Publications

Laser beam welding is the principal welding process for the joining of Sandia weapon components because it can provide a small fusion zone with low overall heating. Improved process robustness is desired since laser energy absorption is extremely sensitive to joint variation and filler metal is seldom added. This project investigated the experimental and theoretical advantages of combining a fiber optic delivered Nd:YAG laser with a miniaturized GMAW system. Consistent gas metal arc droplet transfer employing a 0.25 mm diameter wire was only obtained at high currents in the spray transfer mode. Excessive heating of the workpiece in this mode was considered an impractical result for most Sandia micro-welding applications. Several additional droplet detachment approaches were investigated and analyzed including pulsed tungsten arc transfer(droplet welding), servo accelerated transfer, servo dip transfer, and electromechanically braked transfer. Experimental observations and rigorous analysis of these approaches indicate that decoupling droplet detachment from the arc melting process is warranted and may someday be practical.

Abstract not provided.

Abstract not provided.

The Solar Thermal Program at Sandia supports work developing dish/Stirling systems to convert solar energy into electricity. Heat pipe technology is ideal for transferring the energy of concentrated sunlight from the parabolic dish concentrators to the Stirling engine heat tubes. Heat pipes can absorb the solar energy at non-uniform flux distributions and release this energy to the Stirling engine heater tubes at a very uniform flux distribution thus decoupling the design of the engine heater head from the solar absorber. The most important part of a heat pipe is the wick, which transports the sodium over the heated surface area. Bench scale heat pipes were designed and built to more economically, both in time and money, test different wicks and cleaning procedures. This report covers the building, testing, and post-test analysis of the sixth in a series of bench scale heat pipes. Durability heat pipe No.6 was built and tested to determine the effects of a high temperature bakeout, 950 C, on wick corrosion during long-term operation. Previous tests showed high levels of corrosion with low temperature bakeouts (650-700 C). Durability heat pipe No.5 had a high temperature bakeout and reflux cleaning and showed low levels of wick corrosion after long-term operation. After testing durability heat pipe No.6 for 5,003 hours at an operating temperature of 750 C, it showed low levels of wick corrosion. This test shows a high temperature bakeout alone will significantly reduce wick corrosion without the need for costly and time consuming reflux cleaning.

Abstract not provided.

This report presents the major findings of the Montana State University Composite Materials Fatigue Program from 1997 to 2001, and is intended to be used in conjunction with the DOE/MSU Composite Materials Fatigue Database. Additions of greatest interest to the database in this time period include environmental and time under load effects for various resin systems; large tow carbon fiber laminates and glass/carbon hybrids; new reinforcement architectures varying from large strands to prepreg with well-dispersed fibers; spectrum loading and cumulative damage laws; giga-cycle testing of strands; tough resins for improved structural integrity; static and fatigue data for interply delamination; and design knockdown factors due to flaws and structural details as well as time under load and environmental conditions. The origins of a transition to increased tensile fatigue sensitivity with increasing fiber content are explored in detail for typical stranded reinforcing fabrics. The second focus of the report is on structural details which are prone to delamination failure, including ply terminations, skin-stiffener intersections, and sandwich panel terminations. Finite element based methodologies for predicting delamination initiation and growth in structural details are developed and validated, and simplified design recommendations are presented.

This report describes research and development of the large eddy simulation (LES) turbulence modeling approach conducted as part of Sandia's laboratory directed research and development (LDRD) program. The emphasis of the work described here has been toward developing the capability to perform accurate and computationally affordable LES calculations of engineering problems using unstructured-grid codes, in wall-bounded geometries and for problems with coupled physics. Specific contributions documented here include (1) the implementation and testing of LES models in Sandia codes, including tests of a new conserved scalar--laminar flamelet SGS combustion model that does not assume statistical independence between the mixture fraction and the scalar dissipation rate, (2) the development and testing of statistical analysis and visualization utility software developed for Exodus II unstructured grid LES, and (3) the development and testing of a novel new LES near-wall subgrid model based on the one-dimensional Turbulence (ODT) model.

This report summarizes progress from the Laboratory Directed Research and Development (LDRD) program during fiscal year 2001. In addition to a programmatic and financial overview, the report includes progress reports from 295 individual R and D projects in 14 categories.

