Publications

Electrical characteristics of hybrid power sources consisting of Li-ion cells and double-layer capacitors were studied at 25 C and {minus}20 C. The cells were initially evaluated for pulse performance and then measured in hybrid modes of operation where they were coupled with the high-power capacitors. Cells manufactured by Panasonic measured at 25 C delivered full capacities of 0.76 Ah for pulses up to 3A and cells from A and T delivered full capacities of 0.73 Ah for pulses up to 4A. Measured cell resistances were 0.15 ohms and 0.12 ohms, respectively. These measurements were repeated at {minus}20 C. Direct coupling of the cells and capacitors (coupled hybrid) using 10F Panasonic capacitors in a 8F series/parallel combination extended the full capacity pulse limits (3.0V threshold) to 5.6A for the Panasonic cells and to 9A for the A and T cells. A similar arrangement using 100F capacitors from Elna in a 60F combination increased the Panasonic cell limit to 10 A. Operation in an uncoupled hybrid mode using uncoupled cell/capacitor discharge allowed fill cell capacity usage at 25 C up to the capacitor discharge limit and showed a factor of 5 improvement in delivered capacity at {minus}20 C.

Differential scanning calorimetry (DSC) analysis was used to identify thermal reactions in Sony-type lithium-ion cells and to correlate these reactions with interactions of cell constituents and reaction products. An electrochemical half-cell was used to cycle the anode and cathode materials and to set the state-of-charge (SOC). Three temperature regions of interaction were identified and associated with the SOC (degree of Li intercalation) of the cell. Anodes were shown to undergo exothermic reactions as low as 80 C involving decomposition of the solid electrolyte interphase (SEI) layer. The LiPF{sub 6} salt in the electrolyte (EC:PC:DEC/1M LiPF{sub 6}) was seen to play an essential role in this reaction. DSC analysis of the anodes from disassembled Sony cells showed similar behavior to the half-cell anodes with a strong exotherm beginning in the 80 C--90 C range. Exothermic reactions were also observed in the 200 C--300 C region between the intercalated lithium anodes, the LiPF{sub 6} salt, and the PVDF binder. These reactions were followed by a high-temperature reaction region, 300 C--400 C, also involving the PVDF binder and the intercalated lithium anodes. Cathode exothermic reactions with the PVDF binder were observed above 200 C and increased with the SOC (decreasing Li content in the cathode). No thermal reactions were seen at lower temperatures suggesting that thermal runaway reactions in this type of cell are initiated at the anode. An Accelerating Rate Calorimeter (ARC) was used to perform measurements of thermal runaway on commercial Sony Li-ion cells as a function of SOC. The cells showed sustained thermal output as low as 80 C in agreement with the DSC observations of anode materials but the heating rate was strongly dependent on the SOC.

Short pulse laser damage and ablation of amorphous, diamond-like carbon films is investigated. Material removal is due to fracture of the film and ejection of large fragments, which exhibit a broadband emission of microsecond duration.

Pre-and post-test analytical predictions of the dynamic behavior of a 1:10 scale model Reinforced Concrete Containment Vessel are presented. This model, designed and constructed by the Nuclear Power Engineering Corp., was subjected to seismic simulation tests using the high-performance shaking table at the Tadotsu Engineering Laboratory in Japan. A group of tests representing design-level and beyond-design-level ground motions were first conducted to verify design safety margins. These were followed by a series of tests in which progressively larger base motions were applied until structural failure was induced. The analysis was performed by ANATECH Corp. and Sandia National Laboratories for the US Nuclear Regulatory Commission, employing state-of-the-art finite-element software specifically developed for concrete structures. Three-dimensional time-history analyses were performed, first as pre-test blind predictions to evaluate the general capabilities of the analytical methods, and second as post-test validation of the methods and interpretation of the test result. The input data consisted of acceleration time histories for the horizontal, vertical and rotational (rocking) components, as measured by accelerometers mounted on the structure's basemat. The response data consisted of acceleration and displacement records for various points on the structure, as well as time-history records of strain gages mounted on the reinforcement. This paper reports on work in progress and presents pre-test predictions and post-test comparisons to measured data for tests simulating maximum design basis and extreme design basis earthquakes. The pre-test analyses predict the failure earthquake of the test structure to have an energy level in the range of four to five times the energy level of the safe shutdown earthquake. The post-test calculations completed so far show good agreement with measured data.

