utility applications. The scope of the study included the analysis of costs for existing and planned battery, SMES, and flywheel energy storage systems. The analysis also identified the potential for cost reduction of key components.

A robot`s configuration space (c-space) is the space of its kinematic degrees of freedom, e.g., the joint-space of an arm. Sets in c-space can be defined that characterize a variety of spatial relationships, such as contact between the robot and its environment. C-space techniques have been fundamental to research progress in areas such as motion planning and physically-based reasoning. However, practical progress has been slowed by the difficulty of implementing the c-space abstraction inside each application. For this reason, we proposed a Configuration Space Toolkit of high-performance algorithms and data structures meeting these needs. Our intent was to develop this robotics software to provide enabling technology to emerging applications that apply the c-space abstraction, such as advanced motion planning, teleoperation supervision, mechanism functional analysis, and design tools. This final report presents the research results and technical achievements of this LDRD project. Key results and achievements included (1) a hybrid Common LISP/C prototype that implements the basic C-Space abstraction, (2) a new, generic, algorithm for constructing hierarchical geometric representations, and (3) a C++ implementation of an algorithm for fast distance computation, interference detection, and c-space point-classification. Since the project conclusion, motion planning researchers in Sandia`s Intelligent Systems and Robotics Center have been using the CSTk libcstk.so C++ library. The code continues to be used, supported, and improved by projects in the ISRC.

Under the sponsorship of the Department of Energy, Office of Utility Technologies, the Energy Storage System Analysis and Development Department at Sandia National Laboratories (SNL) conducted a cost analysis of energy storage systems for electric utility applications. The scope of the study included the analysis of costs for existing and planned battery, SMES, and flywheel energy storage systems. The analysis also identified the potential for cost reduction of key components.

Sandia`s Superconductivity Technology Program is a thallium-based high-temperature superconductor (HTS) research and development program consisting of efforts in powder synthesis and process development, open-system thick film conductor development, wire and tape fabrication, and HTS motor design. The objective of this work is to develop high-temperature superconducting conductors (wire and tape) capable of meeting requirements for high-power electrical devices of interest to industry. The research efforts currently underway are: (1) Process development and characterization of thallium-based high-temperature superconducting closed system wire and tape, (2) Investigation of the synthesis and processing of thallium-based thick films using two-zone processing, and (3) Cryogenic design of a 30K superconducting motor. This report outlines the research that has been performed during FY96 in each of these areas.

A pulsed rf plasma technique is capable of generating ceramic particles of 10 manometer dimension. Experiments using silane/ammonia and trimethylchlorosilane/hydrogen gas mixtures show that both silicon nitride and silicon carbide powders can be synthesized with control of the average particle diameter from 7 to 200 nm. Large size dispersion and much agglomeration appear characteristic of the method, in contrast to results reported by another research group. The as produced powders have a high hydrogen content and are air and moisture sensitive. Post-plasma treatment in a controlled atmosphere at elevated temperature (800{degrees}C) eliminates the hydrogen and stabilizes the powder with respect to oxidation or hydrolysis.

The Waste Isolation Pilot Plant (WIPP), a facility located in a bedded salt formation in Carlsbad, New Mexico, is being used by the U.S. Department of Energy to demonstrate the technology for safe handling and disposal of transuranic wastes produced by defense activities in the United States. In support of that demonstration, mechanical tests on salt were conducted in the laboratory to characterize material behavior at the stresses and temperatures expected for a nuclear waste repository. Many of those laboratory test programs have been carried out in the RE/SPEC Inc. rock mechanics laboratory in Rapid City, South Dakota; the first program being authorized in 1975 followed by additional testing programs that continue to the present. All of the WIPP laboratory data generated on salt at RE/SPEC Inc. over the last 20 years is presented in this data report. A variety of test procedures were used in performance of the work including quasi-static triaxial compression tests, constant stress (creep) tests, damage recovery tests, and multiaxial creep tests. The detailed data is presented in individual plots for each specimen tested. Typically, the controlled test conditions applied to each specimen are presented in a plot followed by additional plots of the measured specimen response. Extensive tables are included to summarize the tests that were performed. Both the tables and the plots contain cross-references to the technical reports where the data were originally reported. Also included are general descriptions of laboratory facilities, equipment, and procedures used to perform the work.

A nonnalized X-ray induced gain coefficient, 1.48 x 10{sup -3} cm{sup -1}/krad, has been determined for Cr,Nd:GSGG. Hermes III, a 20 ns, 2 MeV X-ray source, is used to irradiate the sample. Doping levels of 1 x 10{sup 20} and 2 x 10{sup 20} /cm{sup 3} respectively, for Cr and Nd are used. A proposed heuristic model in which excited Gd transfers its excitation to Cr which then transfers its excitation to Nd is described.