To identify connections between technology needs for countering terrorism and underlying science issues and to recommend investment strategies to increase the impact of basic research on efforts to counter terrorism.

Sensitivity/uncertainty analyses are necessary to determine where to allocate resources for improved predictions in support of our nation's nuclear safety mission. Yet, sensitivity/uncertainty analyses are not commonly performed on complex combustion models because the calculations are time consuming, CPU intensive, nontrivial exercises that can lead to deceptive results. To illustrate these ideas, a variety of sensitivity/uncertainty analyses were used to determine the uncertainty associated with thermal decomposition of polyurethane foam exposed to high radiative flux boundary conditions. The polyurethane used in this study is a rigid closed-cell foam used as an encapsulant. The response variable was chosen as the steady-state decomposition front velocity. Four different analyses are presented, including (1) an analytical mean value (MV) analysis, (2) a linear surrogate response surface (LIN) using a constrained latin hypercube sampling (LHS) technique, (3) a quadratic surrogate response surface (QUAD) using LHS, and (4) a direct LHS (DLHS) analysis using the full grid and time step resolved finite element model. To minimize the numerical noise, 50 μm elements and approximately 1 ms time steps were required to obtain stable uncertainty results. The complex, finite element foam decomposition model used in this study has 25 input parameters that include chemistry, polymer structure, and thermophysical properties. The surrogate response models (LIN and QUAD) are shown to give acceptable values of the mean and standard deviation when compared to the fully converged DLHS model. © 2002 Elsevier Science B.V. All rights reserved.

We have used a nonionic inverse micelle synthesis technique to form nanoclusters of platinum and palladium. These nanoclusters can be rendered hydrophobic or hydrophilic by the appropriate choice of capping ligand. Unlike Au nanoclusters, Pt nanoclusters show great stability with thiol ligands in aqueous media. Alkane thiols, with alkane chains ranging from C6 to C18, were used as hydrophobic ligands, and with some of these we were able to form two-dimensional and/or three-dimensional superlattices of Pt nanoclusters as small as 2.7 nm in diameter. Image processing techniques were developed to reliably extract from transmission electron micrographs (TEMs) the particle size distribution, and information about the superlattice domains and their boundaries. The latter permits us to compute the intradomain vector pair correlation function of the particle centers, from which we can accurately determine the lattice spacing and the coherent domain size. From these data the gap between the particles in the coherent domains can be determined as a function of the thiol chain length. It is found that as the thiol chain length increases, the interparticle gaps increase more slowly than the measured hydrodynamic radius of the functionalized nanoclusters in solution, possibly indicating thiol chain interdigitation in the superlattices.

Abstract not provided.

The oxidation behavior of nickel-matrix/aluminum-particle composite coatings was studied using thermogravimetric (TG) analysis and long-term furnace exposure in air at 1000°C. The coatings were applied by the composite-electrodeposition technique and vacuum heat treated for 3 hr at 825°C prior to oxidation testing. The heat-treated coatings consisted of a two-phase mixture of γ (Ni) + γ′(Ni3Al). During short-term exposure at 1000°C, a thin α-Al2O3 layer developed below a matrix of spinel NiAl2O4, with θ-Al2O3 needles at the outer oxide surface. After 100 hr of oxidation, remnants of θ-Al2O3 are present with spinel at the surface and an inner layer of θ-Al2O3. After 1000-2000 hr, a relatively thick layer of α-Al2O3 is found below a thin, outer spinel layer. Oxidation kinetics are controlled by the slow growth of the inner Al2O3 layer at short-term and intermediate exposures. At long times, an increase in mass gain is found due to oxidation at the coating-substrate interface and enhanced scale formation possibly in areas of reduced Al content. Ternary Si additions to Ni-Al composite coatings were found to have little effect on oxidation performance. Comparison of coatings with bulk Ni-Al alloys showed that low Al γ-alloys exhibit a healing Al2O3 layer after transient Ni-rich oxide growth. Higher Al alloys display Al2O3-controlled kinetics with low mass gain during TG analysis.

