The emergence of several rapid prototyping & manufacturing (RP&M) technologies is having a dramatic impact on investment casting. While the most successful of the rapid prototyping technologies are almost a decade old, relatively recent process advances in their application have produced some remarkable success in utilizing their products as patterns for investment castings. Sandia National Laboratories has been developing highly coupled experimental and computational capabilities to examine the investment casting process with the intention of reducing the amount of time required to manufacture castings, and to increase the quality of the finished product. This presentation will begin with process aspects of RP&M pattern production and handling, shell fabrication, burnout, and casting. The emphasis will be on how the use of Stereolithography (SL) or Selective Laser Sintered (SLS) patterns differs from more traditional wax pattern processes. Aspects of computational simulation to couple design, thermal analysis, and mold filling will be discussed. Integration of these topics is probably the greatest challenge to the use of concurrent engineering principles with investment casting. Sandi has conducted several experiments aimed at calibrating computer codes and providing data for input into these simulations. Studied involving materials as diverse as stainless steel and gold have been conducted to determine liquid metal behavior in molds via real time radiography. The application of these experiments to predictive simulations will be described.
A number of experiments were conducted to determine the economic viability of applying various ultraviolet (UV) oxidation processes to a waste water stream containing approximately 12 mg/L total organic carbon (TOC), predominately ethylene glycol. In all experiments, a test solution was illuminated with either near-UV or a far-UV light alone or in combination with a variety of photocatalysts and oxidants. Based upon the outcomes of this project, both UV/photocatalysis and UV/ozone processes are capable of treating the water sample to below detection capabilities of TOC. However, the processes are fairly energy intensive; the most efficient case tested required 11 kWh per order of magnitude reduction in TOC per 1000 L. If energy consumption rates of 5-10 kWh/1000 L are deemed reasonable, then further investigation is recommended.
A sinkhole measuring 11 m (36 ft) across and 9 m (30 ft) deep was first observed in alluvium overlying the Weeks Island, Louisiana, salt dome in May 1992, but it was about a year old, based on initial surface appearance and subsequent reverse extrapolation of growth rates. A second and much smaller sinkhole was identified in early 1995, nearly three years later. Their position directly over the edges of the SPR oil storage chamber, a former room-and-pillar salt mine, caused apprehension. The association of sinkholes over mines is well established and this occurrence suggested that groundwater influx undoubtedly was causing salt dissolution at shallow depth, and associated collapse of soil at the surface. Leaks of groundwater into other salt mines in Louisiana and elsewhere led to flooding and eventual abandonment (Coates et al., 1981). Consequently, much attention has been and continues to be given to characterizing these sinkholes, and to mitigation. This paper summarizes current engineering geologic concepts, and briefly describes diagnostic and risk mitigation efforts being conducted by the US Department of Energy, operator of the Strategic Petroleum Reserve (Bauer et al., 1994).
BISDN services will involve the integration of high speed data, voice, and video functionality delivered via technology similar to Asynchronous Transfer Mode (ATM) switching and SONET optical transmission systems. Customers of BISDN services may need a variety of data authenticity and privacy assurances, via Asynchronous Transfer Mode (ATM) services Cryptographic methods can be used to assure authenticity and privacy, but are hard to scale for implementation at high speed. The incorporation of these methods into computer networks can severely impact functionality, reliability, and performance. While there are many design issues associated with the serving of public keys for authenticated signaling and for establishment of session cryptovariables, this paper is concerned with the impact of encryption itself on such communications once the signaling and setup have been completed. Network security protections should be carefully matched to the threats against which protection is desired. Even after eliminating unnecessary protections, the remaining customer-required network security protections can impose severe performance penalties. These penalties (further discussed below) usually involve increased communication processing for authentication or encryption, increased error rate, increased communication delay, and decreased reliability/availability. Protection measures involving encryption should be carefully engineered so as to impose the least performance, reliability, and functionality penalties, while achieving the required security protection. To study these trade-offs, a prototype encryptor/decryptor was developed. This effort demonstrated the viability of implementing certain encryption techniques in high speed networks. The research prototype processes ATM cells in a SONET OC-3 payload. This paper describes the functionality, reliability, security, and performance design trade-offs investigated with the prototype.