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.

Modular fixturing kits are sets of components used for flexible, rapid construction of fixtures. A modular vise is a parallel-jaw vise, each jaw of which is a modular fixture plate with a regular grid of precisely positioned holes. To fixture a part, one places pins in some of the holes so that when the vise is closed, the part is reliably located and completely constrained. The modular vise concept can be adapted easily to the design of modular parallel-jaw grippers for robots. By attaching a grid-plate to each jaw of a parallel-jaw gripper, one gains the ability to easily construct high-quality grasps for a wide variety of parts from a standard set of hardware. Wallack and Canny developed an algorithm for planning planar grasp configurations for the modular vise. In this paper, the authors expand this work to produce a 3-d fixture/gripper design tool. They describe several analyses they have added to the planar algorithm, including a 3-d grasp quality metric based on force information, 3-d geometric loading analysis, and inter-gripper interference analysis. Finally, the authors describe two applications of their code. One of these is an internal application at Sandia, while the other shows a potential use of the code for designing part of an agile assembly line.

With a goal of producing faster, safer, and cheaper technologies for nuclear waste cleanup, Sandia is actively developing and extending intelligent systems technologies. Graphical Programming is a key technology for robotic waste cleanup that Sandia is developing for this goal. This paper describes Sancho, Sandia most advanced Graphical Programming supervisory software. Sancho, now operational on several robot systems, incorporates all of Sandia`s recent advances in supervisory control. Sancho, developed to rapidly apply Graphical Programming on a diverse set of robot systems, uses a general set of tools to implement task and operational behavior. Sancho can be rapidly reconfigured for new tasks and operations without modifying the supervisory code. Other innovations include task-based interfaces, event-based sequencing, and sophisticated GUI design. These innovations have resulted in robot control programs and approaches that are easier and safer to use than teleoperation, off-line programming, or full automation.

In an effort to develop cost-efficient techniques for remediating uranium contaminated groundwater at DOE Uranium Mill Tailing Remedial Action (UMTRA) sites nationwide, Sandia National Laboratories (SNL) deployed a pilot scale research project at an UMTRA site in Durango, CO. Implementation included design, construction, and subsequent monitoring of an in situ passive reactive barrier to remove Uranium from the tailings pile effluent. A reactive subsurface barrier is produced by emplacing a reactant material (in this experiment various forms of metallic iron) in the flow path of the contaminated groundwater. Conceptually the iron media reduces and/or adsorbs uranium in situ to acceptable regulatory levels. In addition, other metals such as Se, Mo, and As have been removed by the reductive/adsorptive process. The primary objective of the experiment was to eliminate the need for surface treatment of tailing pile effluent. Experimental design, and laboratory and field results are discussed with regard to other potential contaminated groundwater treatment applications.

An overview of the operations of Sandia`s Microelectronics Development Lab (MDL) is to develop radiation hardened IC, but techniques used for IC processing have been applied to a variety of related technologies such as micromechanics, smart sensors, and packaging.

A new diode laser using a Tapered-Rib Adiabatic-Following Fiber Coupler to achieve 2D mode expansion and narrow, symmetric far-field emission without epitaxial regrowth or sharply-defined tips on tapered waveguides is presented.

This report presents the results of a development effort to design, test and begin production of a new class of small photovoltaic (PV) charge controllers. Sandia National Laboratories provided technical support, test data and financial support through a Balance-of-System Development contract. One of the objectives of the development was to increase user confidence in small PV systems by improving the reliability and operating life of the system controllers. Another equally important objective was to improve the economics of small PV systems by extending the battery lifetimes. Using new technology and advanced manufacturing techniques, these objectives were accomplished. Because small stand-alone PV systems account for over one third of all PV modules shipped, the positive impact of improving the reliability and economics of PV systems in this market segment will be felt throughout the industry. The results of verification testing of the new product are also included in this report. The initial design goals and specifications were very aggressive, but the extensive testing demonstrates that all the goals were achieved. Production of the product started in May at a rate of 2,000 units per month. Over 40 Morningstar distributors (5 US and 35 overseas) have taken delivery in the first 2 months of shipments. Initial customer reactions to the new controller have been very favorable.