Investigation and evaluation of a complex system is often accomplished through the use of performance measures based on system response models. The response models are constructed using computer-generated responses supported where possible by physical test results. The general problem considered is one where resources and system complexity together restrict the number of simulations that can be performed. The levels of input variables used in defining environmental scenarios, initial and boundary conditions and for setting system parameters must be selected in an efficient way. This report describes an algorithmic approach for performing this selection.

Minimizing the likelihood of solder joint embrittlement in connectors is realized by reducing or eliminating retained Au plating and/or Au-Sn intermetallic compound formation from the assemblies. Gold removal is performed most effectively by using a double wicking process. When only a single wicking procedure can be used, a higher soldering temperature improves the process of Au removal from the connector surfaces and to a nominal extent, removal of Au-contaminated solder from the joint. A longer soldering time did not appear to offer any appreciable improvement toward removing the Au-contaminated solder from the joint. Because the wicking procedure was a manual process, it was operator dependent.

The canonical variate analysis technique is used in this investigation, along with a data transformation algorithm, to identify a system in a transform space. The transformation algorithm involves the preprocessing of measured excitation/response data with a zero-memory-nonlinear transform, specifically, the Rosenblatt transform. This transform approximately maps the measured excitation and response data from its own space into the space of uncorrelated, standard normal random variates. Following this transform, it is appropriate to model the excitation/response relation as linear since Gaussian inputs excite Gaussian responses in linear structures. The linear model is identified in the transform space using the canonical variate analysis approach, and system responses in the original space are predicted using inverse Rosenblatt transformation. An example is presented.

A partial non-dimensionalization of the Navier-Stokes equations is used to obtain order of magnitude estimates of the rate-controlling transport processes in the reacting portion of a fire plume as a function of length scale. Over continuum length scales, buoyant times scales vary as the square root of the length scale; advection time scales vary as the length scale, and diffusion time scales vary as the square of the length scale. Due to the variation with length scale, each process is dominant over a given range. The relationship of buoyancy and baroclinc vorticity generation is highlighted. For numerical simulation, first principles solution for fire problems is not possible with foreseeable computational hardware in the near future. Filtered transport equations with subgrid modeling will be required as two to three decades of length scale are captured by solution of discretized conservation equations. By whatever filtering process one employs, one must have humble expectations for the accuracy obtainable by numerical simulation for practical fire problems that contain important multi-physics/multi-length-scale coupling with up to 10 orders of magnitude in length scale.

A subgrid model is presented for use in CFD fire simulations to account for thermal suppressants and strain. The extinguishment criteria is based on the ratio of a local fluid-mechanics time-scale to a local chemical time-scale compared to an empirically-determined critical Damkohler number. Local extinction occurs if this time scale is exceeded, global fire extinguishment occurs when local extinction has occurred for all combusting cells. The fluid mechanics time scale is based on the Kolmogorov time scale and the chemical time scale is based on blowout of a perfectly stirred reactor. The input to the reactor is based on cell averaged temperatures, assumed stoichiometric fuel/air composition, and cell averaged suppressant concentrations including combustion products. A detailed chemical mechanism is employed. The chemical time-scale is precalculated and mixing rules are used to reduce the composition space that must be parameterized. Comparisons with experimental data for fire extinguishment in a flame-stabilizing, backward-facing step geometry indicates that the model is conservative for this condition.

Florida legislation enacted in 1976 directed the Florida Solar Energy Center (FSEC) to develop standards for solar energy systems manufactured or sold in the state, establish criteria for testing the performance of solar energy systems, and provide a means to display compliance with approved performance tests for these systems. This mandate has been effectively implemented for both solar domestic water heating and solar pool heating systems. With growing interest and markets for photovoltaic systems, plans are presently being developed to expand the scope of the mandate to include photovoltaic technology. This paper discusses four complementary facets of a photovoltaic (PV) system certification program. They include PV module performance characterization and rating; PV system design review and approval; examination and authorization of photovoltaic system installers; and inspection and acceptance testing of PV system installation. The suggested photovoltaic system process builds on lessons learned from over 20 years of testing, certifying and labeling of solar thermal collectors, and the certification of solar thermal systems.