Laser safety evaluation and output emission measurements were performed (during October and November 2001) on SNL MILES and Mini MILES laser emitting components. The purpose, to verify that these components, not only meet the Class 1 (eye safe) laser hazard criteria of the CDRH Compliance Guide for Laser Products and 21 CFR 1040 Laser Product Performance Standard; but also meet the more stringent ANSI Std. z136.1-2000 Safe Use of Lasers conditions for Class 1 lasers that govern SNL laser operations. The results of these measurements confirmed that all of the Small Arms Laser Transmitters, as currently set (''as is''), meet the Class 1 criteria. Several of the Mini MILES Small Arms Transmitters did not. These were modified and re-tested and now meet the Class 1 laser hazard criteria. All but one System Controllers (hand held and rifle stock) met class 1 criteria for single trigger pulls and all presented Class 3a laser hazard levels if the trigger is held (continuous emission) for more than 5 seconds on a single point target. All units were Class 3a for ''aided'' viewing. These units were modified and re-tested and now meet the Class 1 hazard criteria for both ''aided'' as well as ''unaided'' viewing. All the Claymore Mine laser emitters tested are laser hazard Class 1 for both ''aided'' as well as ''unaided'' viewing.

The use of biometrics for the identification of individuals is becoming more prevalent in society and in the general government community. As the demand for these devices increases, it becomes necessary for the user community to have the facts needed to determine which device is the most appropriate for any given application. One such application is the use of biometric devices in areas where an individual may not be able to present a biometric feature that requires contact with the identifier (e.g., when dressed in anti-contamination suits or when wearing a respirator). This paper discusses a performance evaluation conducted on the IrisScan2200 from Iridian Technologies to determine if it could be used in such a role.

The theory, numerical algorithm, and user documentation are provided for a new ''Centroidal Voronoi Tessellation (CVT)'' method of filling a region of space (2D or 3D) with particles at any desired particle density. ''Clumping'' is entirely avoided and the boundary is optimally resolved. This particle placement capability is needed for any so-called ''mesh-free'' method in which physical fields are discretized via arbitrary-connectivity discrete points. CVT exploits efficient statistical methods to avoid expensive generation of Voronoi diagrams. Nevertheless, if a CVT particle's Voronoi cell were to be explicitly computed, then it would have a centroid that coincides with the particle itself and a minimized rotational moment. The CVT code provides each particle's volume and centroid, and also the rotational moment matrix needed to approximate a particle by an ellipsoid (instead of a simple sphere). DIATOM region specification is supported.

This report describes the results of a Laboratory-Directed Research and Development project on techniques for pattern discovery in discrete event time series data. In this project, we explored two different aspects of the pattern matching/discovery problem. The first aspect studied was the use of Dynamic Time Warping for pattern matching in continuous data. In essence, DTW is a technique for aligning time series along the time axis to optimize the similarity measure. The second aspect studied was techniques for discovering patterns in discrete event data. We developed a pattern discovery tool based on adaptations of the A-priori and GSP (Generalized Sequential Pattern mining) algorithms. We then used the tool on three different application areas--unattended monitoring system data from a storage magazine, computer network intrusion detection, and analysis of robot training data.

The requirements in modeling and simulation are driven by two fundamental changes in the nuclear weapons landscape: (1) The Comprehensive Test Ban Treaty and (2) The Stockpile Life Extension Program which extends weapon lifetimes well beyond their originally anticipated field lifetimes. The move from confidence based on nuclear testing to confidence based on predictive simulation forces a profound change in the performance asked of codes. The scope of this document is to improve the confidence in the computational results by demonstration and documentation of the predictive capability of electrical circuit codes and the underlying conceptual, mathematical and numerical models as applied to a specific stockpile driver. This document describes the High Performance Electrical Modeling and Simulation software normal environment Verification and Validation Plan.

FAILPROB is a computer program that applies the Weibull statistics characteristic of brittle failure of a material along with the stress field resulting from a finite element analysis to determine the probability of failure of a component. FAILPROB uses the statistical techniques for fast fracture prediction (but not the coding) from the N.A.S.A. - CARES/life ceramic reliability package. FAILPROB provides the analyst at Sandia with a more convenient tool than CARES/life because it is designed to behave in the tradition of structural analysis post-processing software such as ALGEBRA, in which the standard finite element database format EXODUS II is both read and written. This maintains compatibility with the entire SEACAS suite of post-processing software. A new technique to deal with the high local stresses computed for structures with singularities such as glass-to-metal seals and ceramic-to-metal braze joints is proposed and implemented. This technique provides failure probability computation that is insensitive to the finite element mesh employed in the underlying stress analysis. Included in this report are a brief discussion of the computational algorithms employed, user instructions, and example problems that both demonstrate the operation of FAILPROB and provide a starting point for verification and validation.