Three characteristic regimes were identified during wet thermal oxidation of AlxGa(1-x)As (x=1 to 0.90) on GaAs: oxidation of Al and Ga in the alloy to form to an amorphous oxide layer, formation and elimination of elemental As and of amorphous As2O3, and crystallization of the oxide film. Residual As can produce up to a 100fold increase in leakage current and a 30% increase in bulk dielectric constant. Very low As levels produce partial Fermi-level pinning at the oxidized AlxGa(1-x)As/GaAs interface. Local Schottky- barrier pinning of the Fermi level at As precipitates at the oxide/GaAs interface may be the source of the apparent high interface state density. The presence of thermodynamically favored interfacial As may impose a fundamental limit on the application of AlGaAs wet oxidation for achieving MIS devices without post-oxidation processing to remove the residual As from the interface.

The primary objective of this project was to further develop close-coupled barrier technology for the containment of subsurface waste or contaminant migration. A close-coupled barrier is produced by first installing a conventional cement grout curtain followed by a thin inner lining of a polymer grout. The resultant barrier is a cement polymer composite that has economic benefits derived from the cement and performance benefits from the durable and chemically resistant polymer layer. The technology has matured from a regulatory investigation of issues concerning barriers and barrier materials to a pilot-scale, multiple individual column injections at Sandia National Labs (SNL) to full scale demonstration. The feasibility of this barrier concept was successfully proven in a full scale ``cold site`` demonstration at Hanford, WA. Consequently, a full scale deployment of the technology was conducted at an actual environmental restoration site at Brookhaven National Lab (BNL), Long Island, NY. This paper discusses the installation and performance of a technology deployment implemented at OU-1 an Environmental Restoration Site located at BNL.

The objective of this project is the development of a new class of supramolecular assemblies for applications in biosensors and biodevices. The supramolecular assemblies are based on membranes and Langmuir-Blodgett (LB) films composed of naturally-occurring or synthetic lipids, which contain electrically and/or photochemically active components. The LB films are deposited onto electrically-active materials (metal, semiconductors). The active components film components (lipo-porphyrins) at the surface function as molecular recognition sites for sensing proteins and other biomolecules, and the porphyrins and other components (e.g., fullerenes) incorporated into the films serve as photocatalysts and vectorial electron-transport agents. Computer-aided molecular design (CAMD) methods are used to tailor the structure of these film components to optimize function. Molecular modeling is also used to predict the location, orientation, and motion of these molecular components within the films. The result is a variety of extended, self-assembled molecular structures that serve as devices for sensing proteins and biochemicals or as other bioelectronic devices.

This report summarizes the three-year LDRD program directed at developing catalysts based on metalloporphyrins to reduce carbon dioxide. Ultimately it was envisioned that such catalysts could be made part of a solar-driven photoredox cycle by coupling metalloporphyrins with semiconductor systems. Such a system would provide the energy required for CO{sub 2} reduction to methanol, which is an uphill 6-electron reduction. Molecular modeling and design capabilities were used to engineer metalloporphyrin catalysts for converting CO{sub 2} to CO and higher carbon reduction products like formaldehyde, formate, and methanol. Gas-diffusion electrochemical cells were developed to carry out these reactions. A tin-porphyrin/alumina photocatalyst system was partially developed to couple solar energy to this reduction process.

Plasma discharges involving mixtures of chlorine and boron trichloride are widely used to etch metals in the production of very-large-scale-integrated circuits. Energetic ions play a critical role in this process, influencing the etch rates, etch profiles, and selectivity to different materials. The authors are using a gridded energy analyzer to measure positive ion energy distributions and fluxes at the grounded electrode of high-density inductively-coupled rf discharges. In this paper, they present details of ion energies and fluxes in discharges containing mixtures of chlorine and boron trichloride.

Implementation of optical imagery in a diffuse inhomogeneous medium such as biological tissue requires an understanding of photon migration and multiple scattering processes which act to randomize pathlength and degrade image quality. The nature of transmitted light from soft tissue ranges from the quasi-coherent properties of the minimally scattered component to the random incoherent light of the diffuse component. Recent experimental approaches have emphasized dynamic path-sensitive imaging measurements with either ultrashort laser pulses (ballistic photons) or amplitude modulated laser light launched into tissue (photon density waves) to increase image resolution and transmissive penetration depth. Ballistic imaging seeks to compensate for these {open_quotes}fog-like{close_quotes} effects by temporally isolating the weak early-arriving image-bearing component from the diffusely scattered background using a subpicosecond optical gate superimposed on the transmitted photon time-of-flight distribution. The authors have developed a broadly wavelength tunable (470 nm -2.4 {mu}m), ultrashort amplifying optical gate for transillumination spectral imaging based on optical parametric amplification in a nonlinear crystal. The time-gated image amplification process exhibits low noise and high sensitivity, with gains greater than 104 achievable for low light levels. We report preliminary benchmark experiments in which this system was used to reconstruct, spectrally upcovert, and enhance near-infrared two-dimensional images with feature sizes of 65 {mu}m/mm{sup 2} in background optical attenuations exceeding 10{sup 12}. Phase images of test objects exhibiting both absorptive contrast and diffuse scatter were acquired using a self-referencing Shack-Hartmann wavefront sensor in combination with short-pulse quasi-ballistic gating. The sensor employed a lenslet array based on binary optics technology and was sensitive to optical path distortions approaching {lambda}/100.