A summary of multidimensional modeling is presented which describes coupled thermals chemical and mechanical response of reactive and nonreactive materials. This modeling addresses cookoff of energetic material (EM) prior to the onset of ignition. Cookoff, lasting from seconds to days, sensitizes the EM whereupon combustion of confined, degraded material determines the level of violence. Such processes are dynamic, occurring over time scales of millisecond to microsecond, and thus more amenable for shock physics analysis. This work provides preignition state estimates such as the amount of decomposition, morphological changes, and quasistatic stress states for subsequent dynamic analysis. To demonstrate a fully-coupled thermal/chemical/quasistatic mechanical capability, several example simulations have been performed: (1) the one-dimensional time-to-explosion experiments, (2) the Naval Air Weapon Center`s (NAWC) small scale cookoff bomb, (3) a small hot cell experiment and (4) a rigid, highly porous, closed-cell polyurethane foam. Predictions compared adequately to available data. Deficiencies in the model and future directions are discussed.
An overview of the major sensor and actuator projects using the micromachining capabilities of the Microelectronics Development Laboratory at Sandia National Laboratories is presented. Development efforts are underway for a variety of surface micromachined sensors and actuators. A technology that embeds micromechanical devices below the surface of the wafer prior to microelectronics fabrication has also been developed for integrating microelectronics with surface micromachined micromechanical devices.
Electrochemical power sources that utilize zinc electrodes possess many advantages. Zinc is abundantly available, benign, inexpensive, stable over a wide operating temperature range, and has a high oxidation potential. In spite of these advantageous characteristics, rechargeable electrochemical systems based on zinc chemistry have not found widespread use. The major disadvantages of zinc electrodes are that they have limited cycle life due to zinc slumping and zinc electrode shape changes in alkaline solutions resulting from the solubility of zincate (Zn(OH){sub 4}{sup 2-}) in these solutions. As a result, premature cell failure often results due to cell shorting caused by dendritic growth as well as zinc slumping. In this paper we describe the chemical and physical characteristics of electrolyte solutions employing additives, particularly for zinc based electrochemical systems. These electrolytes are prepared using the alkali metal salts of 1,3,5-phenyltrisulfonic acid in combination with potassium hydroxide. The alkali metal salts of the acid possess good thermal stability, good ionic conductivity, and have a wide electrochemical voltage window in aqueous systems. With these electrolyte solutions improved cycle life was achieved in Zn/NiOOH and Zn/AgO. Improved cycle life with this additive is attributed to decreased zincate solubility, resulting in reduced zinc slumping and electrode shape changes. In addition, increased shelf-life and reduced self-discharge were also observed in many alkaline power sources.
The authors report about the shock-compression response of highly porous (55% and 65% dense) mixtures of 4Al + 3SiO{sub 2} powders having shock-induced phase transitions and chemical reactions. Shock recovery experiments were performed using the CETR/Sawaoka plate-impact system (P = 40 to 100 GPa) and the Sandia Momma Bear A Comp B fixture (P = 22 to 45 GPa). The recovered compacts contained the high pressure stishovite phase, products of chemical reaction, as well as unreacted constituents. The reaction products formed included Al{sub 2}O{sub 3} metallic Si (ambient and high pressure phases), SiAl intermetallic, and kyanite (Al{sub 2}SiO{sub 5}). The shock-induced chemical reaction in 4Al + 3SiO{sub 2} powder mixtures, appears to have been accompanied (or assisted) by the formation of stishovite, a high pressure phase of quartz.
