Publications

This paper presents experimental data and computational modeling for a well-defined glass material. The experimental data cover a wide range of strains, strain rates, and pressures that are obtained from quasi-static compression and tension tests, split Hopkinson pressure bar compression tests, explosively driven flyer plate impact tests, and depth of penetration ballistic tests. The test data are used to obtain constitutive model constants for the improved Johnson-Holmquist (JH-2) brittle material model. The model and constants are then used to perform computations of the various tests.

At Sandia National Laboratories in Albuquerque, the author designed and fabricated a precision wire feeder to be used with high energy density (electron beam and laser beam) welding for weld joints where filler wire might be needed to fill a gap or to adjust the chemical composition so that a crack-free weld could be made. The wire feeder incorporates a 25,000 step-per-revolution motor to power a urethane-coated drive roll. A microprocessor-based controller provides precise control of the motor and allows both continuous and pulsed feeding of the wire. A unidirectional 0.75-in.-dia ball bearing is used to press the wire against the drive roll. A slight constant backward tension is maintained on the wire spool by a Bodine torque motor. A Teflon tube is used to guide the wire from the drive roll to the vicinity of the weld, where a hypodermic needle is used to aim the wire into the weld pool. The operation of the wire feeder was demonstrated by feeding a 10-mil-dia, Type 304 stainless steel wire into a variety of CO{sub 2} laser beam welds. The resulting welds are smooth and continuous, and the welds are considered to be completely satisfactory for a variety of applications.

Several government agencies and industrial sectors have recognized the need for, and payoff of, investing in the methodologies and associated technologies for improving the product realization process. Within the defense community as well as commercial industry, there are three major needs. First, they must reduce the cost of military products, of related manufacturing processes, and of the enterprises that have to be maintained. Second, they must reduce the time required to realize products while still applying the latest technologies. Finally, they must improve the predictability of process attributes, product performance, cost, schedule and quality. They must continue to advance technology, quickly incorporate their innovations in new products and in processes to produce them, and they need to capitalize on the raw computational power and communications bandwidth that continues to become available at decreasing cost. Sandia National Laboratories initiative is pursuing several interrelated, key concepts and technologies in order to enable such product realization process improvements: model-based design; intelligent manufacturing processes; rapid virtual and physical prototyping; and agile people/enterprises. While progress in each of these areas is necessary, this paper only addresses a portion of the overall initiative. First a vision of a desired future capability in model-based design and virtual prototyping is presented. This is followed by a discussion of two specific activities parametric design analysis of Synthetic Aperture Radars (SARs) and virtual prototyping of miniaturized high-density electronics -- that exemplify the vision as well as provide a status report on relevant work in progress.

One of the tasks of the Lethality Group within US Army Space and Strategic Defense Command (USASSDC) is the development of a capability to simulate various missile intercept scenarios using computer codes. Currently under development within USASSDC and its various contractor organizations is a group of codes collected under a master code called PEGEM for Post Event Ground Effects Model. Among the various components of the code are modules which are used to predict atmospheric dispersion and transport of particles or droplets following release at the altitude specified in the missile intercept scenario. The atmospheric transport code takes into account various source term data from the intercept such as: initial cloud size; droplet or particle size distribution; and, total mass of agent released. An ongoing USASSDC experimental program termed Crystal Mist involved release of precision glass beads under various altitude and meteorological conditions to assist in validation and refinement of various codes that are components of PEGEM used to predict particle atmospheric transport and diffusion following a missile intercept. Here, soda-lime glass beads used in the Crystal Mist series of atmospheric transport and diffusion tests were characterized by scanning electron microscopy and automated image processing routines in order to fully define their size distributions and morphology. Four bead size classifications ranging from a median count diameter of 45 to 200 micrometers were found to be approximately spherical and to fall within the supplier`s sizing specifications. Log-normal functions fit to the measured size distributions resulted in geometric standard deviations ranging from 1.08 to 1.12, thereby fulfilling the field trial requirements for a relatively narrow bead size distribution.

A novel, folded compact range configuration has been developed at the Sandia National Laboratories compact range antenna and radar cross section measurement facility, operated by the Radar/Antenna Department 2343, as a means of performing indoor, environmentally-controlled, far-field simulations of synthetic aperture radar (SAR) coherent change detection (CCD) measurements. This report describes the development of the folded compact range configuration, as well as the initial set of coherent change detection measurements made with the system. These measurements have been highly successful, and have demonstrated the viability of the folded compact range concept in simulating SAR CCD measurements. It is felt that follow-on measurements have the potential of contributing significantly to the body of knowledge available to the scientific community involved in CCD image generation and processing, and that this tool will be a significant aid in the research and development of change detection methodologies.