In-situ optical diagnostics and ion beam diagnostics for plasma-etch and reactive-ion-beam etch (RIBE) tools have been developed and implemented on etch tools in the Compound Semiconductor Research Laboratory (CSRL). The optical diagnostics provide real-time end-point detection during plasma etching of complex thin-film layered structures that require precision etching to stop on a particular layer in the structure. The Monoetch real-time display and analysis program developed with this LDRD displays raw and filtered reflectance signals that enable an etch system operator to stop an etch at the desired depth within the desired layer. The ion beam diagnostics developed with this LDRD will permit routine analysis of critical ion-beam profile characteristics that determine etch uniformity and reproducibility on the RIBE tool.

Sandia's Archimedes 3.0{copyright} Automated Assembly Analysis System has been applied successfully to several large industrial and weapon assemblies. These have included Sandia assemblies such as portions of the B61 bomb, and assemblies from external customers such as Cummins Engine Inc., Raytheon (formerly Hughes) Missile Systems and Sikorsky Aircraft. While Archimedes 3.0{copyright} represents the state-of-the-art in automated assembly planning software, applications of the software made prior to the technological advancements presented here showed several limitations of the system, and identified the need for extensive modifications to support practical analysis of assemblies with several hundred to a few thousand parts. It was believed that there was substantial potential for enhancing Archimedes 3.0{copyright} to routinely handle much larger models and/or to handle more modestly sized assemblies more efficiently. Such a mature assembly analysis capability was needed to support routine application to industrial assemblies that overstressed the system, such as full nuclear weapon assemblies or full-scale aerospace or military vehicles.

A reaction mechanism for TEOS/O{sub 3} CVD in a SVG/WJ atmospheric pressure furnace belt reactor has been developed and calibrated with experimental deposition rate data. One-dimensional simulations using this mechanism successfully reproduce the trends observed in a set of 31 experimental runs in a WJ-TEOS999 reactor. Two-dimensional simulations using this mechanism successfully reproduce the average deposition rates for 3 different experimental conditions in a WJ-1500TF reactor, although the deposition profiles predicted by the model are flatter than the experimental static prints.

The frequencies of the bursting events associated with the streamwise coherent structures of spatially developing incompressible turbulent boundary layers were predicted using global numerical solution of the Orr-Sommerfeld and the vertical vorticity equations of hydrodynamic stability problems. The structures were modeled as wavelike disturbances associated with the turbulent mean flow. The global method developed here involves the use of second and fourth order accurate finite difference formula for the differential equations as well as the boundary conditions. An automated prediction tool, BURFIT, was developed. The predicted resonance frequencies were found to agree very well with previous results using a local shooting technique and measured data.

This proposal provides the rationale for an advanced system called Diagnostics-while-drilling (DWD) and describes its benefits, preliminary configuration, and essential characteristics. The central concept is a closed data circuit in which downhole sensors collect information and send it to the surface via a high-speed data link, where it is combined with surface measurements and processed through drilling advisory software. The driller then uses this information to adjust the drilling process, sending control signals back downhole with real-time knowledge of their effects on performance. The report presents background of related previous work, and defines a Program Plan for US Department of Energy (DOE), university, and industry cooperation.

The main goal of this research was to develop degradable systems either by developing weaklink-containing polymers or identifying commercial polymeric systems which are easily degraded. In both cases, the degradation method involves environmentally friendly chemistries. The weaklinks are easily degradable fragments which are introduced either randomly or regularly in the polymer backbone or as crosslinking sites to make high molecular weight systems via branching. The authors targeted three general application areas: (1) non-lethal deterrents, (2) removable encapsulants, and (3) readily recyclable/environmentally friendly polymers for structural and thin film applications.

Abstract not provided.