Recent research has shown that dilute SC-1 chemistries, when combined with high frequency sonication (megasonics) can be highly effective for particle removal. The mechanism by which the SC-1 chemistry facilitates particle removal remains unclear. Experiments were performed under extremely dilute conditions in order to help elucidate a cleaning mechanism. Results indicate that hydrogen peroxide, under extremely dilute conditions, is not necessary for effective particle removal. The increase in haze commonly attributed to increased surface roughness is not observed when sufficiently dilute ammonium hydroxide (e.g., 1:2700) is used. The role of hydrogen peroxide, when more concentrated chemistries are used, may be simply to mitigate surface etching and roughening, rather than to play an active role in particle removal.
Stand-alone photovoltaic (PV) systems typically depend on battery storage to supply power to the load when there is cloudy weather or no sun. Reliable operation of the load is often dependent on battery performance. This paper presents test procedures for lead-acid batteries which identify initial battery preparation, battery capacity after preparation, charge regulation set-points, and cycle life based on the operational characteristics of PV systems.
Dish/Stirling is a solar thermal electric technology which couples parabolic, point-focusing solar collectors and heat engines which employ the Stirling thermodynamic cycle. Since the late 1970s, the development of Dish/Stirling systems intended for commercial use has been in progress in Germany, Japan, and the US. In the next several years it is expected that one or more commercial systems will enter the market place. This paper provides a general overview of this emerging technology, including: a description of the fundamental principles of operation of Dish/Stirling systems; a presentation of the major components of the systems (concentrator, receiver, engine/alternator, and controls); an overview of the actual systems under development around the world, with a discussion of some of the technical issues and challenges facing the Dish/Stirling developers. A brief discussion is also presented of potential applications for small Dish/Stirling systems in northern Mexico.
Occasionally one may be confronted by a hexahedral or quadrilateral mesh containing doublets, two faces sharing two edges. In this case, no amount of smoothing will produce a mesh with agreeable element quality: in the planar case, one of these two faces will always have an angle of at least 180 degrees between the two edges. The authors describe a robust scheme for refining a hexahedral or quadrilateral mesh to separate such faces, so that any two faces share at most one edge. Note that this also ensures that two hexahedra share at most one face in the three dimensional case. The authors have implemented this algorithm and incorporated it into the CUBIT mesh generation environment developed at Sandia National Laboratories.
The ability to perform effective adaptive analysis has become a critical issue in the area of physical simulation. Of the multiple technologies required to realize a parallel adaptive analysis capability, automatic mesh generation is an enabling technology, filling a critical need in the appropriate discretization of a problem domain. The paving algorithm`s unique ability to generate a function-following quadrilateral grid is a substantial advantage in Sandia`s pursuit of a modified h-method adaptive capability. This characteristic combined with a strong transitioning ability allow the paving algorithm to place elements where an error function indicates more mesh resolution is needed. Although the original paving algorithm is highly serial, a two stage approach has been designed to parallelize the algorithm but also retain the nice qualities of the serial algorithm. The authors approach also allows the subdomain decomposition used by the meshing code to be shared with the finite element physics code, eliminating the need for data transfer across the processors between the analysis and remeshing steps. In addition, the meshed subdomains are adjusted with a dynamic load balancer to improve the original decomposition and maintain load efficiency each time the mesh has been regenerated. This initial parallel implementation assumes an approach of restarting the physics problem from time zero at each interaction, with a refined mesh adapting to the previous iterations objective function. The remeshing tools are being developed to enable real time remeshing and geometry regeneration. Progress on the redesign of the paving algorithm for parallel operation is discussed including extensions allowing adaptive control and geometry regeneration.