This report summarizes a number of research efforts completed over the past 20 years in the El Paso del Norte region to characterize pollution sources and air quality trends. The El Paso del Norte region encompasses the cities of El Paso, Texas and Ciudad Juarez, Chihuahua and is representative of many US-Mexico border communities that are facing important air quality issues as population growth and industrialization of Mexican border communities continue. Special attention is given to a group of studies carried out under special US Congressional funding and administered by the US Environmental Protection Agency. Many of these studies were fielded within the last several years to develop a better understanding of air pollution sources and trends in this typical border community. Summary findings from a wide range of studies dealing with such issues as the temporal and spatial distribution of pollutants and pollution potential from both stationary and mobile sources in both cities are presented. Particular emphasis is given to a recent study in El Paso-Ciudad Juarez that focussed on winter season PM{sub 10} pollution in El Paso-Ciudad Juarez. Preliminary estimates from this short-term study reveal that biomass combustion products and crustal material are significant components of winter season PM{sub 10} in this international border community.

This report summarizes the activities of a Lab Directed Research and Development (LDRD) Project to investigate the viability of asynchronous transfer mode (ATM) switching technology in the local area network (LAN) environment. A number of ATM based LANs were constructed and their performance capabilities were measured. The summary report notes the measurements and lessons learned from the two-year effort.

In today`s world, accurate finite-element simulations of large nonlinear systems may require meshes composed of hundreds of thousands of degrees of freedom. Even with today`s fast computers and the promise of ever-faster ones in the future, central processing unit (CPU) expenditures for such problems could be measured in days. Many contemporary engineering problems, such as those found in risk assessment, probabilistic structural analysis, and structural design optimization, cannot tolerate the cost or turnaround time for such CPU-intensive analyses, because these applications require a large number of cases to be run with different inputs. For many risk assessment applications, analysts would prefer running times to be measurable in minutes. There is therefore a need for approximation methods which can solve such problems far more efficiently than the very detailed methods and yet maintain an acceptable degree of accuracy. For this purpose, we have been working on two methods of approximation: neural networks and spring-mass models. This paper presents our work and results to date for spring-mass modeling and analysis, since we are further along in this area than in the neural network formulation. It describes the physical and numerical models contained in a code we developed called STRESS, which stands for ``Spring-mass Transient Response Evaluation for structural Systems``. The paper also presents results for a demonstration problem, and compares these with results obtained for the same problem using PRONTO3D, a state-of-the-art finite element code which was also developed at Sandia.

Traditional approaches to the assessment of information systems have treated system security, system reliability, data integrity, and application functionality as separate disciplines. However, each areas requirements and solutions have a profound impact on the successful implementation of the other areas. A better approach is to assess the ``surety`` of an information system, which is defined as ensuring the ``correct`` operation of an information system by incorporating appropriate levels of safety, functionality, confidentiality, availability, and integrity. Information surety examines the combined impact of design alternatives on all of these areas. We propose a modelling approach that combines aspects of fault trees and influence diagrams for assessing information surety requirements under a risk assessment framework. This approach allows tradeoffs to be based on quantitative importance measures such as risk reduction while maintaining the modelling flexibility of the influence diagram paradigm. This paper presents an overview of the modelling method and a sample application problem.

A thermomechanical analysis of a continuous fiber metal matrix composite (MMC) subjected to cyclic loading is performed herein. The analysis includes the effects of processing induced residual thermal stresses, matrix inelasticity, and interface cracking. Due to these complexities, the analysis is performed computationally using the finite element method. Matrix inelasticity is modelled with a rate dependent viscoplasticity model. Interface fracture is modelled by the use of a nonlinear interface constitutive model. The problem formulation is summarized, and results are given for a four-ply unidirectional SCS-6/{beta}21S titanium composite under high temperature isothermal mechanical fatigue. Results indicate rate dependent viscoplasticity can be a significant mechanism for dissipating the energy available for damage propagation, thus contributing to improved ductility of the composite. Results also indicate that the model may be useful for inclusion in life prediction methodologies for MMC`s.

In this paper a brief description of dynamic techniques commonly available for determining material property studies is presented. For many impact applications, the material generally experiences a complex loading path. In most cases, the initial loading conditions can be represented by the shock commonly referred to as the Hugoniot state. Subsequent loading or release structure, i.e., off-Hugoniot states would however be dependent on the physical processes dominating the material behavior. The credibility of the material model is tested by the accuracy of predictions of off-Hugoniot states. Experimental techniques commonly used to determine off-Hugoniot states are discussed in this survey.