A microfabrication process is described that provides for the batch realization of miniature rare earth based permanent magnets. Prismatic geometry with features as small as 5 microns, thicknesses up through several hundred microns and with submicron tolerances may be accommodated. The processing is based on a molding technique using deep x-ray lithography as a means to generate high aspect-ratio precision molds from PMMA (poly methyl methacrylate) used as an x-ray photoresist. Subsequent molding of rare-earth permanent magnet (REPM) powder combined with a thermosetting plastic binder may take place directly in the PMMA mold. Further approaches generate an alumina form replicated from the PMMA mold that becomes an intermediate mold for pressing higher density REPM material and allows for higher process temperatures. Maximum energy products of 3--8 MGOe (Mega Gauss Oersted, 1 MGOe = 100/4{pi} kJ/m{sup 3}) are obtained for bonded isotropic forms of REPM with dimensions on the scale of 100 microns and up to 23 MGOe for more dense anisotropic REPM material using higher temperature processing. The utility of miniature precision REPMs is revealed by the demonstration of a miniature multipole brushless DC motor that possesses a pole-anisotropic rotor with dimensions that would otherwise prohibit multipole magnetization using a multipole magnetizing fixture at this scale. Subsequent multipole assembly also leads to miniaturized Halbach arrays, efficient magnetic microactuators, and mechanical spring-like elements which can offset miniaturized mechanical scaling behavior.

The role of the alumina particle phase and size on polish rate and process temperature was studied to elucidate removal mechanisms involved in tungsten CMP using potassium iodate-based slurries. Additional work including polishing of blanket PETEOS and titanium films, and polishing of M1 to V1 to M2 electrical test structures was performed to determine the performance of the various aluminas in production CMP. The polish rate of tungsten was highest with alpha alumina. Delta/theta and gamma alumina showed lower polish rates. Tungsten and PETEOS polish rates increased with particle size. Only alpha alumina was able to clear the titanium barrier stack. The size of the alpha alumina did not effect the electrical characteristics of short loop electrical test structures.

This report presents the findings of the Chemical Compatibility Program developed to evaluate plastic packaging components that may be incorporated in packaging mixed-waste forms for transportation. Consistent with the methodology outlined in this report, the authors performed the second phase of this experimental program to determine the effects of simulant Hanford tank mixed wastes on packaging seal materials. That effort involved the comprehensive testing of five plastic liner materials in an aqueous mixed-waste simulant. The testing protocol involved exposing the materials to {approximately}143, 286, 571, and 3,670 Krad of gamma radiation and was followed by 7-, 14-, 28-, 180-day exposures to the waste simulant at 18, 50, and 60 C. Fluorocarbon (FKM) rubber samples subjected to the same protocol were then evaluated by measuring seven material properties: specific gravity, dimensional changes, mass changes, hardness, compression set, vapor transport rates, and tensile properties. From the analyses, they determined that FKM rubber is not a good seal material to withstand aqueous mixed wastes having similar composition to the one used in this study. They have determined that FKM rubber has limited chemical durability after exposure to gamma radiation followed by exposure to the Hanford tank simulant mixed waste at elevated temperatures above 18 C.

PDS/PIO is a lightweight, parallel interface designed to support efficient transfers of massive, grid-based, simulation data among memory, disk, and tape subsystems. The higher-level PDS (Parallel Data Set) interface manages data with tensor and unstructured grid abstractions, while the lower-level PIO (Parallel Input/Output) interface accesses data arrays with arbitrary permutation, and provides communication and collective I/O operations. Higher-level data abstraction for finite element applications is provided by PXI (Parallel Exodus Interface), which supports, in parallel, functionality of Exodus II, a finite element data model developed at Sandia National Laboratories. The entire interface is implemented in C with Fortran-callable PDS and PXI wrappers.

This analysis provides a preliminary investigation into using Twin-Wire Arc Thermal Spray and Cold Spray as material deposition processes for LIGA applications. These spray material processes were studied to make an initial determination of their potential as alternatives to producing mechanical parts via the electroplating process. Three materials, UltraMachinable{reg_sign} Stainless Steel, BondArc{reg_sign}, and aluminum, were sprayed using Thermal Spray. Only aluminum was sprayed using the Cold Spray process. Following the spray procedure, the test specimens were released from a copper mold and then tested. Three tests, density, tensile strength, and porosity, were performed on the specimens to determine the spray effect on material properties. Twin-Wire Arc Thermal Spray did not demonstrate adequate deposition properties and does not appear to be a good process candidate for LIGA. However, Cold Spray yielded better density results and warrants further investigation to analyze the minimum feature size produced by the process.