Although the frequency dependent conductivity, {sigma}({omega}), of ion-containing glasses displays power law dispersion ({sigma}({omega}) {approx} {omega}{sup n}) that can usually be described by a master curve, several findings have suggested that this scaling fails at low temperatures as indicated by a temperature dependence of the scaling exponent, n. The authors investigate this behavior in the frequency range between 1 Hz and 10{sup 6} Hz for a different materials including alkali metaphosphate glasses and a polymer. They identify two distinct regimes of conductive behavior, {sigma}{sub {vert_bar}} and {sigma}{sub {parallel}}. The first, {sigma}{sub {vert_bar}}, is strongly temperature dependent and appears to obey a master curve representation. The second, {sigma}{sub {parallel}}, exhibits only a weak temperature dependence with a roughly linear frequency dependence. A strong depression of {sigma}{sub {vert_bar}} occurs for the mixed alkali case, but {sigma}{sub {parallel}} is unaffected and occurs at roughly the same location in all the alkali compositions studied. They propose that {sigma}{sub {parallel}} does not arise from cation motion, but rather originates from a second mechanisms likely involving small distortions of the underlying glassy matrix. This assignment of {sigma}{sub {parallel}} is further supported by the roughly universal location of {sigma}{sub {parallel}}, to within an order of magnitude, of a variety of materials, including a polymer electrolyte and a doped crystal. Since {sigma}{sub {vert_bar}}(T) and {sigma}{sub {parallel}}(T {approx} const.) are viewed as separate phenomena, the temperature dependence of the scaling exponent is shown to result merely from a superposition of these two contributions and does not indicate any intrinsic failure of the scaling property of {sigma}{sub {vert_bar}}.
The needs of today`s advanced societies have moved well beyond the requirements for food and shelter, etc., and now are focused on such concerns as international peace and domestic security, affordable health care, the swift and secure transmission of information, the conservation of resources, and a clean environment. Progress in materials science and engineering is impacting each of these concerns. This paper will present some examples of how this is occurring, and then comment on ethical dilemmas that can arise as a consequence of technological advances. The need for engineers to participate more fully in the development of public policies that help resolve such dilemmas, and so promote the benefits of advancing technology to society, will be discussed.
The Web Interface Template System (WITS) is a tool for software developers. WITS is a three-tiered, object-oriented system operating in a Client/Server environment. This tool can be used to create software applications that have a Web browser as the user interface and access a Sybase database. Development, modification, and implementation are greatly simplified because the developer can change and test definitions immediately, without writing or compiling any code. This document explains WITS functionality, the system structure and components of WITS, and how to obtain, install, and use the software system.
In order to provide a strategy for space reactor technology development, the Defense Nuclear Agency (DNA) has authorized a brief review of potential national needs that may be addressed by space reactor systems. a systematic approach was used to explore needs at several levels that are increasingly specific. Level 0 -- general trends and issues; Level 1 -- generic space capabilities to address trends; Level 2 -- requirements to support capabilities; Level 3 -- system types capable of meeting requirements; Level 4 --generic reactor system types; and Level 5 -- specific baseline systems. Using these findings, a strategy was developed to support important space reactor technologies within a limited budget. A preliminary evaluation identified key technical issues and provide a prioritized set of candidate research projects. The evaluation of issues and the recommended research projects are presented in a companion paper.
Electron induced etching of sapphire in the presence of Cs has been studied using a variety of surface analytical techniques. We find that this process occurs on both the (0001) and (1102) orientations of sapphire. Monolayer amounts of Al and sub-oxides of Al are thermally desorbed from the surface at temperatures as low as 1000 K when the surface is irradiated with electrons in the presence of Cs. Etching is highly dependent on Cs coverage with the (0001) and (1102) surfaces requiring 2.0 {times} 10{sup 14} and 3.4 {times} 10{sup 14} atoms/cm{sup 2} to support etching, respectively. Adsorption profiles demonstrate that these coverages correspond to initial saturation of the surface with Cs. Electron damage of the surface in the absence of Cs also produces desorption of Al and sub-oxides of Al indicating a possible mechanism for etching. The impact of etching on the surface is to increase the adsorption capacity on the (0001) surface while decreasing both initial adsorption probability and capacity on the (1102) surface.
Glowka, D.A.; Dennis, T.; Le, Phi; Cohen, J.; Chow, J.