There has been some concern that, as nuclear power plants age, protective measures taken to control and minimize the impact of fire may become ineffective, or significantly less effective, and hence result in an increased fire risk. One objective of the Fire Vulnerability of Aged Electrical Components Program is to assess the effects of aging and service wear on the fire vulnerability of electrical equipment. An increased fire vulnerability of components may lead to an overall increase in fire risk to the plant. Because of their widespread use in various electrical safety systems, electromechanical relays were chosen to be the initial components for evaluation. This test program assessed the impact of operational and thermal aging on the vulnerability of these relays to fire-induced damage. Only thermal effects of a fire were examined in this test program. The impact of smoke, corrosive materials, or fire suppression effects on relay performance were not addressed in this test program. The purpose of this test program was to assess whether the fire vulnerability of electrical relays increased with aging. The sequence followed for the test program was to: identify specific relay types, develop three fire scenarios, artificially age several relays, test the unaged and aged relays in the fire exposure scenarios, and compare the results. The relays tested were Agastat GPI, General Electric (GE) HMA, HGA, and HFA. At least two relays of each type were artificially aged and at least two relays of each type were new. Relays were operationally aged by cycling the relay under rated load for 2,000 operations. These relays were then thermally aged for 60 days with their coil energized.

An approach is described for performing scoping calculations of radionuclide release fractions from target materials being considered for use in the Accelerator Production of Tritium (APT) project, and some illustrative results are presented. The releases are evaluated for postulated accident scenarios involving severe overheating of either of two neutron source target materials, tungsten and lead. The potential for vaporization of radionuclides produced by spallation and neutron capture reactions is evaluated using a model that includes production of volatile species by reaction with steam, hydrogen, and/or oxygen. Emphasis is on release from the neutron source materials themselves, with a more limited treatment being given for radionuclides produced in other parts of the target/blanket assemblies. In the tungsten neutron source target, the low rate of diffusion within the tungsten is shown to limit releases of even volatile species to small values in a chemically inert or reducing environment. However, oxidative ablation of tungsten could permit considerably larger releases of volatile species in steam-rich or oxygen-rich environments. Tungsten radionuclides would dominate the source term for accident conditions considered the most plausible. For the lead neutron source target, the releases are predicted to be dominated by mercury radionuclides. Quantitative source term evaluation for this target is complicated because, in any accident sufficiently severe to be of much concern, lead melting will likely result in loss of target geometry. Hence, results presented for release from the lead must be carefully qualified. Extensive parametric results are presented for release from both neutron source materials. These results may be used to perform scoping estimates of radionuclide releases for additional APT accident scenarios as the controlling parameters for these scenarios become better defined.

The majority of all oil well footage drilled is in shales and other clay-bearing rocks. The mechanical strength of these formations usually is not an issue as regards their fast penetration by the drill bit. The difficulties associated with these formations arise due to the chemically reactive nature of such formations, causing the cuttings to stick to the bit. This causes a decrease in the rate of penetration of the drill bit and also has a detrimental effect on the state of the wellbore. This report presents a radical approach to preventing the adherence of shale cuttings to the bit. It consists of applying a direct electrical potential between the rock and the bit while drilling, while making the latter the cathode. Due to the process of electro-osmosis that occurs in shales, this results in the migration of a thin layer of water to the interface between the metal body (cathode) and the rock (anode). It has been demonstrated that this layer of water at the interface aids in the penetration of single-point indenters and also facilitates their withdrawal. Interfacial friction between a shale and a metal body was reduced, as was the tendency of shale cuttings to adhere to the metal surface. All of these combined to cause significant increases in the rate of penetration of a cathodic bit, as compared to the case when no potential was applied. It has been shown that when the bit was made the cathode, the maximum advantage was obtained when drilling conditions got worse, making it ideally suited for field applications. It was also shown that in the time intervals relevant to drilling operations, an amount of water sufficient to provide a coating on the bit was migrated out of a shale. It is believed that since the contact between the metal and the shale completes the electrical circuit to produce the driving force, this technique should work under most operating conditions. 63 refs.

Sandia National Laboratories, New Mexico, conducts the Utility Battery Storage Systems Program, which is sponsored by the US Department of Energy`s Office of Energy Management. The goal of this program is to assist industry in developing cost-effective battery systems as a utility resource option by 2000. Sandia is responsible for the engineering analyses, contracted development, and testing of rechargeable batteries and systems for utility energy storage applications. This report details the technical achievements realized during fiscal year 1994.