This report documents the strategies for verification and validation of the codes LSP and ICARUS used for simulating the operation of the neutron tubes used in all modern nuclear weapons. The codes will be used to assist in the design of next generation neutron generators and help resolve manufacturing issues for current and future production of neutron devices. Customers for the software are identified, tube phenomena are identified and ranked, software quality strategies are given, and the validation plan is set forth.

Abstract not provided.

The theory and algorithm for the Material Point Method (MPM) are documented, with a detailed discussion on the treatments of boundary conditions and shock wave problems. A step-by-step solution scheme is written based on direct inspection of the two-dimensional MPM code currently used at the University of Missouri-Columbia (which is, in turn, a legacy of the University of New Mexico code). To test the completeness of the solution scheme and to demonstrate certain features of the MPM, a one-dimensional MPM code is programmed to solve one-dimensional wave and impact problems, with both linear elasticity and elastoplasticity models. The advantages and disadvantages of the MPM are investigated as compared with competing mesh-free methods. Based on the current work, future research directions are discussed to better simulate complex physical problems such as impact/contact, localization, crack propagation, penetration, perforation, fragmentation, and interactions among different material phases. In particular, the potential use of a boundary layer to enforce the traction boundary conditions is discussed within the framework of the MPM.

Nuclear energy has been proposed as a heat source for producing hydrogen from water using a sulfur-iodine thermochemical cycle. This document presents an assessment of the suitability of various reactor types for this application. The basic requirement for the reactor is the delivery of 900 C heat to a process interface heat exchanger. Ideally, the reactor heat source should not in itself present any significant design, safety, operational, or economic issues. This study found that Pressurized and Boiling Water Reactors, Organic-Cooled Reactors, and Gas-Core Reactors were unsuitable for the intended application. Although Alkali Metal-Cooled and Liquid-Core Reactors are possible candidates, they present significant development risks for the required conditions. Heavy Metal-Cooled Reactors and Molten Salt-Cooled Reactors have the potential to meet requirements, however, the cost and time required for their development may be appreciable. Gas-Cooled Reactors (GCRs) have been successfully operated in the required 900 C coolant temperature range, and do not present any obvious design, safety, operational, or economic issues. Altogether, the GCRs approach appears to be very well suited as a heat source for the intended application, and no major development work is identified. This study recommends using the Gas-Cooled Reactor as the baseline reactor concept for a sulfur-iodine cycle for hydrogen generation.

The blast parameters for the 6-foot diameter by 200-foot long, explosively driven shock tube are presented in this report. The purpose, main characteristics, and blast simulation capabilities of this PETN Primacord, explosively driven facility are included. Experimental data are presented for air and Sulfurhexaflouride (SF6) test gases with initial pressures between 0.5 to 12.1 psia (ambient). Experimental data are presented and include shock wave time of amval at various test stations, flow duration, static or side-on overpressure, and stagnation or head-on overpressure. The blast parameters calculated from the above measured parameters and presented in this report include shock wave velocity, shock strength, shock Mach number, flow Mach Number, reflected pressure, dynamic pressure, particle velocity, density, and temperature. Graphical data for the above parameters are included. Algorithms and least squares fit equations are also included.

The assembly and packaging of MEMS (Microelectromechanical Systems) devices raise a number of issues over and above those normally associated with the assembly of standard microelectronic circuits. MEMS components include a variety of sensors, microengines, optical components, and other devices. They often have exposed mechanical structures which during assembly require particulate control, free space in the package, non-contact handling procedures, low-stress die attach, precision die placement, unique process schedules, hermetic sealing in controlled environments (including vacuum), and other special constraints. These constraints force changes in the techniques used to separate die on a wafer, in the types of packages which can be used, in the assembly processes and materials, and in the sealing environment and process. This paper discusses a number of these issues and provides information on approaches being taken or proposed to address them.