Cooperative research is currently underway among five drill bit companies and Sandia National Laboratories to improve synthetic-diamond drill bits for hard-rock applications. This work, sponsored by the US Department of Energy and individual bit companies, is aimed at improving performance and bit life in harder rock than has previously been possible to drill effectively with synthetic-diamond drill bits. The goal is to extend to harder rocks the economic advantages seen in using synthetic-diamond drill bits in soft and medium rock formations. Four projects are being conducted under this research program. Each project is investigating a different area of synthetic diamond bit technology that builds on the current technology base and market interests of the individual companies involved. These projects include: optimization of the PDC claw cutter; optimization of the Track-Set PDC bit; advanced TSP bit development; and optimization of impregnated-diamond drill bits. This paper describes the progress made in each of these projects to date.
The Sandia National Laboratories (SNL) Safeguards and Seals Evaluation Program is evaluating new fiber optic active seal technologies for use at Department of Energy (DOE) facilities. The goal of the program is to investigate active seal technologies that can monitor secured containers storing special nuclear materials (SNM) within DOE vaults. Specifically investigated were active seal technologies that can be used as tamper-indicating devices to monitor secured containers within vaults while personnel remain outside the vault area. Such a system would allow minimal access into vaults while ensuring container content accountability. The purpose of this report is to discuss tamper-indicating devices that were evaluated for possible DOE use. While previous seal evaluations (Phase I and II) considered overall facility applications, this discussion focuses specifically on their use in vault storage situations. The report will highlight general background information, specifications and requirements, and test procedures. Also discussed are the systems available from four manufacturers: Interactive Technologies, Inc., Fiber SenSys, Inc., Inovonics, Inc., and Valve Security Systems.
This paper describes the techniques used to resolve invalid connectivity created as a natural part of the whisker weaving algorithm. These techniques rely on the detection of {open_quotes}repeated hexes{close_quotes} in the STC data, which indicate face pairs which share two edges. The {open_quotes}repeated hex{close_quotes} case is described in detail, including the resolution technique by which a self-intersecting whisker sheet with two independent face loops are created. The algorithm used to construct the primal of an all-hexahedral mesh (i.e. the actual nodes and hex elements) from the connectivity data contained in the STC is also described. The primal is constructed using a {open_quotes}gift-wrapping{close_quotes} algorithm, where all the mesh edges and hexes containing a particular node are found by traversing between hexes already known to share the node. This algorithm is implemented inside the CUBIT code and is used to generate meshes for several example problems.
A first-principles approach to radiation hardness assurance was described that provides the technical background to the present US and European total-dose radiation hardness assurance test methods for MOS technologies, TM 1019.4 and BS 22900. These test methods could not have been developed otherwise, as their existence depends not on a wealth of empirical comparisons of IC data from ground and space testing, but on a fundamental understanding of MOS defect growth and annealing processes. Rebound testing should become less of a problem for advanced MOS small-signal electronics technologies for systems with total dose requirements below 50--100 krad(SiO{sub 2}) because of trends toward much thinner gate oxides. For older technologies with thicker gate oxides and for power devices, rebound testing is unavoidable without detailed characterization studies to assess the impact of interface traps on devices response in space. The QML approach is promising for future hardened technologies. A sufficient understanding of process effects on radiation hardness has been developed that should be able to reduce testing costs in the future for hardened parts. Finally, it is hoped that the above discussions have demonstrated that the foundation for cost-effective hardness assurance tests is laid with studies of the basic mechanisms of radiation effects. Without a diligent assessment of new radiation effects mechanisms in future technologies, one cannot be assured that the present generation of radiation test standards will continue to apply.
The SANDUS (SANdia Digital Underground System) waveform digitizing system was developed by the instrumentation development division in support of underground nuclear testing and first fielded in the late 70`s. This system has been successfully used for over a decade for the digitization of signals from DC to 10 Mhz. This report is intended to be a broad survey of the fundamental performance characteristics of the system. The data included herein were obtained from a small number of channels under a limited number of configurations and should provide the reader with the general range of performance parameters. As a survey, the laboratory and analytical procedures for the tests have not been detailed.