The Plasma Technology Directory has two main goals: (1) promote, coordinate, and share plasma technology experience and equipment within the Department of Energy; and (2) facilitate technology transfer to the commercial sector where appropriate. Personnel are averaged first by Laboratory and next by technology area. The technology areas are accelerators, cleaning and etching deposition, diagnostics, and modeling.

This paper presents a concept for fusing 3-dimensional image reconnaissance data with LADAR imagery for aim point refinement. The approach is applicable to fixed or quasi-fixed targets. Quasi-fixed targets are targets that are not expected to be moved between the time of reconnaissance and the time of target engagement. The 3-dimensional image data is presumed to come from standoff reconnaissance assets tens to hundreds of kilometers from the target area or acquisitions prior to hostilities. Examples are synthetic aperture radar (SAR) or stereoprocessed satellite imagery. SAR can be used to generate a 3-dimensional map of the surface through processing of data acquired with conventional SAR acquired using two closely spaced, parallel reconnaissance paths, either airborne or satellite based. Alternatively, a specialized airborne SAR having two receiving antennas may be used for data acquisition. The data sets used in this analysis are: (1) LADAR data acquired using a Hughes-Danbury system flown over a portion of Kirtland AFB during the period September 15--16, 1993; (2) two pass interferometric SAR data flown over a terrain-dominated area of Kirtland AFB; (3) 3-dimensional mapping of an urban-dominated area of the Sandia National Laboratories and adjacent cultural area extracted from aerial photography by Vexcel Corporation; (4) LADAR data acquired at Eglin AFB under Wright Laboratory`s Advanced Technology Ladar System (ATLAS) program using a 60 {mu}J, 75 KHz Co{sub 2} laser; and (5) two pass interferometric SAR data generated by Sandia`s STRIP DCS (Data Collection System) radar corresponding to the ATLAS LADAR data. The cultural data set was used in the urban area rather than SAR because high quality interferometric SAR data were not available for the urban-type area.

Finite Element Analysis capability for application to welding has been developed and enhanced during a two year Cooperative Research and Development Agreement(CRADA) between Pratt & Whitney, United Technologies Research Center, and Sandia National Laboratories. Because of the nature of electron beam welding at Pratt & Whitney -- set-up is time consuming, the parts to be welded are complicated, and experimentation is costly -- finite element analysis has found many potential applications. The results of most interest in these analyses are the residual stress and final distortion of the component. The work has made use of the Sandia finite element codes JACQ3D, for thermal analysis, and JAS3D, for mechanical analysis. Both codes use an efficient, non-linear conjugate gradient solution technique, which enables large problems to be solved on engineering workstations. This presentation describes several technical challenges that were overcome in the application of the Sandia codes to this class of problems. Stress and distortion results predicted for an electron beam weld of a PW4000 gas turbine engine drum rotor will also be discussed.

Selecting a risk-based tool to aid in decision making is as much of a challenge as properly using the tool once it has been selected. Failure to consider customer and stakeholder requirements and the technical bases and differences in risk-based decision making tools will produce confounding and/or politically unacceptable results when the tool is used. Selecting a risk-based decisionmaking tool must therefore be undertaken with the same, if not greater, rigor than the use of the tool once it is selected. This paper presents a process for selecting a risk-based tool appropriate to a set of prioritization or resource allocation tasks, discusses the results of applying the process to four risk-based decision-making tools, and identifies the ``musts`` for successful selection and implementation of a risk-based tool to aid in decision making.

With the infusion of information technologies into product development and production processes, effective management of product data is becoming essential to modern production enterprises. When an enterprise-wide Product Data Manager (PDM) is implemented, PDM designers must satisfy the requirements of individual users with different job functions and requirements, as well as the requirements of the enterprise as a whole. Concern must also be shown for the interrelationships between information, methods for retrieving archival information and integration of the PDM into the product development process. This paper describes a user-driven approach applied to PDM design for an agile manufacturing pilot project at Sandia National Laboratories that has been successful in achieving a much faster design-to-production process for a precision electro mechanical surety device.