In order to determined the capabilities of a thermal battery with high-voltage and high-power requirements, a detailed characterization of the candidate LiSi/LiCl-LiBr-LiF/CoS{sub 2} electrochemical couple was conducted. The rate capability of this system was investigated using 0.75 inch-dia. and 1.25 inch-dia. single and multiple cells under isothermal conditions, where the cells were regularly pulsed at increasingly higher currents. Limitations of the electronic loads and power supplies necessitated using batteries to obtain the desired maximum current densities possible for this system. Both 1.25 inch-dia. and 3 inch-dia. stacks were used with the number of cells ranging from 5 to 20. Initial tests involved 1.25 inch-dia. cells, where current densities in excess of 15 A/cm{sup 2} (>200 W/cm{sup 2}) were attained with 20-cell batteries during 1-s pulses. In subsequent follow-up tests with 3 inch-dia., 10-cell batteries, ten 400-A 1-s pulses were delivered over an operating period often minutes. These tests formed the foundation for subsequent full-sized battery tests with 125 cells with this chemistry.

Cobble mulch and composted biosolids, greenwaste, and dairy manure were added to arid soil in an attempt to improve plant establishment and production, minimize erosion, increase evapotranspiration, and reduce leaching. Twenty-four plots (10 x 10 m) were established in a completely randomized block design (8 treatments, 3 plots per treatment). Treatments included (1) non-irrigated control, (2) irrigated control, (3) non-irrigated greenwaste compost (2.5 yd{sup 3} per plot), (4) irrigated greenwaste compost (5 yd{sup 3} per plot), (5) non-irrigated biosolids compost (2.5 yd{sup 3} per plot), (6) irrigated biosolids compost (5 yd{sup 3} per plot), (7) cobble-mulch, and (8) non-irrigated dairy manure compost (2.5 yd{sup 3} per plot). Soil samples were collected from each plot for laboratory analyses to assess organic matter contents, macro-nutrient levels and trace metal contents, and nitrogen mineralization potential. All plots were seeded similarly with approximately equal portions of cool and warm season native grasses. The organic composts (greenwaste, biosolids, dairy manure) added to the soils substantially increased soil organic matter and plant nutrients including total nitrogen and phosphorus. However, the results of a laboratory study of the soils' nitrogen mineralization potential after the application of the various composts showed that the soil nitrogen-supplying capability decreased to non-amended soil levels by the start of the second growing season. Thus, from the standpoint of nitrogen fertilizer value, the benefits of the organic compost amendments appear to have been relatively short-lived. The addition of biosolids compost, however, did not produce significant changes in the soils' copper, cadmium, lead, and zinc concentrations and thus did not induce adverse environmental conditions due to excessive heavy metal concentrations. Supplemental irrigation water during the first and second growing seasons did not appear to increase plant biomass production in the irrigated control plots over that produced in the non-irrigated control plots. This surprising result was probably due to the cumulative effects of other factors that influenced the initial establishment and production of plants in the plots (e.g., plant species competition, seed germination delay times, differences in nutrient release and availability). Variation within individual plots, and among the three replicate plots associated with each treatment, rendered many of the recorded differences in vegetation establishment and production statistically insignificant. However, after two complete growing seasons the highest total plant foliar cover and the greatest biomass production and plant species diversity occurred in the cobble-mulched plots. These results suggest that cobble-mulch may be the desired amendment in re-vegetated arid landfill covers if the principal objectives are to quickly establish vegetation cover, stabilize the site from erosion, and increase water usage by plants, thereby reducing the potential for leaching and contaminant movement from the landfill's waste-bearing zone.

This report documents the decommissioning and abandonment activities at the Weeks Island Strategic Petroleum Reserve (SPR) site, Iberia Parish, Louisiana, that were concluded in 1999. These activities required about six years of intense operational, engineering, geotechnical, and management support efforts, following initiation of site abandonment plans in 1994. The Weeks Island SPR mine stored about 72.5 million bbl of crude oil following oil fill in 1980--1982, until November 1995, when the DOE initiated oil drawdown procedures, with brine refill and oil skimming, and numerous plugging and sealing activities. About 98% of the crude oil was recovered and transferred to other SPR facilities in Louisiana and Texas; a small amount was also sold. This document summarizes recent pre- and post-closure: conditions of surface features at the site, including the sinkholes, the freeze wall, surface subsidence measurements and predictions; conditions within the SPR mine, including oil recovery, brine filling, and the Markel Wet Drift; risk assessment evaluations relevant to the decommissioning and long-term potential environmental impacts; continuing environmental monitoring activities at the site; and, an overview on the background and history of the Weeks Island SPR facility.