A physical model is developed to quantify the contribution of oxide-trapped charge to enhanced low-dose-rate gain degradation in BJTs. Simulations show that space charge limited transport is partially responsible for the low-dose-rate enhancement.

An experimental program was performed that examined the physical and mechanical properties of several candidate, lead (Pb)-free solder alloys. The project was separated into three tasks designated as follows: (1) Alloy Development, (2) Intermetallic Compound (IMC) Growth, and (3) Mechanical Testing. Task 1, Alloy Development, examined the impact that small Pb additions had on the physical and mechanical properties of several Pb-free solders. Task 2, Intermetallic Compound (IMC) Growth investigated the development of the IMC layer between several Pb-free solder alloys and Cu. Quantitative analyses established the kinetics of layer growth in the solid state as a result of elevated temperature aging treatments, and as a function of the composition of the solder. Liquid state IMC layer growth as well as dissolution rates of Cu substrates by molten solders were quantitatively documented. Task 3, Mechanical Properties, performed a series of experiments that provided fracture toughness measurement, thermomechanical fatigue evaluations, and creep deformation data on a number of the Pb-free solders as well as on Pb-free alloys that had been contaminated with controlled quantities of Pb additions. The data obtained from these tests results relative performance information as well as valuable input data for computer models. Several ancillary tests were also performed to support partner company efforts.

Experimental work conducted by D. B. Adolf has shown that a separable K-BKZ constitutive equation works reasonable well in predicting the stress relaxation observed in single step strain experiments for carbon black filled rubber. However, the memory requirements and numerical efficiency of the K-BKZ equation do not make it well suited for use in a production, three-dimensional finite element code. As an alternative, D. J. Segalman, K. Zuo, and D. Parsons have developed a "damage-like" constitutive equation which is computationally attractive. This formalism has been installed in the JAS3D finite element code. The requisite code inputs and numerical details of the constitutive integration are discussed, and solutions to selected problems are presented. Comparisons are made to data collected from both single and double step strain experiments.

DIAMOND FORTUNE was a nuclear explosion detonated inside an 11 m hemispherical cavity in tuff at the Nevada Test Site. Previous cavity explosions such as STERLING and MILL YARD have shown a substantial decrease in the expected ground motion. These types of cavity tests present a serious problem for a Comprehensive Test Ban (CTB). Not only is detection a problem, but presently there is no seismic method to discriminate between a tamped and cavity explosion. DIAMOND FORTUNE allowed us to examine several aspects of a cavity explosion in the context of a CTB. On this test, there were two groups of accelerometers fielded. One group was located in the free-field at sites above and below the cavity within 30 m of the source. The second group consisted of a line of gauges placed in the invert of P-tunnel extending from 44 m to 224 m from the source. The purpose of this arrangement was to measure ground motion in an effort to detect a non-symmetric radiation pattern due to the hemisphere, examine the high frequency propagation of the free-field signals as a possible discriminate, and calculate the decoupling factor. The radiation pattern experiment was conducted in an effort to determine if the asymmetry of a hemispherical cavity could provide a preferred direction of transmission. The analysis indicated a definite radiation pattern with larger amplitudes transmitted through the spherical surface than the plane surface. The possibility of using high frequency signals as a discriminant of tamped versus cavity explosions is implied by the MILL YARD data. MILL YARD was also a nuclear explosion in an 11 m hemispherical cavity. The free-field ground motion signals from this test (<25 m) contained very large high frequency amplitudes ([approx]1000 Hz) in their spectra. DIAMOND FORTUNE also exhibited high frequency signals with comer frequencies twice that of the scaled tamped DISTANT ZENITH event.

A large-scale field demonstration comparing and contrasting final landfill cover designs has been constructed and is currently being monitored. Four alternative cover designs and two conventional designs (a RCRA Subtitle ``D`` Soil Cover and a RCRA Subtitle ``C`` Compacted Clay Cover) were constructed of uniform size, side-by-side. The demonstration is intended to evaluate the various cover designs based on their respective water balance performance, ease and reliability of construction, and cost. This paper provides an overview of the construction costs of each cover design.