As industries position themselves for the competitive markets of today, and the increasingly competitive global markets of the 21st century, agility, or the ability to rapidly develop and produce new products, represents a common trend. Agility manifests itself in many different forms, with the agile manufacturing paradigm proposed by the Iacocca Institute offering a generally accepted, long-term vision. In its many forms, common elements of agility or agile manufacturing include: changes in business, engineering and production practices, seamless information flow from design through production, integration of computer and information technologies into all facets of the product development and production process, application of communications technologies to enable collaborative work between geographically dispersed product development team members and introduction of flexible automation of production processes. Industry has rarely experienced as dramatic an infusion of new technologies or as extensive a change in culture and work practices. Human factors will not only play a vital role in accomplishing the technical and social objectives of agile manufacturing. but has an opportunity to participate in shaping the evolution of industry paradigms for the 21st century.

The purpose of an intelligent alarm analysis system is to provide complete and manageable information to a central alarm station operator by applying alarm processing and fusion techniques to sensor information. This paper discusses the sensor fusion approach taken to perform intelligent alarm analysis for the Advanced Exterior Sensor (AES). The AES is an intrusion detection and assessment system designed for wide-area coverage, quick deployment, low false/nuisance alarm operation, and immediate visual assessment. It combines three sensor technologies (visible, infrared, and millimeter wave radar) collocated on a compact and portable remote sensor module. The remote sensor module rotates at a rate of 1 revolution per second to detect and track motion and provide assessment in a continuous 360` field-of-regard. Sensor fusion techniques are used to correlate and integrate the track data from these three sensors into a single track for operator observation. Additional inputs to the fusion process include environmental data, knowledge of sensor performance under certain weather conditions, sensor priority, and recent operator feedback. A confidence value is assigned to the track as a result of the fusion process. This helps to reduce nuisance alarms and to increase operator confidence in the system while reducing the workload of the operator.

Sandia National Laboratories faces institutional challenges that are unique in its history. Never before have the national laboratories been viewed so critically, and never before has their role been the subject of such study and debate. At the same time, the opporunities to render `exceptional service in the national interest` have never been greater. The business of Sandia today and into the foreseeable future will rely on a strong, integrated technical foundation, represented most fundamentally by its core competencies. While is is impossible to foresee precisely what missions Sandia will pursue many years from now, one thing is clear: Central to its service to the nation will be the application of science-based engineering skills to the stewardship of the nuclear weapons stockpile. Whether on not the nation ever builds a new nuclear weapon, those that remain in stockpile will require continuous stewardship based on the integration of scientific understanding with experienced systems engineering. Sandia`s steadfast commitment to DOE`s stockpile stewardship mission will also be evident in the production of limited numbers of certain vital weapon components as the weapons production complex is realigned. Complementing this enduring responsibility will be expanded missions in energy, environment, and economic competitiveness. The work for other federal agencies will be jointly sponsored under high-level agreements with DOE. Multi-institutional teams will become a common way of doing business. The multiprogram laboratory model will evolve toward a new model of multi-laboratory programs addressing major national needs. Sandia will be a distinct and important component of an integrated system of national laboratories.

The characteristics of a piezoresistive accelerometer in shock environments are being studied at Sandia National Laboratories in the Mechanical Shock Testing Laboratory. A Hopkinson bar capability has been developed to extend our undemanding of the piezoresistive accelerometer, in two mechanical configurations, in the high frequency, high shock environments where measurements are being made. Two different Hopkinson bar materials are being used: Titanium and beryllium The in-axis performance of the piezoresistive accelerometer for frequencies of dc-10 kHz and shock magnitudes of up to 150,000 g as determined from measurements with a titanium Hopkinson bar are presented. The beryllium Hopkinson bar configuration is described. Preliminary in-axis characteristics of the piezoresistive accelerometer at a nominal shock level of 50,000 g for a frequency range of DC-30 kHz determined from the beryllium bar are presented.

The goal of assembly sequencing is to plan a feasible series of operations to construct a product from its individual parts. Previous research has thoroughly investigated assembly sequencing under the assumption that parts have nominal geometry. This paper considers the case where parts have toleranced geometry. Its main contribution is an efficient procedure that decides if a product admits an assembly sequence with infinite translations that is feasible for all possible instances of the components within the specified tolerances. If the product admits one such sequence, the procedure can also generate it. For the cases where there exists no such assembly sequence, another procedure is proposed which generates assembly sequences that are feasible only for some values of the toleranced dimensions. If this procedure produces no such sequence, then no instance of the product is assemblable. Finally, this paper analyzes the relation between assembly and disassembly sequences in the presence of toleranced parts. This work assumes a simple, but non-trivial tolerance language that falls short of capturing all imperfections of a manufacturing process. Hence, it is only one step toward assembly sequencing with toleranced parts.